TURBOCHARGER SYSTEM
- Turn ignition off. Connect a scan tool to Data Link Connector (DLC). Start engine. Using scan tool check charge air adaptation percentage wile driving vehicle. Charge air adaptation is normally very slow. Maximum charge air adaptation pulse ratio is 100 percent and minimum is -100 percent. If charge air adaptation percentage pulse ratio is high and positive, check for faulty charge air bypass valve, internal leak in bypass valve, plugged air cleaner or a faulty turbo charger. If charge air adaptation percentage pulse ratio is high and negative, check for faulty charge air bypass valve or faulty turbo charger. Repair or replace as necessary. If charge air adaptation pulse ratio is okay, go to next step.
- Turn engine off. Backprobing, connect test light between positive battery terminal and negative side of charge air control valve connector (Blue wire). Start engine and allow it to idle. Test light should flash. Repair or replace as necessary. If test light flashes, using scan tool check charge air control valve pulse ratio percentage. Charge air control valve pulse ratio should be about 2 percent at idle. Repair or replace as necessary. If charge air control valve percentage is as specified, go to next step.
Bypass Control Valve
Turn ignition off. Disconnect bypass control valve connector. Measure resistance between bypass control valve connector terminals. Resistance should be 35-45 ohms at 68°F (20°C). If resistance is not as specified, replace bypass control valve.
Charge Air Bypass Valve
Disconnect vacuum hose from charge air bypass valve. Apply vacuum to charge air bypass valve. (Scheme 26) Vacuum should hold. Remove charge air bypass valve. With vacuum applied, apply air pressure to turbocharger side of charge air bypass valve. Air should flow through valve.
Scheme 26
Charge Air Control Valve (9-3 & 9-5 - 2.3L)
| CAUTION | DO NOT activate charge air control valve for more than 60 seconds. |
- Turn ignition off. Disconnect vacuum hoses and connector from charge air control valve. Measure resistance between charge air control valve connector terminals. Resistance should be 7-9 ohms at 68°F (20°C). If resistance is as specified, go to next step. If resistance is not as specified, replace charger air control valve.
- Connect charge air control valve connector. Connect scan tool and turn ignition on. Using scan tool, activate charge air control valve. Charge air control valve should sound when activated. Disconnect charge air control valve connector. Connect a vacuum gauge to port "W" and apply vacuum to port "C" of charge air control valve. (Scheme 27) Vacuum should be present.
- Move vacuum gauge to port "R" and apply vacuum to port "C". Vacuum should not be present. Apply battery voltage to Yellow/Gray wire of charge air control valve and ground Blue wire. With vacuum gauge at port "R", apply vacuum to port "C" of charge air control valve. (Scheme 27) Vacuum should be present. Repair or replace as necessary.
Scheme 27
Turbo Wastegate & Diaphragm (9-3 & 9-5 - 2.3L)
Remove exhaust pipe bend from turbocharger and visually inspect wastegate valve. Ensure wastegate valve is in contact with turbine housing. Check for carbon deposits. Repair as necessary. Remove seal and remove wastegate control valve operating arm-to-turbocharger wastegate clip. Ensure operating arm moves freely and does not bind. Replace components as necessary. If operating arm moves freely, apply air pressure to wastegate control valve diaphragm nipple. Push rod should move out without binding. Remove air pressure from wastegate control valve diaphragm nipple. Push rod should return. Replace as necessary. See TURBOCHARGERS in REMOVAL, OVERHAUL & INSTALLATION article.
Ground Circuit
- Turn ignition off. Measure resistance between specified ECM terminal and ground. See «GROUND TERMINAL IDENTIFICATION»(ref-12212-S41825301832002012400000) table. (Scheme 28) Resistance should be zero ohms. If resistance is as specified, go to next step. If resistance is not as specified, repair open circuit between ECM and ground. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
- Start engine. Measure voltage between specified ECM terminal and ground. See «GROUND TERMINAL IDENTIFICATION»(ref-12212-S41825301832002012400000) table. If one volt or more is present, inspect for open circuit, corrosion, or loose connection on appropriate circuit.
| Model | Terminal (Wire Color) |
|---|---|
| 9-3 & 9-5 (2.0L & 2.3L) | No. 25 (Black Wire), 47 (Black Wire) & 62 (Black Wires) |
| 9-5 (3.0L) | No. 25 (Black Wire) & 47 (Black Wire) |
GROUND TERMINAL IDENTIFICATION
Power Circuit
- Turn ignition off. Check for battery voltage between specified ECM terminal and ground. See «POWER TERMINAL IDENTIFICATION»(ref-12212-S07832107192002012400000) table. (Scheme 28) If battery voltage exists, go to next step. If battery voltage does not exist, repair open circuit between ECM and specified fuse located in instrument panel fuse block, located at left end of instrument panel. See «POWER TERMINAL IDENTIFICATION»(ref-12212-S07832107192002012400000) table. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS.
- Turn ignition on. Check for battery voltage between specified ECM terminal and ground. See «POWER TERMINAL IDENTIFICATION»(ref-12212-S07832107192002012400000) table. If battery voltage does not exist, repair open circuit between ECM and specified fuse located in instrument panel fuse block, located at left end of instrument panel. See «POWER TERMINAL IDENTIFICATION»(ref-12212-S07832107192002012400000) table.
| Model | Fuse No. | Terminal (Wire Color) | |
|---|---|---|---|
| 9-3 | |||
| Ignition Off | 28 | No. 23 (Pink/White Wire) | |
| Ignition On | 17 | No. 43 (Yellow/Grey Wire) | |
| 9-5 | |||
| Ignition Off | 17 | No. 23 (Red Wire) | |
| Ignition On | 27 | No. 43 (Red/Blue Wire) | |
POWER TERMINAL IDENTIFICATION
Scheme 28
CHARGE AIR PRESSURE/INTAKE AIR TEMPERATURE SENSOR
- Connect vacuum/pressure gauge to intake manifold. Turn ignition on. Backprobing charge air pressure/intake air temperature sensor connector, measure voltage between charge air pressure/intake air temperature sensor connector terminals "A" and "C" with pressure and vacuum applied. See «COMPONENT LOCATIONS»(ref-12212-S38035885092002012200000). (Scheme 29) See «MANIFOLD ABSOLUTE PRESSURE/CHARGE AIR PRESSURE SENSOR VOLTAGES»(ref-12212-S34699078972002012200000) table. Replace sensor if voltage is not as specified.
- To test intake air temperature sensor on 9-3 and 9-5 (2.3L) models, turn ignition on. Backprobing, measure voltage between intake air temperature sensor terminals "A" and "B" with engine running and at deferring engine temperatures. (Scheme 29) Turn ignition off. Disconnect intake air temperature sensor connector. Start engine. Measure resistance between intake air temperature sensor terminals "A" and "B" at deferring engine temperatures.
- To test intake air temperature sensor on 9-5 (3.0L) models, turn ignition on. Backprobing, measure voltage between intake air temperature sensor terminals "B" and "D". (Scheme 29) Turn ignition off. Disconnect intake air temperature sensor connector. Start engine. Measure resistance between intake air temperature sensor terminals "B" and "D".
Scheme 29
| Vacuum/Pressure | Volts | |
|---|---|---|
| In. Hg | ||
| 7.4 | 0.9 | |
| 14.8 | 1.3 | |
| 29.53 | 2.1 | |
| Psi | ||
| 18.1 | 2.5 | |
| 21.8 | 2.9 | |
| 25.4 | 3.3 | |
MANIFOLD ABSOLUTE PRESSURE/CHARGE AIR PRESSURE SENSOR VOLTAGES
| Temperature - °F (°C) | Volts | Ohms |
|---|---|---|
| 22 (-30) | 4.5 | 20,000-30,000 |
| 14 (-10) | 3.9 | 7000-11,400 |
| 68 (20) | 2.4 | 2100-2900 |
| 104 (40) | 1.5 | 1000-1300 |
| 140 (60) | 0.9 | 565-670 |
| 176 (80) | 0.5 | 295-365 |
| 194 (90) | 0.4 | 240-260 |
INTAKE AIR TEMPERATURE (IAT) SENSOR RESISTANCE
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
- Backprobing ECT sensor, turn ignition on. See «COMPONENT LOCATIONS»(ref-12212-S38035885092002012200000) . Measure voltage between sensor terminals. See «ENGINE COOLANT TEMPERATURE (ECT) SENSOR RESISTANCE»(ref-12212-S22300664182002012200000) table. Replace sensor if voltage is not as specified.
- Turn ignition off. Disconnect ECT sensor connector. Measure resistance between sensor terminals. See «ENGINE COOLANT TEMPERATURE (ECT) SENSOR RESISTANCE»(ref-12212-S22300664182002012200000) table. Replace sensor if resistance is not as specified.
| Temperature - °F (°C) | Volts | Ohms |
|---|---|---|
| 22 (-30) | 4.8 | 20,000-30,000 |
| 14 (-10) | 4.5 | 7000-11,400 |
| 68 (20) | 3.6 | 2100-2900 |
| 104 (40) | 2.7 | 1000-1300 |
| 140 (60) | 1.9 | 565-670 |
| 176 (80) | 1.2 | 295-365 |
| 194 (90) | 1.0 | 240-260 |
| 230 (110) | 0.65 | 140-160 |
ENGINE COOLANT TEMPERATURE (ECT) SENSOR RESISTANCE
CRANKSHAFT POSITION (CKP) SENSOR
Turn ignition off. Disconnect CKP sensor connector. See COMPONENT LOCATIONS. To test CKP sensor, measure resistance between CKP terminals No. 1 and No. 2. (Scheme 30) See CRANKSHAFT POSITION SENSOR RESISTANCE table. Replace sensor if resistance is not as specified.
Scheme 30
| Temperature - °F (°C) | Ohms |
|---|---|
| 68 (20) | 770-950 |
CRANKSHAFT POSITION SENSOR RESISTANCE
HEATED OXYGEN SENSOR (HO2S)
Turn ignition off. Disconnect HO2S connector. See COMPONENT LOCATIONS. Start engine. To test HO2S, measure voltage between terminals No. 3 and No. 4. Terminals No. 3 and No. 4 are Gold-plated. (Scheme 30) See HEATED OXYGEN SENSOR (HO2S) VOLTAGE table. Replace sensor if voltage is not as specified.
| Condition | Volts |
|---|---|
| Lean | .1-0.4 |
| Rich | 0.6-0.9 |
HEATED OXYGEN SENSOR (HO2S) VOLTAGE
HEATED OXYGEN SENSOR (HO2S) HEATER RESISTANCE
Turn ignition off. Disconnect HO2S connector. See COMPONENT LOCATIONS. To test HO2S heater resistance, measure resistance between HO2S terminals No. 1 and No. 2. (Scheme 30) Resistance should be 9 ohms at 68°F (20°C). Replace sensor if resistance is not as specified.
MASS AIR FLOW (MAF) SENSOR
Backprobing MAF sensor, start engine. See COMPONENT LOCATIONS. Measure frequency at MAF sensor terminal No. 1. (Scheme 30) Replace sensor if frequency is not as specified.
| Air Flow (Grams/Second) | Frequency (Hertz) |
|---|---|
| 0 | 100-300 |
| 1 | 1045 |
| 1.5 | 1312 |
| 2 | 1527 |
| 3.5 | 2012 |
| 5 | 2355 |
| 7.5 | 2788 |
| 10 | 3134 |
| 15 | 3678 |
| 20 | 4095 |
| 30 | 4764 |
| 40 | 5289 |
| 50 | 5730 |
| 60 | 6114 |
| 80 | 6753 |
| 100 | 7286 |
| 120 | 7743 |
| 140 | 8158 |
MASS AIR FLOW FREQUENCY
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
- Connect vacuum/pressure gauge to intake manifold. Turn ignition on. On 9-3 models, backprobing MAP sensor connector, measure voltage between MAP sensor terminals "A" and "D" with pressure and vacuum applied. See «COMPONENT LOCATIONS»(ref-12212-S38035885092002012200000). (Scheme 31) See «MANIFOLD ABSOLUTE PRESSURE/CHARGE AIR PRESSURE SENSOR VOLTAGES»(ref-12212-S34699078972002012200000) table. Replace sensor if voltage is not as specified.
- On 9-5 models, measure voltage between manifold absolute pressure sensor terminals "A" and "B". (Scheme 31) Replace sensor if voltage is not as specified.
Scheme 31
THROTTLE POSITION & PEDAL POSITION SENSORS
Backprobing electronic throttle actuator connector. See COMPONENT LOCATIONS . Turn ignition on. Measure voltage between specified terminals. See THROTTLE/PEDAL POSITION SENSOR VOLTAGES table. Replace throttle/pedal position sensor along with throttle body if voltage is not as specified.
| Sensor - Throttle/Pedal Position | Backprobe Between Terminals No. (1) | Voltage | |
|---|---|---|---|
| Throttle Position Sensor 1 | |||
| Closed | 6-9 | 0.065-1.090 | |
| Open | 6-9 | 3.930-4.775 | |
| Throttle Position Sensor 2 | |||
| Closed | 8-9 | 3.910-4.935 | |
| Open | 8-9 | 0.025-1.070 | |
| Pedal Position Sensor 1 | |||
| Released | 1-9 | 3.990-4.645 | |
| Depressed | 1-9 | 0.400-1.055 | |
| Pedal Position Sensor 2 | |||
| Released | 3-9 | 0.355-1.010 | |
| Depressed | 3-9 | 3.945-4.600 | |
| (1) (Scheme 32)or (Scheme 33) | |||
| (1) | (Scheme 32)or (Scheme 33) |
THROTTLE/PEDAL POSITION SENSOR VOLTAGES
Scheme 32
Scheme 33
ECM
See ELECTRONIC CONTROL MODULE (ECM) under COMPUTERIZED ENGINE CONTROLS.
Ignition Discharge Module (IDM)
Connect TECH 2 scan tool to Data Link Connector (DLC). Remove ignition discharge module. Inspect IDM seals, springs and electrical connector for wear or damage. (Scheme 34) Repair or replace as necessary. Reconnect electrical connector. Install test spark plugs into IDM and connect SST 86 10 867 spark plug grounding lead (or equivalent). (Scheme 35) Turn ignition on. Keep IDM in upright position and use scan tool to select ACTIVATE: IGNITION COIL CYL 1-6. Test several cylinders to compare to each other. If any ignition coil does not spark, replace IDM.
Scheme 34
Scheme 35
A/C Relay
- Remove relay from engine compartment fuse/relay block. (Scheme 36)or (Scheme 37). Measure resistance between A/C relay terminals No. 4 and No. 5. Resistance should be 80-90 ohms at 68°F (20°C). If resistance is not as specified, replace relay. Check for continuity between relay terminals No. 1 and 2. If continuity is not present, go to next step. If continuity is present, replace relay.
- Using jumper wires, apply battery voltage to terminal No. 4 and ground to terminal No. 5. (Scheme 41) Check for continuity between relay terminals No. 1 and 2. If continuity is not present, replace relay. If continuity is present, inspect associated wiring for short or open circuits. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. Repair wiring as necessary.
Scheme 36
Scheme 37
Scheme 38
Scheme 39
Scheme 40
Scheme 41
Scheme 42
Fuel Pump Relay
- Remove fuel pump relay from instrument panel relay block. (Scheme 38)or (Scheme 39). Measure resistance between fuel pump relay terminals No. 4 and No. 5. Resistance should be 80-90 ohms at 68°F (20°C). If resistance is not as specified, replace relay. Check for continuity between relay terminals No. 1 and 2. If continuity is not present, go to next step. If continuity is present, replace relay.
- Using jumper wires, apply battery voltage to terminal No. 4 and ground to terminal No. 5. (Scheme 41) Check for continuity between relay terminals No. 1 and 2. If continuity is not present, replace relay. If continuity is present, inspect associated wiring for short or open circuits. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. Repair wiring as necessary.
Limp-Home Solenoid Relay
- Remove limp-home solenoid relay from instrument panel relay block. (Scheme 38)or (Scheme 39). Measure resistance between limp-home solenoid relay terminals No. 3 and No. 5. Resistance should be 70-80 ohms at 68°F (20°C). If resistance is not as specified, replace relay. Check for continuity between relay terminals No. 1 and 2. If continuity is not present, go to next step. If continuity is present, replace relay.
- Using jumper wires, apply battery voltage to terminal No. 3 and ground to terminal No. 5. (Scheme 42) Measure resistance between relay terminals No. 1 and 2. If continuity is not present, replace relay. If continuity is present, inspect associated wiring for short or open circuits. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. Repair wiring as necessary.
Main Relay
- Remove main relay from instrument panel relay block. (Scheme 38)or (Scheme 39). Measure resistance between main relay terminals No. 4 and No. 5. Resistance should be 80-90 ohms at 68°F (20°C). If resistance is not as specified, replace relay. Check for continuity between relay terminals No. 1 and 2. If continuity is not present, go to next step. If continuity is present, replace relay.
- Using jumper wires, apply battery voltage to terminal No. 4 and ground to terminal No. 5. (Scheme 41) Check for continuity between relay terminals No. 1 and 2. If continuity is not present, replace relay. If continuity is present, inspect associated wiring for short or open circuits. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. Repair wiring as necessary.
Air Injection Pump Relay (9-5 - 3.0L)
- Remove relay from instrument panel relay block. (Scheme 39) Measure resistance between air injection pump relay terminals No. 4 and No. 5. Resistance should be 80-90 ohms at 68°F (20°C). If resistance is not as specified, replace relay. Check for continuity between relay terminals No. 1 and 2. If continuity is not present, go to next step. If continuity is present, replace relay.
- Using jumper wires, apply battery voltage to terminal No. 4 and ground to terminal No. 5. (Scheme 41) Check for continuity between relay terminals No. 1 and 2. If continuity is not present, replace relay. If continuity is present, inspect associated wiring for short or open circuits. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. Repair wiring as necessary.
Limp-Home Solenoid
Disconnect limp-home solenoid connector. Measure resistance between limp-home solenoid terminals. Resistance should be between 1.5-1.9 ohms at 68°F (20°C). If resistance is not as specified, replace limp-home solenoid along with throttle body and reset. See RESETTING LIMP-HOME SOLENOID under in appropriate SELF-DIAGNOSTICS article.
FUEL DELIVERY
Note. For fuel system testing, see FUEL PRESSURE & FLOW TESTS under FUEL SYSTEM in BASIC DIAGNOSTIC PROCEDURES article.
Fuel Injectors
Unplug suspect fuel injector connector. Measure resistance between injector terminals. Resistance should be 15.15-16.75 ohms with injector at 68°F (20°C). If resistance is not as specified, replace injector.
IGNITION SYSTEM
Note. For basic ignition checks, see IGNITION CHECK under BASIC DIAGNOSTIC PROCEDURES article.
See CRANKSHAFT POSITION (CKP) SENSOR under MODULES, RELAYS & SOLENOIDS.
See MODULES under MODULES, RELAYS & SOLENOIDS.
Advance Components
Timing advance is controlled by the ECM. Trionic engine management system uses spark plugs to measure combustion chamber resistance, which is in turn used to control ignition timing, turbo charge and throttle position.
Knock Sensor (KS)
No external knock sensor is used on Trionic engine management system. Knock control is accomplished by measuring spark plug resistance and adjusting ignition timing accordingly.
Spark Plugs
Spark plugs play an important part in controlling timing, turbo charge and throttle position because they are used as sensors in the combustion chambers. To check for proper operation of spark plugs, remove ignition discharge module (IDM). Remove spark plugs. Inspect for deposits or damage to porcelain or electrode. Replace if necessary.
EVAP Canister
The EVAP canister is located behind fuel tank on 9-3, and on top of fuel tank on 9-5. For testing of EVAP system, see DTC P0442 & P0455: EVAP SYSTEM LEAK DETECTED under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.
EVAP Canister Purge Valve
Disconnect purge valve connector. Measure resistance between purge valve terminals. Resistance should be between 40-50 ohms at 68°F (20°C). If resistance is not as specified, replace EVAP canister purge valve.
EVAP Shut-Off Valve
Disconnect EVAP shut-off valve connector. Measure resistance between EVAP shut-off valve terminals. Resistance should be between 23-26 ohms at 68°F (20°C). If resistance is not as specified, replace EVAP shut-off valve.
Fuel Tank Pressure Sensor
For diagnostic trouble shooting procedures, see DTC P0452-P0453: FUEL TANK PRESSURE (FTP) SENSOR CIRCUIT under DIAGNOSTIC TESTS in appropriate SELF-DIAGNOSTICS article.
AIR INJECTION - 9-5 (3.0L)
For diagnostic procedures, see P0410: SECONDARY AIR INJECTION SYSTEM - INCORRECT AIRFLOW under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - 9-5 article.
MISCELLANEOUS CONTROLS
Note. Although some of the controlled devices listed here are not technically engine performance components, they can affect driveability if they malfunction.
See RELAYS under MODULES, RELAYS & SOLENOIDS.
Cooling Fan Control Relay (4-Pin)
- Remove cooling fan control relay from engine compartment fuse/relay block. (Scheme 36)or (Scheme 37). Check for continuity between relay terminals No. 1 and 2. If continuity is not present, go to next step. If continuity is present, replace relay.
- Using jumper wires, apply battery voltage to terminal No. 4 and ground to terminal No. 5. (Scheme 41) Check for continuity between relay terminals No. 1 and 2. If continuity is not present, replace relay. If continuity is present, inspect associated wiring for short or open circuits. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. Repair wiring as necessary.
Cooling Fan Control Relay (5-Pin)
- Remove relay from engine compartment fuse/relay block. (Scheme 37) Check for continuity between relay terminals No. 1 and 3. If continuity is not present, replace relay. If continuity is present, check for continuity between relay terminals No. 1 and 2. If continuity is not present, go to next step. If continuity is present, replace relay.
- Using jumper wires, apply battery voltage to terminal No. 4 and ground to terminal No. 5. (Scheme 40) Check for continuity between relay terminals No. 1 and 2. If continuity is not present, replace relay. If continuity is present, inspect associated wiring for short or open circuits. See appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS. Repair wiring as necessary.