94 Chevrolet Diesel SM Supp

C/K, G, P3
TRUCK
DIESEL SUPPLEMENT
1994
CAUTION
To reduce the chance of personal injury and/or property damage, the

following instructions must be carefully observed:
Proper service and repair are important to the safety of the service
technician and the safe, reliable operation of all motor vehicles. If part
replacement is necessary, the part must be replaced with one of the
same part number or with an equivalent part. Do not use a replacement
part of lesser quality.
The service procedures recommended and described in this service

manual are effective methods of performing service and repair. Some
of these procedures require the use of tools specifically designed for
the purpose.
Accordingly, anyone who intends to use a replacement part, service

procedure, or tool which is not recommended by the vehicle
manufacturer, must first determine that neither his safety nor the safe
operation of the vehicle will be jeopardized by the replacement part,
service procedure, or tool selected.
It is important to note that this manual contains various 'Cautions' and

'Notices' that must be carefully observed in order to reduce the risk of
personal injury during service or repair, or the possibility that improper
service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these 'Cautions' and 'Notices' are not
exhaustive, because it is impossible to warn of all the possible
hazardous consequences that might result from failure to follow these
instructions.
i
CAUTION: GM service manuals are intended for u s e by professional, qualified
technicians. Attempting repairs or service without the appropriate training, tools, and
equipment could c a u s e injury to you or others and damage to your vehicle that may
c a u s e it not to operate properly.
ii
1994
C/K, G AND P3 T R U C K
DRTVEABILITY AND EMISSIONS (DIESEL)
S E R V I C E MANUAL SUPPLEMENT
FOREWORD
This manual has been prepared as a supplement

to the 1994 C/K, G and P3 Service Manuals.
It contains the latest product information specific
to the 6.5 liter V8(Diesel) engine and related TABLE OF CONTENTS SECTION
components available at the time of publication DRTVEABILITY & EMISSIONS(C/K)
approval. Whenever it becomes necessary to refer DRTVEABILITY & EMISSIONS (G)
sections not included in this supplement, refer to DRTVEABILITY & EMISSIONS (P3)
the applicable 1994 C/K, G, P3 Service Manuals.
Information pertaining to the operation of the
vehicle is contained in the Owner's manual which
accompanies each vehicle. The right is reserved to
make changes at any time without notice.
Any references to brand names in this manual is

intended merely as an example of the types of
lubricants, tools, and materials recommended for
use in service.
GENERAL MOTORS CORPORATION

DETROIT, MICHIGAN
No part of this publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to
electronic, mechanical, photocopying, recording or otherwise, with the prior written permission of General Motors Corp. This includes all text,
illustrations, tables and charts.
1994 G E N E R A L M O T O R S C O R P O R A T I O N A L L R I G H T S R E S E R V E D 2-94 L I T H O I N U.S.A.

GENERAL MOTORS SERVICE MANUAL COMMENTS
If you find an error, emission or have a suggestion cm any • Model year and vehicle line
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you. • Vehicle Identification Number of vehicle being
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• Section and page numbers)
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• Your phone number Owner's Manual.
GM Service Technology Group

C/K
DRIVE ABILITY
AND
EMISSIONS
(DIESEL)
SECTION 3
DRIVEABILITY AND EMISSIONS (DIESEL) 3-1
SECTION 3
CONTROL MODULE SYSTEM
CONTENTS
General Description 3-3 PCM Diagnosis . . . . . . . 3-17
Powertrain Control Module (PCM) 3-3 PROM 3-17
PCM Learning Ability 3-3 Fuel Control • 3-17
Electrostatic Discharge Damage 3-4 PCM Sensors and Input Signals 3-17
PCM Function 3-4 Engine Coolant Temperature (ECT)
Memory 3-4 Sensor • 3-17
ROM 3-4 Accelerator Pedal Position (APP)
RAM . 3-4 Module 3-17
PROM 3-5 Pump Cam Signal 18
PCM Sensors and Input Signals 3-5 Fuel Temperature Sensor 18
Engine Coolant Temperature (ECT) Crankshaft Position Sensor 18
Sensor 3-5 Intake Air Temperature (IAT) Sensor . • 18
Accelerator Pedal Position (APP) EGR Control Pressure/BARO Sensor •.. 18
Module . . . . . . . . . . . . . . . . . . . 3-5 Boost Sensor 18
Optical Sensor 3-5 Vehicle Speed Sensor (VSS) 18
High Resolution Signal 3-5 Fuel Inject Signal 18
Pump Cam Signal 3-5 Brake Switches 18
Fuel Temperature Sensor 3-6 Glow Plug Signal 3-18
Crankshaft Position Sensor • 3-6 Cruise Control • • 3-19
Intake Air Temperature (IAT) Sensor • 3-6 A/C Signal 3-19
EGR Control Pressure/BARO Sensor . . 3-6 Automatic Transmission Sensors
Boost Sensor 3-7 and Signals • • • 3-19
Vehicle Speed Sensor (VSS) . . . . . . . . . 3-7 CHART A-1
Vehicle Speed Signal (VSS) Buffer No MIL (Service Engine Soon) . . . . . . 3-20
Module 3-7 CHART A-2
Fuel Inject Signal 3-7 No Scan Data or Will Not Flash MIL
Brake Switch Signals 3-7 or MIL (Service Engine Soon)
Glow Plug Signal 3-7 "ON" Steady 3-22
Cruise Control Signal 3-8 CHART A-3
A/C Signal .... 3-8 Engine Cranks But Will Not Run 3- 24
Automatic Transmission Sensors CHART A-5
and Signals 3-8 Fuel Pump Relay Circuit Diagnosis 3-26
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 3-9 EGR Control Pressure/BARO Sensor
Diagnostic Information 3-9 Output Check 3-28
Malfunction Indicator Lamp (MIL) Cruise Control Signal Diagnosis • 3-30
"Service Engine Soon" . . . . . . . . . . 3-9 A/C Signal Diagnosis 3-31
"Service Throttle Soon" Lamp 3-9 Restricted Exhaust System Check 3-32
On-Board Diagnostic (OBD) System Check 3-9 Diagnostic Trouble Code (DTC)
On-Board Diagnostic (OBD) System Check Identification 3-33
(With Tech 1 Scan Tool) 3-10 DTC 13- Engine Shutoff Solenoid Circuit
Typical Tech 1 Engine Data Values . . . . . . 3-12 Fault
3-36
Engine Tech 1 Data Definitions . . . . . . . . 3-13 DTC 14 - Engine Coolant Temperature (ECT)
Tech 1 Scan Tool 3-15 Circuit Low (High Temperature
PCM Information Modes 3-15 Indicated) ••••• ...
3-38
Normal (Open) Mode 3-15 DTC 15 - Engine Coolant Temperature (ECT)
Diagnostic Mode • • • • • •••• 3-15 Circuit High (Low Temperature
Reading Diagnostic Trouble Codes 15 Indicated) . . . . . . . . . . . . . . . . . .
3-40
DTC12 3- 15 DTC 16-Vehicle Speed Signal
Clearing Diagnostic Trouble Codes . . . . 3- 16 Buffer Fault 3-42
Intermittens 3- 16 DTC 17- High Resolution Circuit Fault • . • 3-44
Scan Tool Use with Intermittents ... 3- 16 DTC 18-Pump Cam Reference Pulse
T100 - GM CAMS 3 16 Error 3-46
3-2 DRIVEABILITY AND EMISSIONS (DIESEL)
DTC 19 - Crankshaft Position Reference DTC 63 - Accelerator Pedal Position (APP) 3

Error . . . . . . . . . . . . . . . . . . ^ . . . 3-48 Circuit High 3-104
DTC 21 - Accelerator Pedal Position (APP) 1 DTC 64 - Accelerator Pedal Position (APP) 3
Circuit High . 3-50 Circuit Low 3-106
Circuit Low 3-52 Circuit Range Fault 3-108
DTC 23 - Accelerator Pedal Position (APP) 1 DTC 71 - Set/Coast Switch Fault 3-110
Circuit Range Fault 3-54 DTC 76 - Resume/Accel Switch Fault . . . . 3-112
DTC 25 - Accelerator Pedal Position (APP) 2 DTC 78 - Wastegate Solenoid Fault . . . . . 3-114
Circuit High 3-56 DTC 84 - Accelerator Pedal Position (APP)
DTC 26 - Accelerator Pedal Position (APP) 2 Circuit Fault . . . . . . . . . . . . . . . . . 3-116
Circuit Low 3-58 DTC 88 - TDC Offset Error 3-118
DTC 27 - Accelerator Pedal Position (APP) 2 DTC 91 - Cylinder Balance Fault . . . . . . . 3-119
Circuit Range Fault 3-60 DTC 92 - Cylinder Balance Fault . . . . . . . 3-119
DTC 29 - Glow Plug Relay Circuit Fault . . . 3-62 DTC 93 - Cylinder Balance Fault 3-119
DTC 31 - EGR Control Pressure/BARO DTC 94 - Cylinder Balance Fault 3-120
Sensor Circuit Low (High Vacuum) . . . 3-64 DTC 95 - Cylinder Balance Fault . . . . . . . 3-120
DTC 32 - EGR Circuit Error 3-66 DTC96-CylinderBalance Fault . . . . . . . 3-120
DTC 33 - EGR Control Pressure/BARO DTC97-CylinderBalance Fault 3-121
Sensor Circuit High (Low Vacuum) . . . 3-68 DTC 98 - Cylinder Balance Fault . . . . . . . 3-121
DTC 34 - Injection Timing Stepper (ITS) Motor DTC 99 - Accelerator Pedal Position (APP) 2
Circuit Fault 3-70 5 Volt Reference Fault 3-122
DTC 35 - Injection Pulse Width Error PCM Wiring Diagram (1 of 7) . . . . . . . . 3-124
(Response Time Short) . . . . . . . . . . . 3-72 PCM Connector Terminal End View
DTC 36 - Injection Pulse Width Error (1of6) 3-131
(Response Time Long) 3-74 On-Vehicle Service 3-137
DTC 41 - Brake Switch Circuit Fault .... 3-76 Wire Harness 3-137
DTC 42 - Fuel Temperature Circuit Low Connectors and Terminals • • • • 3-137
(High Temperature Indicated) . . . . . . 3-78 Micro-Pack . . . . . . . . . . . . . . . . . . 3-138
DTC 43 - Fuel Temperature Circuit High Metri- Pack 3-138
(Low Temperature Indicated) ...... 3-80 Weather-Pack 3-138
DTC 44 - EGR Pulse Width Error 3-82 Compact Three 3-139
DTC 45 - EGR Vent Error . 3-84 Powertrain Control Module (PCM) . . . . . 3-139
DTC 46 - MIL "Service Engine Soon" PCM or PROM Replacement 3-140
Circuit Fault 3-86 If PCM Is Being Replaced . . . . . . . . . . . 3-140
DTC 47 - Intake Air Temperature (IAT) Functional Check 3-140
Circuit Low (High Temperature TDC Offset Program Procedure 3-140
Indicated) 3-88 PCM Sensors and Input Switches 3-141
DTC 48 - Intake Air Temperature (IAT) Engine Coolant Temperature (ECT)
Circuit High (Low Temperature Sensor 3-141
Indicated) 3-90 Accelerator Pedal Position (APP)
DTC 49 - "Service Throttle Soon" Module 3-141
Lamp Circuit Fault 3-92 Optical/Fuel Temperature Sensor . . . . 3-141
DTC 51 - PROM Error (Faulty or Crankshaft Position Sensor 3-141
Incorrect PROM) 3-94 Intake Air Temperature (IAT) Sensor • . 3-142
DTC 54 - PCM Fuel Circuit Error 3-95 EGR Control Pressure/BARO Sensor . . . 3-142
DTC 56 - Injection Pump Calibration BoostSensor . . . . . . . . . . . . . . . . . 3-142
Resistor Error 3-96 Wastegate Solenoid 3-143
DTC 57-PCM 5 Volt Shorted .. 3-98 Vehicle Speed Sensor (VSS) 3-143
DTC 61 - Turbo Boost Sensor VSS Buffer Module .. .... 3-143
Circuit High 3-100 Brake Switches 3-143
DTC 62 - Turbo Boost Sensor Cruise Control Switches 3-143
Circuit Low 3-102 Parts Information . . . . . . . . 3-143
GENERAL DESCRIPTION
The control module system has a computer, problems, alert the driver through the MIL (Service
Powertrain Control Module (PCM) to control fuel Engine Soon), and store one or more DTCs which
delivery, timing, and some emission control systems. identify the problem areas to aid the technician in
The control module system, monitors a number of making repairs. See diagnosis section for more
engine and vehicle functions (Figure 3-1) and controls information.
the following operations: The PCM is designed to process the various input
• Fuel control. information (Figure 3-1) and then sends the necessary
• Fuel injection timing. electrical responses to control fuel delivery, timing and
• Exhaust gas recirculation. other emission control systems. The input information
• Transmission shift and shift quality functions. has an interrelation to more than one output,
Specific transmission control diagnostics are therefore, i f the one input failed i t could effect more
covered in SECTION 10 of this service manual. than one systems operation.
POWERTRAIN CONTROL MODULE (PCM) PCM Learning Ability

Figure 3-2
The PCM has a "learning" ability which allows i t
The diesel Powertrain Control Module (PCM) is to make corrections for minor variations in the fuel
located i n the passenger compartment and is the system to improve driveability. I f the battery is
control center of the control module system. The PCM disconnected to clear DTCs, or for repair, the
used on the electronic fuel injected 6.5L diesel is "learning" process has to begin all over again.
referred to as PCME. A change may be noted i n the vehicle's
The PCM constantly looks at the information from performance. To "teach" the vehicle, make sure the
various sensors, and controls the systems that affect engine is at operating temperature, and drive at part
vehicle performance. The PCM performs the t h r o t t l e , w i t h moderate acceleration and i d l e
diagnostic function of the system. I t can recognize conditions, until normal performance returns.
operational
OPERATING CONDITIONS SENSED SYSTEMS CONTROLLED
• A/C Status • Exhaust Gas Recirculation (EGR) Operation

• Vehicle Speed (VSS) • Injection Timing
• Engine Coolant Temperature (ECT) • Fuel Control
• Crankshaft Position - Idle Speed and Quality
• Engine Speed (RPM) • Diagnostics
• Injection Pump Timing - Malfunction Indicator Lamp (MIL)
- High Resolution Signal "Service Engine Soon"
- Pump Cam Reference Signal POWERTRAIN - "Service Throttle Soon" Lamp
• Boost Pressure CONTROL
- Data Output
• System Voltage MODULE
(PCM) • Turbo Boost
• Accelerator Pedal Position (APP) • Transmission Functions
• EGR Control Pressure - Electronic Automatic Transmission
• Barometric Pressure (BARO) • Glow Plug System
• Intake Air Temperature (IAT) • Cruise Control
• Brake Switch
• Transmission Functions
• Fuel Temperature
• Cruise Control Request
3-11-33
*AII systems not used on all engines. PS 17155
Figure 3-1 - Control Module System

3-4 DRIVE ABILITY AND EMISSIONS (DIESEL)
NOTICE: The PCM must be maintained at a

temperature below 85°C (185°F) at all times. This
is most essential i f the vehicle is put through a
paint baking process. The PCM w i l l become
inoperative i f its temperature exceeds 85°C
(185°F). Therefore, i t is recommended that
temporary insulation be placed around the PCM
during the time the vehicle is in a paint oven or
other high temperature processes.
Electrostatic Discharge Damage
Electronic components used in control systems are

often designed to carry very low voltage, and are very
susceptible to damage caused by electrostatic
discharge. It is possible for less than 100 volts of static
electricity to cause damage to some electronic
components. By comparison, it takes as much as 4,000 Figure 3-2 - Powertrain Control Module
volts for a person to even feel the zap of a static
discharge. PCM FUNCTION
There are several ways for a person to become
statically charged. The most common methods of The PCM supplies a buffered 5 or 12 volts to power
charging are by friction and by induction. An example various sensors or switches. This is done through
of charging by friction is a person sliding across a car resistances in the PCM which are so high in value that
seat, in which a charge of as much as 25,000 volts can a test light will not light when connected to the circuit.
build up. Charging by induction occurs when a person In some cases, even an ordinary shop voltmeter will
with well insulated shoes stands near a highly charged not give an accurate reading because its resistance is
object and momentarily touches ground. Charges of too low. Therefore, the use of a 10 megohm input
the same polarity are drained off, leaving the person impedance digital voltmeter is necessary to assure
highly charged with the opposite polarity. Static accurate voltage readings.
charges of either type can cause damage, therefore, i t The input/output devices in the PCM include
is important to use care when handling and testing analog to digital converters, signal buffers, counters,
electronic components. and special drivers. The PCM controls output circuits
such as the inject solenoids, etc. by controlling the
NOTICE." To prevent possible Electrostatic ground circuit through transistors or a device called a
Discharge damage: driver in the PCM.
• Do Not touch the PCM connector pins or
soldered components on the PCM circuit board. MEMORY
• When handling a PROM, Do Not touch the
component leads, and Do Not remove integrated There are three types of memory storage within
circuit from carrier. the PCM: ROM, RAM and PROM.
• Be sure to follow the guidelines listed below i f
servicing any of these electronic components. ROM
1. Do not open the replacement part package
until i t is time to install the part. Read Only Memory (ROM) is a permanent memory
2. Avoid touching electrical terminals of the part. that is physically soldered to the circuit boards within
3. Before removing the part from its package, the PCM. The ROM contains the overall control
ground the package to a known good ground on algorithms. Once the ROM is programmed, it cannot
the vehicle. be changed. The ROM memory is non-volatile, and
4. Always touch a known good ground before does not need power to be retained.
handling the part. This step should be
repeated before installing the part if the part RAM
has been handled while sliding across the seat,
while sitting down from a standing position, or Random Access Memory ( R A M ) is the
while walking a distance. microprocessor "scratch pad." The processor can write
into, or read from this memory as needed.
DRIVE ABILITY AND EMISSIONS (DIESEL) 3-5
This memory is volatile and needs a constant supply of The PCM supplies a 5 volt signal to the Engine
voltage to be retained. I f the voltage is lost, the Coolant Temperature (ECT) sensor through a resistor
memory is lost. in the PCM and measures the voltage. The voltage
will be high when the engine is cold, and low when the
PROM engine is hot. By measuring the voltage, the PCM
Figure 3-4 knows the engine coolant temperature. Engine
coolant temperature affects fuel control and the glow
Programmable Read Only Memory (PROM) is the plug system.
portion of the PCM that contains the different engine
calibration information that is specific to year, model
and emissions.
The PROM also contains specific calibration
information used to allow fuel delivery if other parts of
the PCM are damaged. The PROM is a non-volatile
memory that is read only by the PCM.
While one PCM part number can be used by many
vehicle lines, a PROM is very specific and must be
used for the right vehicle. For this reason, it is very
1 HARNESS CONNECTOR
important to check the latest parts book and service
bulletin information for the correct part number when 2 LOCKING TAB
replacing a PROM. 3
SENSOR 5S1640-6E
A PCM used for service comes without a PROM.
Figure 3-3 - Engine Coolant Temperature (ECT)
The PROM should be retained with the vehicle
Sensor
following PCM replacement. The PROM from an old
PCM must be carefully removed and installed in the Accelerator Pedal Position (APP) Module
new PCM refer to "On-Vehicle Service." Figure 3-4
PCM SENSORS AND INPUT SIGNALS The APP module contains three potentiometers (a
device for measuring an unknown voltage or potential
In addition to the PCM, the control module system difference by comparison to a standard voltage). Each
has some or all of the following information sensors: of the APP sensors send a varying voltage to the PCM.
• Engine Coolant Temperature (ECT) sensor. By monitoring the output voltage from the
• Accelerator Pedal Position (APP) module. Accelerator Pedal Position (APP) module, the PCM
• Optical sensor. can determine fuel delivery based on the accelerator
• Fuel temperature sensor. pedal position (driver demand).
• Crankshaft position sensor.
• Intake Air Temperature (IAT) sensor. Optical Sensor
• EGR control pressure sensor.
• Barometric Pressure (BARO) sensor. The optical sensor sends what is called a High
• Boost sensor. Resolution Signal and a Pump Cam signal to the PCM.
• Vehicle Speed Sensor (VSS).
And some or all of the following input signals: High Resolution Signal
• Fuel inject signal.
• Brake switch signals. The PCM uses this signal to determine injection
• Glow plug signal. timing and for fuel control and is one of the most
• Cruise control signals. important inputs to the PCM.
• A/C signal.
Pump Cam Signal
• Automatic transmission sensors and signals.
Engine Coolant Temperature (ECT) Sensor The Pump Cam signal reference pulses are used by
Figure 3-3 the PCM to calculate injection timing and is one of the
most important inputs to the PCM.
The Engine Coolant Temperature (ECT) sensor is
a thermistor (a resistor which changes value based on
temperature) mounted in the engine coolant stream.
Low coolant temperature produces a high resistance
(100,000 ohms at -40°C/-40°F) while high temperature
causes low resistance (70 ohms at 130°C/266°F).
1 ACCELERATOR PEDAL POSITION (APP) MODULE
PS 16763 PS1751S
Figure 3-4 - Accelerator Pedal Position (APP) Module Figure 3-5 - Optical/Fuel Temperature Sensor
Fuel Temperature Sensor
Figure 3-5
The fuel temperature sensor is part of the

optical/fuel temperature sensor. The PCM uses the
fuel temperature signal for fuel control.
Crankshaft Position Sensor
The crankshaft position sensor provides a signal

which the PCM uses as reference to calculate RPM and 1 IAT SENSOR (TYPICAL)
crankshaft position. 7S3263-6E
Figure 3-6 - Intake Air Temperature (IAT) Sensor

Intake Air Temperature (IAT) Sensor
Figure 3-6 EGR Control Pressure/BARO Sensor
Figure 3-7
The Intake A i r Temperature (IAT) sensor is a
thermistor (a resistor which changes value based on On vehicles equipped with EGR, the EGR control
temperature) mounted in the intake manifold. pressure/BARO sensor, mounted on the left side of the
Low temperature produces a high resistance cowl, is used to monitor the amount of vacuum in the
(100,000 ohms at -40°C/-40°F) while high temperature EGR circuit. It senses the actual vacuum in the EGR
causes low resistance (70 ohms at 130°C/266°F). vacuum line and sends a signal back to the PCM. The
The control module supplies a 5 volt signal to the signal is compared to the desired EGR calculated by
sensor through a resistor in the control module and the PCM. If there is a difference in the PCM command
measures the voltage. The voltage will be high when and what is at the EGR valve sensed by the EGR
the intake air is cold, and low when the air is hot. By control pressure/BARO sensor on vehicles not equipt
measuring the voltage, the control module knows the with EGR this sensor is used only to measure BARO,
intake air temperature. the PCM makes minor adjustments to correct.
The IAT signal is used by the control module to
control fuel.
DR1VEABILITY AND EMISSIONS (DIESEL) 3-7
When a major difference is sensed, the PCM Vehicle Speed Signal (VSS) Buffer Module
recognizes a fault and sends a maximum EGR signal.
This sensor is also used to measure barometric The VSS buffer module is an electronic device.
pressure (BARO) under certain conditions, which The VSS buffer module process inputs from the vehicle
allows the PCM to automatically adjust for different speed sensor and outputs various signals. The VSS
altitudes. buffer module outputs a 4000 pulse per mile signal.
This signal is used by the PCM to determine vehicle
speed. The PCM uses vehicle speed signal input for
cruise control and fuel cutoff. The VSS buffer module
is matched to the vehicle based on transmission, final
drive ratio and tire size. The VSS buffer module is
located behind the instrument panel.
Fuel Inject Signal
The fuel injector driver receives an inject

command signal from the PCM and provides a current
regulated output to the fuel solenoid that controls
injection. It also returns an injection pulse width
signal back to the PCM to inform i t when the fuel
1 SENSOR solenoid has actually seated.
2 ELECTRICAL CONNECTOR
6S2648-6E
Brake Switch Signals
Figure 3-7 - EGR Control Pressure/BARO Sensor The TCC normally closed brake switch supplies a
Boost Sensor B + signal into the PCM. The signal voltage is opened
Figure 3-8 when the brakes are applied.
The cruise control normally open brake switch
The boost sensor measures the changes in the supplies a B + signal to the PCM when the brake is
intake manifold pressure. The boost sensor converts applied. These signals are used by the PCM to control
engine load and speed changes, then converts the transmission and cruise control functions. The brake
change in readings to voltage output. switches are part of the stoplamp switch.
The PCM sends a 5 volt reference signal to the
boost sensor. As the manifold pressure changes, the G l o w Plug Signal
electrical resistance of the boost sensor also changes.
By monitoring the sensor output voltage, the PCM The glow plug system is used to assist in providing
detects the boost pressure. A high pressure (high the heat required to begin combustion during engine
voltage) requires more fuel. A lower pressure (low starting at cold ambient temperatures.
voltage) required less fuel.
The control module uses the boost pressure signal
to control fuel delivery.
Vehicle Speed Sensor (VSS)
The VSS is attached to the output shaft housing.

This device contains a permanent magnet surrounded
by a coil of wire producing a magnetic field which is
interrupted by rotor teeth pressed on an output shaft.
As the rotor interrupts the magnetic field an AC
voltage is generated in the circuit.
1 SENSOR
6S2648-6E
Figure 3-8 - Boost Sensor

The glow plugs are heated before and during A/C Signal
cranking, as well as initial engine operation. The
PCM monitors the glow plug relay output. This signal indicated that the A/C compressor
clutch is engaged. The PCM uses this signal to adjust
Cruise Control Signal the idle speed.
The cruise control switches are part of the Automatic Transmission Sensors and Signals
mulitfunction turn signal lever. These switches
enable the driver to control the cruise on/off, set/coast Refer to SECTION 10 of this service manual for a
and resume/accel signals. These signals are inputs to description of automatic transmission sensors and
the fuel control portion of the PCM and allow the PCM signals.
to maintain a desired vehicle speed under normal
driving conditions.
DIAGNOSIS
DIAGNOSTIC INFORMATION "Service Throttle S o o n " Lamp
The diagnostic "tree" charts and functional checks This light is on the instrument panel and has the
in this manual are designed to locate a faulty circuit or following functions:
component through logic based on the process of • I t informs the driver that a problem has
elimination. occurred in the Accelerator Pedal Position
The charts are prepared with the requirements (APP) circuit and the vehicle should be taken
that the vehicle functioned correctly at the time of in for service as soon a reasonably possible.
assembly and that there are no multiple failures. • If APP DTCs are stored by the PCM, the MIL
The PCM performs a continual self-diagnosis on will display these. The "Service Throttle Soon"
certain control functions. This diagnostic capability is Lamp will not display DTCs.
complemented by the diagnostic procedures contained As a bulb and system check, the light will come
i n this manual. The PCM's language for "ON" with the key "ON" for 2 seconds. When the
communicating the source of a malfunction is a system engine is started, the light will turn "OFF." I f the
of Diagnostic Trouble Codes (DTCs). The DTCs are light remains "ON," the self-diagnostic system has
two digit numbers that can range from 12 to 99. When detected a problem. If the problem goes away, the light
a malfunction is detected by the PCM, a DTC is set will go out in most cases after 10 seconds, but a DTC
and the Malfunction Indicator Lamp ( M I L ) is will remain stored in the PCM.
illuminated. When the light remains "ON" while the engine is
running, or when a malfunction is suspected, an
Malfunction Indicator Lamp (MIL) "Service "On-Board Diagnostic (OBD) System Check" must be
Engine Soon" performed. This check will expose malfunctions which
may not be detected if other diagnostics are performed
This light is on the instrument panel and has the prematurely.
following functions:
• I t informs the driver that a problem has ON-BOARD DIAGNOSTIC ( O B D ) S Y S T E M
occurred and that the vehicle should be taken CHECK
in for service as soon as reasonably possible.
• It displays DTCs stored by the PCM which help After the visual/physical underhood inspection,
the technician diagnose system problems. the on-board diagnostic system check, is the starting
As a bulb and system check, the light will come point for all diagnostic procedures or finding the
"ON" with the key "ON" and the engine not running. cause of an emission test failure.
When the engine is started, the light will turn "OFF."
If the light remains "ON", the self-diagnostic system
has detected a problem. If the problem goes away, the
light will go out in most cases after 10 seconds, but a
DTC will remain stored in the PCM.
When the light remains "ON" while the engine is
running, or when a malfunction is suspected due to a
driveability or emissions problem, an Ôn-Board
Diagnostic (OBD) System Check" must be performed.
This check will expose malfunctions which may not be
detected i f other diagnostics are performed
prematurely.
4
l/P HARNESS CONNECTOR (23 PIN)
PCM
451 WHT/BLK DIAGNOSTIC
REQUEST
450 WHT/BLK —IPC! SYSTEM GROUND
F E 0 c B A TO VSS TO FUEL PUMP RELAY

Q o TO PARK/ BUFFER TO FUEL
G H J « L M NEUTRAL MODULE PUMP
SWITCH ENGINE . 551 TAN/WHT PD1 SYSTEM GROUND
DATA LINK GROUND
CONNECTOR 1061 ORN/BLK PC14 SERIAL DATA
(DLC)
rTO BRAKE SWITCH
IGNITION ^ IGNITION FEED
SWITCH - 439 PNK/BLK
10 AMP
B+ — — 440 ORN BATTERY FEED
FUSIBLE E
MIL
LINK OIL PRESSURE SWITCH
JUNCTION MIL "SERVICE
BLOCK 419BRN/WHT ENGINE SOON"
"39 PNK/BLK
"SERVICE CONTROL
ENGINE SOON" l/P BULK HEAD
Si
CONNECTOR (23 PIN)
GAUGES
TO <H 39 PNK/BLK — 960 ORN "SERVICE THROTTLE
IGNITION 20AMP SERVICE i d - SOON " LAMP
SWITCH THROTTLE SOON* CONTROL
LAMP
r-
TO CRUISE PCM CONN. ID
CONTROL SWITCH i
| PA/PB PINK 32 PIN
i PC/PD PINK 24 PIN t
i BC/BD BLUE 32 PIN i 1-4-94
i • NS 14112
i
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK

(WITH TECH 1 SCAN TOOL)
Circuit Description:
The "On-Board Diagnostic (OBD) System Check" is an organized approach to identifying a problem created
by a control module system malfunction. It must be the starting point for any driveabilitv complaint diagnosis,
this will direct the service technician to the next logical step in diagnosing the complaint. Understanding the
chart and using i t properly will reduce diagnostic time and prevent the unnecessary replacement of good parts.
Chart Test Description: Number(s) below refer to 6. Although the PCM is powered up, a "Cranks But
circled number(s) on the diagnostic chart. Will Not Run" symptom could exist because of a
1. When the ignition switch is cycled to "ON," the PCM or system problem.
MIL should turn "ON" briefly, then "OFF" briefly, 7. Comparison of actual control system data with the
then remain "ON" steady. This sequence will Typical Tech 1 Data. Values is a quick check to
determine that the vehicle diagnostics are determine if any parameter is not within limits. A
operational. base engine problem (i.e., advanced cam timing
2. This step will isolate if the customer complaint is may substantially alter sensor values).
a MIL or driveability problem.
3. Although the control module is powered up, a NOTICE: The PCM utilizes a 24 pin "Pink"
symptom could exist because of a system fault. connector, a 32 pin "Pink" connector and a 32 pin
4. Use Tech 1 to aid diagnosis, therefore, serial data "Blue" connector. The 24 pin "Pink" connector is
must be available. If a PROM (MEM-CAL) error is labeled "A" and "B", the 32 pin "Pink" connector is
present, the PCM may have been able to flash DTC labeled "C" and "D" and the 32 pin "Blue"
12/51, but not enable serial data. connector is labeled "C" and " D " . When
5. This step will isolate if the customer complaint is a referencing PCM connector pin outs, the "Blue"
MIL or driveability problem with no MIL. Refer to PCM connector will be referred to as the "E" and
"Diagnostic Trouble Code Identification" in this "F" connector.
section for a list of valid DTCs. An invalid DTC
may be the result of a faulty scan tool, PROM or
PCM.
ON-BOARD DIAGNOSTIC (OBD) SYSTEM

CHECK
• IGNITION "ON." ENGINE "OFF."

• NOTE MIL (SERVICE ENGINE SOON).
©[ STEADY LIGHT
I
©[
2 )\ NO LIGHT FLASHING LIGHT
I
© • WITH TECH 1 SCAN TOOL PERFORM

ONBOARD DIAGNOSTIC SYSTEM CHECK
| REFER TO J
i CHART A-1. i
CHECK FOR GROUNDED
DIAGNOSTIC TEST CKT 451.
OR
JUMPER DATA LINK CONNECTOR
TERMINAL " B " TO " A " .
• DOES MIL FLASH?
YES NO
©[ DOES TECH 1 DISPLAY SCAN DATA? REFER TO CHART A-2.
3
YES NO
©[ ARE ANY DTCs DISPLAYED? ! REFER TO CHART A-2. !
3L
YES NO
6 ) DOES ENGINE START?

0 REFER TO "TYPICAL TECH 1 DATA VALUES" AND
COMPARE SCAN DATA.
YES NO
X
• REFER TO APPLICABLE DTC CHART. I REFER TO CHART A-3. \
START WITH LOWEST DTC.
IF PCM IS FAULTY AND MUST BE REPLACED, "TDC OFFSET" MUST BE PROGRAMMED INTO THE NEW PCM.
REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION.
11-1-93
PS 17310
If after completing the On-Board Diagnostic (OBD) system check and finding the Tech 1 diagnostics
functioning properly and no DTC(s) displayed, the "Typical Tech 1 Engine Data Values" may be used for
comparison with values obtained on the vehicle being diagnosed. The "Typical Tech 1 Engine Data Values" are
an average of display values recorded from normally operating vehicles and are intended to represent what a
normally functioning system would display.
A SCAN TOOL THAT DISPLAYS FAULTY DATA SHOULD NOT BE USED, AND THE PROBLEM
SHOULD BE REPORTED TO THE MANUFACTURER. THE USE OF A FAULTY SCAN TOOL CAN
RESULT IN MISDIAGNOSIS AND UNNECESSARY PARTS REPLACEMENT.
Only the parameters listed below are used in this manual for diagnosing. I f a scan tool displays other
parameters, the values are not recommended by General Motors for use in diagnosing. For more description on
the values and use of the Tech 1 to diagnosis PCM inputs, refer to the applicable diagnosis section in "Component
Systems." If all varies are within the range illustrated, refer to "Symptoms," section.
TYPICAL TECH 1 ENGINE DATA VALUES

Idle / Lower Radiator Hose Hot / Closed Throttle / Park or Neutral / Accessories Off
SCAN Position Units Displayed Typical Data Value Refer To Section:
ENGINE SPEED RPM ± 100 RPM from desired
DESIRED IDLE RPM PCM commanded (based on temp.)
o
ENG COOL TEMP. C7F° 85°C- 105 C(185°F-221°F)
INTAKE AIR TEMP. C7F° 10°C-87°C(50°F- 194°F)
(depends on underhood temperature)
BARO kPa/Volts 70 -100/3.5-4.5 (varies with altitude)
DESIRED EGR kPa/Volts 50 -100 kPa/2.8 - 3.0V (varies)
EGR DUTY CYCLE Percentage 35- 100% (may vary)
WASTEGATE SOL DC Percentage 60- 100% (may vary)
BOOST PRESSURE kPa/Volts 99-160 kPa/1.0-3.5 volts
FUEL TEMPERATURE C7F° 21°C-43°C(70°F- 110°F)
FUEL RATE Millimeters 7-16 mm (varies with engine load)
GLOW PLUG RELAY Volts 12.0-14.5
GLOW PLUG VOLTS Volts 12.0-14.5
DESIRED INJ TIM # of degrees Varies
MEASURED INJ TIM # of degrees Varies
THROTTLE ANGLE Percentage 0-100%
ACCEL PEDPOS1 Volts 0.35-0.95V
ACCEL PED POS 2 Volts 4.0-4.5V
CRUISE CONTROL On/Off Off
MPH km/h 0-98
C/C BRAKE SWITCH Open/Closed Open
TCC BRAKE SWITCH Closed/Open Closed
INJ PULSE WIDTH Milliseconds 1.70-1.90 ms (may vary)
TDC OFFSET # of degrees 0-2.02 (varies)
A/C CLUTCH On/Off Off
SYSTEM VOLTAGE Volts 12.0- 14.5
ENG SHUT OFF On/Off On
CRANK REF MISSED Counts 0 (missed)
CAM REF MISSED Counts 0 (missed)
1-2 SOL/2-3 SOL On/Off On/On
TCC SOLENOID On/Off Off
4WD LOW SWITCH On/Off Off
TRANS RANGE SW Invalid, Rev
Drive 4, Drive 3,
Drive 2, Low,
Park/Neut Park/Neut
CALIBRATION ID 0-9999 Internal
TIME FROM START Hrs/M ins/Sec Varies
11-04-93
PS 16981
ENGINE TECH 1 DATA DEFINITIONS

A list of each data message displayed on the Tech 1 scan tool will be explained in two groups; "Engine" or
"Transmission." This information will assist in emission or driveability problems. The displays can be viewed
while the vehicle is being driven. Always perform the "On-Board Diagnostic (OBD) System Check" first. The
"OBD System Check" will confirm proper system operation.
For transmission data refer to SECTION 10.
ENGINE DATA
ENGINE SPEED - Range 0-9999 RPM - Engine speed is ACCELERATOR PEDAL POSITION (APP 1) - Range 0-5
computed by the PCM from the distributor reference Volts - Used by the PCM to determine the amount of
input (low resolution circuit). It should remain close to throttle demanded by the driver. Should read about
desired idle under various engine loads with engine .35-.9S volts at idle to above 4.0 volts at Wide Open
idling. Throttle (WOT).
DESIRED IDLE - Range 0-3187 RPM - The idle speed ACCELERATOR PEDAL POSITION (APP 2) - Range 0-5
that is commanded by the PCM. The PCM w i l l Volts - Used by the PCM to determine the amount of
compensate for various engine loads based on engine throttle demanded by the driver. Should read about
coolant temperature to keep the engine at the desired 4.5 volts at idle and steadily decrease to about 1.0 volt
speed. at wide open throttle.
ENG COOL TEMP - Range -40°C to 151°C, -40°F to 304°F ACCELERATOR PEDAL POSITION (APP 3) - Range 0-5
- The Engine Coolant Temperature (ECT) sensor is Volts - Used by the PCM to determine the amount of
mounted i n the coolant pump and sends engine throttle demanded by the driver. Should read about
temperature information to the PCM. The PCM 4.0 volts at idle and steadily decrease to about 2.5 volts
supplies 5 volts to the ECT sensor circuit. The sensor at wide open throttle.
is a thermistor which changes internal resistance as
temperature changes. When the sensor is cold CRANK REFERENCE PULSE - Range 0-8 Counts - This is
(internal resistance high), the PCM monitors a high used by the PCM to determine crankshaft position.
signal voltage and interprets it as a cold engine. As The scan tool will display the number of crank pulses
the sensor warms (internal resistance decreases), the missed. At idle it should read 0.
voltage signal will decrease and the PCM w i l l
interpret the lower voltage as a warm engine. CAM REFERENCE PULSE - Range 0-8 Counts - This is
used by the PCM to determine injection pump cam
INTAKE AIR TEMP - Range -40°C to 151°C, -40°F to position. The scan tool will display the number of cam
304°F - The PCM converts the resistance of the intake pulses missed. At idle it should read 0.
air temperature sensor to degrees. Intake A i r
Temperature (IAT) is used by the PCM to adjust fuel BOOST PRESSURE - Range 10-200 kPa/0-5.0 Volts - The
delivery and spark timing according to incoming air amount of turbo boost pressure in the intake manifold.
density. This is measured i n kPa and volts. True boost
pressure is determined by subtracting BARO from the
BARO - Range 10-105 kPa/0.00-5.00 Volts - The BARO actual reading.
reading displayed is determined from the MAP sensor
at ignition "ON," engine "OFF," and WOT conditions. FUEL TEMP - Range -40°C to 151°C -40°F to 304°F -
t
The BARO reading displayed represents barometric There is a thermistor located in the high resolution
pressure and is used to compensate for altitude sensor that determines fuel temperature. When the
differences. sensor is cold (internal resistance high) the PCM
monitors a high signal voltage which it interprets as
THROTTLE ANGLE - Range 0 -100% - Computed by the low fuel temperature. As the sensor warms (internal
PCM from APP module voltage (throttle position) and resistance low) the voltage signal will decrease and the
should display 0% at idle and 100% at wide open PCM will interpret the low voltage as warm fuel.
throttle. Refer to DTC 21 if TP sensor angle is not 0%
at idle. FUEL RATE - Range 0-80 mm - This reading is
displayed in millimeters (mm). This is the amount of
fuel the PCM is requesting.
GLOW PLUG RELAY - Range 0-25.5 Volts - This is the INJECTOR PULSE WIDTH - Tech 1 Range 0.0-4.00
amount of volts the PCM is requesting to be sent to the milliseconds - Indicates the closure time of the fuel
glow plug relay. The PCM will cycle the voltage "ON" solenoid. When engine load is increased, injector pulse
and "OFF." Cycling timing will increase when engine width will fluctuate.
is cold and decrease at warmer temperatures.
EGR DUTY CYCLE - Range 0-100% - The PCM cycles
GLOW PLUG VOLTS - Range 0-25.5 Volts - This is used the EGR solenoid valve "ON" and "OFF." The "ON"
by the PCM to determine if there is voltage coming out time (duty cycle) of the EGR solenoid valve, expressed
of the relay and going towards the glow plugs. During as a percent, determines how much the exhaust gas is
normal operation the volts reading will be lower than recirculated.
glow plug relay voltage because of the high resistance
in the glow plugs. A/C REQUEST - Tech 1 displays " Y E S ' V N O " -
Represents if the A/C request from the control head is
DESIRED INJECTION TIMING - Range 0-25.5 Degrees - being received by the PCM.
The amount of injection timing requested by the PCM.
PARK/NEUTRAL POS - Tech 1 displays - "P-N"-- or -"R-
MEASURED INJECTION TIMING - Range 0-25.0 Degrees DL" - "P-N"~ displayed indicates that the gear select
- Current actual injection timing. lever is in park or neutral.
TDC OFFSET - Range + /- 2,02 Degrees - The PCM has CRUISE CONTROL - Tech 1 Displays "OFF 7"ON" - This
f
the ability to determine the amount of offset needed to will indicate when the cruise control has been enabled.
bring the engine to top dead center. This is used by the This signal is used by the PCM to adjust TCC
PCM to determine proper injection timing and fuel engagement scheduling and to operate PCM cruise
delivery. This value may be displayed as a positive or fuel.
negative number.
1 - 2 SHIFT SOL - Tech 1 displays "ON'7"OFF" - When
EGR DESIRED POSITION - Range 10-103 kPa - The PCM the transmission in in first or fourth gear, the Tech 1
command for EGR vacuum that is desired. should display "ON." When the transmission is in
second or third gear, the Tech 1 should indicate "OFF."
EGR ACTUAL POSITION - Range 10-103 kPa - Current
actual EGR vacuum. 2 - 3 SHIFT SOL - Tech 1 displays "ON"f OFF" - When
the automatic transmission is in first or second gear,
4WD LOW SWITCH - Indicator to PCM when driver the Tech 1 should indicate " O N . " When the
selects 4WD low. transmission is in third or fourth gear, the Tech 1
should display "OFF."
MPH/km/h - Vehicle speed is a PCM internal
parameter. I t is computed by timing pulses coming C/C BRAKE SWITCH - Tech 1 displays "OPEN"/
from the Vehicle Speed Sensor (VSS). Vehicle speed is "CLOSED" - When the brake pedal is applied, the
used in checking TCC lock-up speed or speedometer switch sends a signal to the PCM to disengage cruise
accuracy. Speed is displayed in both Miles Per Hour control.
(mph) and Kilometers Per Hour (km/h).
TCC BRAKE SWITCH - Tech 1 displays "CLOSED"/
PROM ID - The PROM identification parameter "OPEN" - When the brake pedal is applied, the switch
describes the particular PROM used in the PCM being sends a signal to the PCM to disengage the TCC
tested. The PROM contains the PCM program. PROM solenoid. It also serves as a redundant cruise control
ID is used when it is necessary to replace the PROM. disengagement switch.
PROM ID must be specified when ordering new
PROMs. PROM ID should not be confused with "Part TIME FROM START - Range 0 : 0 0 : 0 0 - 1 8 : 1 2 : 1 5
Number/' HR/MIN/SEC - A measure of how long the engine has
been operating. When the ignition is cycled to "OFF"
the value is reset to zero.
12-6-93
PS1S976
TECH 1 SCAN T O O L PCM INFORMATION MODES
The diagnostic procedures in this manual assume The PCM has two modes for t r a n s m i t t i n g
the use of a Tech 1 scan tool. Since the Tech 1, information. The following information will describe
produced by Expertec, is able to perform functions, the system operation in each of the modes.
such as, bidirectional communication that other scan
tools are unable to perform, i t has been made an Normal (Open) Mode
essential tool. Although, the term scan tool will
continue to be used for simplicity's sake, we On engines that can be monitored in the "Open"
recommend the Tech 1 be used whenever possible. mode, certain parameters can be observed without
Explicit instructions on connecting and using the changing the engine operating characteristics. The
various Tech 1 functions are contained in the Tech 1 parameters capable of being read vary with engine
owner's manual. families.
The PCM can communicate a v a r i e t y of
information through Data Link Connector (DLC) Diagnostic Mode
terminal "M". This data is transmitted at high
frequency w h i c h r e q u i r e s a scan tool for When the diagnostic terminal is grounded with the
interpretation. ignition "ON" and the engine "OFF," the system will
enter what is called the diagnostic mode. In this mode
the PCM will:
Display a DTC 12 by flashing the MIL.
OR
Display any stored DTC by flashing the MIL. Each
TERMINAL IDENTIFICATION DTC will be flashed three times.
EJ GROUND EBCM D I A G N O S T I C
TERMINAL (ANTILOCK)
Reading Diagnostic Trouble Codes
• PCM DIAGNOSTIC
TERMINAL
f~T| E A N D C DATA ( R A D I O ) The means of communicating with the control
module is the Data Link Connector (DLC) (refer to
FUEL PUMP PRIME PCM SERIAL Figure 3-9) located under the instrument panel and is
DATA 3-9-93
8S3967-6E sometimes covered by a plastic cover labeled
"DIAGNOSTIC CONNECTOR" The DLC is used in
Data Link Connector (DLC)
the assembly plant to receive engine information to
With an understanding of the data which the scan determine proper operation before it leaves the plant.
tool displays, and knowledge of the circuits involved, The DTC(s) stored in the control module memory can
the scan tool can be very useful i n obtaining be displayed either through the Tech 1 scan tool, a
information which would be more difficult or hand-held diagnostic scanner plugged into the DLC
impossible to obtain with other equipment. connector, or by counting the number of flashes of the
Scan tools do not make the use of diagnostic charts Malfunction Indicator Lamp (MIL) "Service Engine
unnecessary, nor can they indicate exactly where a Soon" when the diagnostic terminal of the DLC is
problem is in a particular circuit. Diagnostic tree grounded. The DLC terminal " B " (diagnostic
charts incorporate diagnosis procedures using a scan terminal) is the second terminal from the right of the
tool where possible and most charts require the use of a DLC top row. The terminal is most easily grounded by
scan tool when i t is applicable. connecting i t to terminal "A" (internal control module
ground), which is located to the right of terminal "B"
A SCAN TOOL THAT DISPLAYS FAULTY DATA on top row of the DLC.
SHOULD NOT BE USED AND THE PROBLEM
SHOULD BE REPORTED TO THE MANUFACTURER. DTC 12
THE USE OF A FAULTY SCAN TOOL CAN RESULT IN
MISDIAGNOSIS AND UNNECESSARY PARTS When terminals "A" and "B" have been connected,
REPLACEMENT. the ignition switch turned to the "ON" position with
the engine not operating, the MIL (Service Engine
The scan tool has the ability to save time in Soon) should flash DTC 12 three times consequently.
diagnosis and prevent the replacement of good parts. This will be the following flash sequence: "flash,
The key to using the scan tool successfully for pause, flash-flash, long pause, flash, pause, flash-flash,
diagnosis lies in the technician's ability to understand long pause, flash, pause, flash-flash." DTC 12
the system being diagnosed, as w e l l as an indicates that the control module diagnostic system is
understanding of the scan tool's limitations. operating properly.
If the DTC 12 is not indicated, and a fault is present Scan Tool Use With Intermittents
within the diagnostic system itself, i t should be
addressed by consulting the appropriate diagnostic In some scan tool applications, the data update
chart in this section. rate makes the tool less effective than a voltmeter,
The malfunction indicator lamp will indicate a such as when trying to detect an intermittent problem
Diagnostic Trouble Code (DTC) three times if a DTC is which lasts for a very short time. However, the scan
present, or it will simply continue to output DTC 12. I f tool allows manipulation of wiring harnesses or
more than one diagnostic trouble code has been stored components under the hood with the engine not
in the control module memory, the DTC(s) will be running, while observing the scan tool readout.
displayed from the lowest to the highest with each The scan tool can be plugged in and observed while
DTC being displayed three times. driving the vehicle under the condition when the MIL
"Service Engine Soon" light turns "ON" momentarily
Clearing Diagnostic Trouble Codes or when the engine driveability is momentarily poor.
I f the problem seems to be related to certain
To clear the DTC(s) from the memory of the control parameters that can be checked on the scan tool, they
module, either to determine i f the malfunction will should be checked while driving the vehicle. I f there
occur again or because repair has been completed, the does not seem to be any correlation between the
Tech 1 scan tool should be used to clear the DTC(s). I f problem and any specific circuit, the scan tool can be
a scan tool is not available the following must be checked on each position, watching for a period of time
performed when all repairs have been completed. This to see i f there is any change in the readings that
will allow all DTC(s) to be cleared. indicates intermittent operation.
1. Ignition "OFF." The scan tool is also an easy way to compare the
2. Ground diagnostic terminal "A" to "B" of DLC. operating parameters of a poorly operating engine
3. Ignition "ON." with those of a known good one. For example, a sensor
4. Fully apply brake pedal. may shift in value but not set a DTC. Comparing the
5. Fully apply accelerator pedal. sensor's readings with those of a known good vehicle
6. Check MIL (Service Engine Soon) for DTC 12. may uncover the problem.
7. Release brake pedal. The scan tool has the ability to save time i n
8. Release accelerator pedal. diagnosis and prevent the replacement of good parts.
9. Check MIL (Service Engine Soon) for DTC 12. The key to using the scan tool successfully for
10. Remove jumper from DLC connector. diagnosis lies i n the technician's ability to understand
11. Turn ignition "OFF." the system he is trying to diagnose as well as an
understanding of the scan tool operation and
NOTICE: To prevent control module damage, the limitations. The technician should read the tool
key must be "OFF" when disconnecting or manufacturer's operating manual to become familiar
reconnecting module power. with the tool's operation.
Intermittents T 1 0 0 - G M CAMS
A corresponding DTC will be stored in the memory The T100-GM CAMS (Computerized Automotive
of the PCM as a history DTC until DTCs have been Maintenance System) is a computerized technician's
cleared. When unexpected DTCs appear during the terminal unit. When connected to a vehicle, performs
code reading process, one can assume that these DTCs engine, electronic circuits and systems test to find
were set by an intermittent malfunction and could be possible vehicle problems in the engine system or the
helpful in diagnosing the system. PCM.
An intermittent DTC may or may not re-set. If it is The terminal diagnoses as follows:
an intermittent failure, a Diagnostic Trouble Code • C i r c u i t diagnostic procedures provide
(DTC) chart is not used. Consult the "Diagnostic Aids" information on how to isolate a problem and
on the page facing the diagnostic chart corresponding repair requirements.
to the intermittent DTC. SECTION "2" also covers • I f no problem exists, engine performance
the topic of "Intermittents." A physical inspection of problems are diagnosed.
the applicable sub-system most often will not resolve • DTCs stored i n the PCM are read and
the problem. diagnosed by the system.
Also needed are a test light, ohmmeter, digital good PCM. Although this is a rare condition, it could
voltmeter with 10 megohms impedance (J 39200), happen.
vacuum gage and jumper wires for diagnosis. Special
tools which are required for system service and the PROM
ones described above are illustrated in SECTION 13.
A PROM that has failed or was i n s t a l l e d
PCM DIAGNOSIS improperly will generally set a DTC 51.
Since the PCM can have a failure which may affect FUELCONTROL
only one circuit, following the diagnostic procedures in
this section can reliably tell when a failure has Fuel delivery is controlled by the control module
occurred in the PCM. Also, a DTC 54 indicates a system.
failure of the PCM. The diagnosis of fuel control starts with "Engine
If a diagnostic chart indicates that the PCM Cranks But Will Not Run" CHART A-3. This chart
connections or PCM is the cause of a problem, and the will test the fuel system and i f there is a problem, will
PCM is replaced, but does not correct the problem, one lead you to checking the fuel lift pump, diagnosing the
of the following may be the reason: injection pump circuit or diagnosing the fuel system.
• There is a problem with the PCM terminal
connections. - The diagnostic chart will say PCM SENSORS AND INPUT SIGNALS
PCM connections or PCM. The terminals may
have to be removed from the connector in order A l l of the sensors and input signals can be
to check them properly. diagnosed by the use of a scan tool. Following is a
• The PCM or PROM is not correct for the short description of how the sensors and signals can be
application. - The incorrect PCM or PROM diagnosed by the use of a scan tool. A scan tool can
may cause a malfunction and may or may not also be used to compare the values for a normal
set a DTC. running engine with the engine you're diagnosing.
• The problem is intermittent. - This means that Refer to "Typical Scan Tech 1 Engine Data Values."
the problem is not present at the time the
system is being checked. In this case, refer to Engine Coolant Temperature (ECT) Sensor
"Driveability Symptoms" portion of the
manual and make a careful p h y s i c a l A scan tool displays engine coolant temperature in
inspection of all portions of the system degrees (Celsius & Fahrenheit). After engine is
involved. started, the temperature should rise steadily to about
• Shorted solenoid, relay coil, or harness. - 90°C (194°F) then stabilize when thermostat opens.
Solenoids and relays are turned "ON" and DTC 14 or DTC 15 indicates a failure in Engine
"OFF" by the PCM, using internal electronic Coolant Temperature (ECT) sensor circuit.
switches called "Drivers." The DTC charts also contain a chart to check for
A shorted solenoid, relay coil, or harness will not ECT sensor resistance values relative to temperature.
damage the PCM, but will cause the circuit and
controlled component to be inoperative. When the Accelerator Pedal Position (APP) Module
circuit fault is not present or has been repaired, the
driver will again operate in a normal manner due to If the PCM has determined that there is a fault in
it's fault protected design. If a fault has been repaired one APP sensor, the PCM will store a current and
in a circuit controlled by a driver, the original PCM history DTC, but, i t will not turn on the "Service
should be reinstalled and the circuit checked for proper Throttle Soon" lamp. The vehicle and throttle pedal
operation. PCM replacement will not be necessary if will operate normally i f only one of the three APP
the repair circuit or component now operates correctly. sensors is at fault. I f the PCM has determined two
J 34636 or BT-8405 testers or equivalent provide a APP sensors are faulty, a current and history DTC will
fast, accurate means of checking for a shorted coil or a set and the PCM will turn on the "Service Throttle
short to battery voltage. Soon" lamp. At this point, some engine performance
• The PROM may be faulty. - Although the PROM will be lost. I f three APP sensors malfunction, a
rarely fails, it operates as part of the PCM. Therefore, current and history DTC will be stored, the "Service
it could be the cause of the problem. Substitute a Throttle Soon" lamp will come "ON," and the PCM will
known good PROM. only allow the vehicle to idle. I f the PCM has
• The replacement PCM may be faulty. - After the recognized an i n t e r m i t t e n t fault (a fault not
PCM is replaced, the system should be rechecked for recognized by the normal APP DTC setting criteria), it
proper operation. I f the diagnostic chart again will then only allow the vehicle to operate under
indicates the PCM is the problem, substitute a known limited performance and store a DTC 84.
A scan tool reads APP 1 position in voltage, and EGR Control Pressure/BARO Sensor
should read about .50 volt while the engine is idling.
Voltage should increase at a steady rate as accelerator A scan tool displays EGR pressure in volts. Low
pedal is moved to Wide Open Throttle (WOT). APP 2 pressure (high vacuum) reads a low voltage while a
position is also read in voltage, and should read about high pressure (low vacuum) reads a high voltage. A
4.5 volts at idle, and should steadily decrease to a failure in the EGR control pressure/BARO sensor
about 1.5 volts as accelerator pedal is moved to WOT. circuit should set a DTC 31 or 33 and using the chart
APP 3 is also read in voltage, and should read about will find the cause of the problem. Any other failure in
4.0 volts at idle, and should steadily decrease to about the EGR system should set a DTC 32, 44 or 45. On
2.0 volts. Its possible idle voltage may vary, because vehicles using only a BARO sensor a failure in the
the PCM has a "learning" ability which allows it to sensor circuit should set a DTC 31 or 33. Also refer to
make corrections for minor variations. "EGR Control Pressure/BARO Sensor Output Check"
in this section.
Pump Cam Signal
Boost Sensor
Loss of cam signal reference pulses will set a DTC
18. I f the cam signal is lost while the engine is At idle, the scan tool will display boost pressure
running, the fuel injection system will shift to a time about the same reading as barometric pressure. When
base fuel injection (backup fuel) mode based on at a full load, with WOT the boost pressure w i l l
crankshaft position sensor signal, and the engine will indicate high pressure or voltage. When at a decel
continue to run. The engine can be restarted and will with throttle closed, the boost sensor will display low
run in the calculated fuel injection mode as long as the pressure or voltage. The boost pressure reading is the
fault is present. opposite of what you would measure on a vacuum
See DTC 18 for further information. gage. When manifold pressure is high, vacuum is low.
A failure in the boost sensor circuit should set a DTC
Fuel Temperature Sensor 61 or 62.
The scan tool displays fuel temperature in degrees Vehicle Speed Sensor (VSS)
(celsius/fahrenheit). DTC 42 or DTC 43 indicate a
failure in the fuel temperature sensor circuit. A scan tool display of mph / km/h should closely
match with the speedometer display. A failure in the
Crankshaft Position Sensor VSS input circuit should set a DTC 24 or DTC 16.
A scan tool displays engine speed in RPM. RPM Fuel Inject Signal
will still be displayed with a fault in this circuit. If the
signal is lost while the engine is running, the fuel A scan tool will display the injection pulse width
injection system will shift to a time base fuel injection feedback in milliseconds. If the PCM detects an error
mode based on pump cam signal, and the engine will in the fuel inject response time, a DTC 35 or DTC 36
continue to run. The engine can be restarted and will will set.
run in the backup fuel mode as long as fault is present.
See DTC 19 for further information. Brake Switches
Intake Air Temperature (IAT) Sensor A scan tool will display the status of the brake
switches. The cruise control brake switch is normally
A scan tool displays temperature of the air open and TCC brake switch normally closed. A
entering the engine and should read close to ambient malfunction in the brake switches circuit should set a
air temperature when the engine is cold, and rise as DTC 37, 38 or 41.
underhood temperature increases. I f the engine has
not been run for several hours (overnight), the IAT G l o w Plug Signal
sensor temperature and engine coolant temperature
should read close to each other. A failure in the IAT A scan tool will display this signal in voltage. A
sensor circuit should set DTC 47 or 48. The DTC chart malfunction in this system should set a DTC 29 or
also contains a "Diagnostic Aid" to check for sensor refer to SECTION 7 for diagnosis of the glow plug
resistance values relative to temperature. control system.
Cruise Control A/C Signal
A scan tool will display cruise control "ON/OFF" The scan tool should indicate A/C clutch "ON"
status. For diagnosis of the cruise control refer to when A/C is selected. Refer to "A/C Signal Diagnosis"
"Cruise Control Diagnosis." A malfunction i n the for diagnosis of the A/C signal.
set/coast switch circuit should set a DTC 71. A
malfunction in the resume/accel switch circuit should Automatic Transmission Sensors and Signals
set a DTC 76.
Refer to SECTION 10 of this service manual for
diagnosis of automatic transmission sensors and
signals.
VP HARNESS CONNECTOR (23 PIN)

PCM
| — 451 WHT/BLK DIAGNOSTIC
— E > REQUEST
450 WHT/BLK —| PC1 S Y S T E M GROUND
E D C B A TOVSS TO FUEL PUMP RELAY

F TO PARK/ BUFFER
c O TOFUEL
G H L M J NEUTRAL MODULE PUMP
SWITCH ENGINE 551 TAN/WHT PD1 SYSTEM GROUND
DATA LINK GROUND ~
(DLC)
T O BRAKE S W I T C H
IGNITION. 439 PNK/BLK IGNITION FEED
SWITCH
440 O R N BATTERY FEED
MIL "SERVICE
419 BRN/WHT ENGINE SOON"
CONTROL
l/P BULK HEAD
CONNECTOR (23 PIN)
960 ORN "SERVICE THROTTLE

IGNITION 'SERVICE SOON " LAMP
SWITCH THROTTLE SOON" CONTROL
LAMP -I
TO CRUISE PCM CONN. ID i
CONTROL SWITCH • iiT^rrri'r 1
| PA/PB - PINK • 32 PIN J
i PC/PD - PINK - 24 PIN i 1-4-94
i BC/BD . BLUE - 32 PIN i
i . . . . . . — _ — -j NS14112
CHART A-1
NO MIL
(SERVICE ENGINE SOON)
There should always be a steady MIL with the ignition "ON" and engine "OFF." Switched battery voltage is
supplied to the lamp. The PCM will control the lamp and turn it "ON" by providing a ground path through CKT
419.
Chart Test Description: Number(s) below refer to Diagnostic Aids: If the engine operates OK, check:
circled number(s) on the diagnostic chart. • Faulty light bulb.
1. If the fusible link is open, refer to wiring diagrams • CKT 419 open.
for complete circuit. • Gauges fuse open. This will result in no brake
2. Using a test light connected to 12 volts, probe each warning light, oil or generator lights, seat belt
of the system ground circuits and check that a good reminder, etc.
ground is present. Refer to "PCM Terminal End
View" in this section for PCM pin locations of
ground circuits.
CHART A-1
NO MIL
© CHECK:
- CONTINUOUS BATTERY FUSIBLE LINK.
- ECM-IGN FUSE.
- GAUGES FUSE.
FUSES OK OPEN FUSE

I
• IGNITION " O F F " LOCATE AND CORRECT SHORT TO
• DISCONNECT PCM CONNECTORS. GROUND THAT HAD AN OPEN FUSE.
• IGNITION "ON," ENGINE "OFF."
• PROBE CKT 440 AND CKT 439
WITH A TEST LIGHT TO GROUND.
TEST LIGHT "ON" TEST LIGHT " O F F " ONE

BOTH CIRCUITS OR BOTH CIRCUITS
PROBE CKT 419 WITH A TEST LIGHT LOCATE AND REPAIR

TO GROUND. OPEN IN CIRCUIT
X
MIL "ON" MIL "OFF"
I Z
© FAULTY PCM GROUNDS
OR
CKT 419 OPEN OR SHORTED
TO VOLTAGE FAULTY BULB.
FAULTY PCM CONNECTORS
OR
FAULTY PCM.
5-4-92
MS 13407
4
PCM
r— 451 WHT/BLK DIAGNOSTIC
REQUEST
450 WHT/BLK — | PC1 SYSTEM GROUND
F E D C B • 7^ TO VSS TO FUEL PUMP RELAY

c
G H L • TO PARK/
NEUTRAL
SWITCH
BUFFER
MODULE
ENGINE
TO FUEL
PUMP
551 TAN/WHT PD1 SYSTEM GROUND
DATA LINK GROUND ~
(DLC) • C D -
TO BRAKE SWITCH
IGNITION IGNITION FEED
439 PNK/BLK
SWITCH
440 ORN BATTERY FEED
MIL "SERVICE
4
419 BRN/WHT ENGINE SOON'
CONTROL
l/P BULK HEAD
CONNECTOR (23 PIN)
TO 960 ORN "SERVICE THROTTLE

IGNITION "SERVICE SOON " LAMP
SWITCH THROTTLE SOON" CONTROL
LAMP
r • -|
TO CRUISE J PCM CONN. ID J
CONTROL SWITCH
! PA/PB - PINK - 32 PIN J
i PC/PD - PINK 24 PIN i
i BC/BD - BLUE 32 PIN < 1-4-94
i -j NS 14112
CHART A-2
NO SCAN DATA OR
WILL NOT FLASH MIL OR
ff ff
MIL (SERVICE ENGINE SOON) O N STEADY
There should always be a steady Malfunction Indicator Lamp (MIL) when the ignition is "ON" and engine
"OFF." Battery ignition voltage is supplied to the lamp. The PCM will turn the lamp "ON" by grounding CKT
419.
With the "diagnostic" terminal grounded, the lamp should flash a DTC 12, followed by any Diagnostic
Trouble Code (DTC) stored in memory.
A steady lamp indicates a short to ground in the lamp control CKT 419 or an open in diagnostic CKT 451.
Chart Test Description: Number(s) below refer to 3. This step will check for an open diagnostic CKT
circled number(s) on the diagnostic chart.. 451.
1. If there is a problem with the PCM that causes a 4. At this point, the MIL wiring is OK. The problem
scan tool not to read serial data, then the PCM is a faulty PROM. If MIL does not flash, the PCM
should not flash a MIL. I f MIL does flash, check should be replaced using the original PROM.
that the scan tool is functioning properly on Replace the PROM only after trying a PCM.
another vehicle. I f the scan is functioning
properly, and CKT 1061 is OK, the PROM or PCM
may be at fault for the NO DLC symptom.
2. If the light goes "OFF" when the PCM connector is
disconnected, then CKT 419 is not shorted to
ground.
CHART A-2
NO SCAN DATA OR WILL
NOT FLASH MIL OR MIL
1
"ON" STEADY
• IGNITION "ON." ENGINE "OFF.
IS THE MIL "ON"?
YES NO
n z
• GROUND DIAGNOSTIC TERMINAL. ' REFER TO CHART A-1. »
DOES MIL FLASH?
YES
© • IGNITION "OFF." © • IF PROBLEM WAS NO SERIAL DATA:

• DISCONNECT PCM CONNECTORS. • CHECK SERIAL DATA CKT 1061 FOR OPEN
• IGNITION " O N " AND NOTE MIL (SERVICE

ENGINE SOON).
OR
SHORT TO GROUND
OR
SHORT TO VOLTAGE BETWEEN PCM AND
DLC. IF OK. IT IS A FAULTY PCM
OR
PROM.
- I •
| MIL "OFF" MIL "ON"
© •
•
IGNITION "OFF."
RECONNECT PCM.
REPAIR SHORT TO
GROUND IN CKT 419.
• IGNITION " O N / E N G I N E STOPPED.
• DIAGNOSTIC TERMINAL NOT GROUNDED.
• BACKPROBE PCM, CKT 451. WITH TEST LIGHT TO GROUND.
DOES MIL FLASH?
1
YES
m
© •
•
CHECK PROM FOR PROPER INSTALLATION.
IF OK. REPLACE PCM USING ORIGINAL PROM.
• CHECK FOR OPEN IN DLC DIAGNOSTIC
TERMINALS " B " AND CKT 451 TO PCM.
• RECHECK FOR FLASHING MIL. • IF OK, CHECK FOR OPEN IN DLC TERMINAL
DOES MIL FLASH? "A" TO PCM AND PCM GROUND, CKT 450.
x
NO YES
X JLZ
REPLACE PROM. SYSTEM OK.
5-5-93
PS 17831
ENGINE HARNESS PCM

CONNECTOR (15 PIN)
TO ENGINE SHUTOFF- 339 PNK

I
4r
SOLENOID
FUEL INJECT CONTROL
1
984 LT GRN FUEL INJECT CONTROL
9S5 RED 985 RED
FUEL INJECT SIGNAL
FUEL 339 PNK
SOLENOID
DRIVER
950 LT GRN PD2 CLOSURE GROUND
t
ENGINE
HARNESS 339 PNK
J CONNECTOR
(8 PIN)
J F/SOL
BLK TO
FUEL IGNITION 20 AMP
SOLENOID SWITCH
RED -
FUEL SOLENOID
HARNESS CONNECTOR PCM com. ID ^ J
PA/PB PINK 32 PIN I
PC/PD PINK 24 PIN I
BC/BD BLUE 32 PIN I
12-9-93
NS 14320
CHART A-3
ENGINE CRANKS BUT WILL NOT RUN
This chart assumes that battery condition and engine cranking speed are OK, adequate fuel in the tank, and
glow plug system operating OK.
Chart Test Description: Number(s) below refer to Diagnostic Aids: If no trouble is found in the fuel
circled number(s) on the diagnostic chart. pump circuit, and the cause of an "Engine Cranks But
1. A Malfunction Indicator Lamp (MIL) "ON" is a Will Not Run" has not been found, check for:
basic test to determine i f there is a 12 volt supply • Water or foreign material in the fuel system.
and ignition 12 volts to PCM. No DLC may be due • Basic engine problem.
to a PCM problem and CHART A-2 will diagnose Note: If crank position sensor and optical sensor
the PCM. are disconnected or inoperable at the same time this
2. This step will check to see i f there is an inject will cause a crank but will not run condition.
command coming from the PCM.
3. This step will check ground circuit.
CHART A-3
© •
•
IGNITION "ON."
DOES MIL "SERVICE ENGINE SOON" LAMP COME "ON"? ENGINE CRANKS BUT WILL NOT RUN
1
YES NO
I E
• INSTALL SCAN T O O L REFER TO CHART A-1.
DOES SCAN TOOL DISPLAY SCAN DATA?
YES NO
• LOOSEN INJECTION LINE AT INJECTOR. REFER TO CHART A-2.

• CRANK ENGINE.
IS THERE FUEL COMING OUT OF INJECTION LINE?
NO YES
• DISCONNECT OPTICAL/FUEL TEMP SENSOR. INJECTION SYSTEM OK, REFER

DOES VEHICLE START? TO DRIVEABILITY SECTION 2.
NO YES
JO
RECONNECT OPTICAL/FUEL TEMP SENSOR. FAULTY INJECTION PUMP.
DISCONNECT FUEL SOLENOID DRIVER.
WITH J 39200 CONNECTED TO GROUND, PROBE
HARNESS TERMINAL "A".
CRANK ENGINE.
IS THERE AT LEAST 1.2 VOLTS?
YES NO
© PROBE TERMINAL " B " AT FUEL SOLENOID

JUMPER HARNESS CONNECTOR WITH TEST
OPEN OR GROUND IN CKT 984
OR
LIGHT CONNECTED TO B +. FAULTY PCM CONNECTION
IS TEST LIGHT " O N " ? OR
FAULTY PCM.
YES NO
PROBE TERMINAL " C " AT FUEL SOLENOID OPEN CKT 950

DRIVER JUMPER HARNESS CONNECTOR WITH OR
TEST LIGHT CONNECTED TO GROUND. FAULTY PCM CONNECTION
FAULTY PCM.
3L
YES NO
I JO
FAULTY INJECTION PUMP. OPEN CKT 339.
11-1-93
REFER TO "ON-VEHICLE SERVICE'' IN THIS SECTION. NS15748
PCM
BATTERY FEED
, PA/PB PINK
» PC/PD PINK
t BCBO BLUE 12-20-93
i NS 15857
CHART A-5
FUEL PUMP RELAY CIRCUIT DIAGNOSIS
When the ignition switch is in the CRANK position, the lift pump circuit is completed through the relay
contacts. During this time, oil pressure is building to the point of closing the contacts of the oil pressure switch.
A minimum of 28 kPa (4 psi) is required to close the switch contacts.
When the ignition is returned to the RUN position, the oil pressure of the running engine maintains
electrical power to the lift pump.
Chart Test Description: Number(s) below refer to Diagnostic Aids: If engine oil pressure drops below
circled numher(s) on the diagnostic chart. 28 kPa (4 psi), the engine will run poorly or stall when
1. This procedure applies direct voltage to run the the lift pump circuit opens.
fuel pump If the pump runs, i t may be a fuel pump
relay circuit problem which the following step will
locate
2. This step checks voltage from the battery and the
ground circuit to the relay.
3. This test determines i f there is voltage from the
battery, terminal "A" to terminal "D" on the relay
connector.
4. This completes the fuel pump relay circuit, but the
oil pressure switch should also be diagnosed.
CHART A-5
FUEL PUMP RELAY
CIRCUIT DIAGNOSIS
© •
•
APPLY FUSED 12 VOLTS TO FUEL PUMP TEST TERMINAL.
LISTEN FOR FUEL PUMP.
DOES FUEL PUMP RUN?
YES NO
-~r-
© •
•
DISCONNECT PUMP RELAY.
IGNITION "ON," ENGINE STOPPED.
OPEN IN CKT 120 OR CKT 450 OR CKT 490
TO THE FUEL PUMP OR FAULTY PUMP.
• PROBE RELAY HARNESS CONNECTOR TERMINAL'
IS TEST LIGHT "ON"?
YES NO
X X
© • CONNECT TEST LIGHT BETWEEN HARNESS
CONNECTOR TERMINAL " A " AND " E " .
REPAIR OPEN CKT 440.
IS TEST LIGHT "ON"?
TL
YES NO
X IE
• CONNECT TEST LIGHT BETWEEN TERMINAL " F " AND GROUND. REPAIR OPEN GROUND CKT 450.
• CRANK ENGINE.
IS TEST LIGHT "ON"?
YES NO
© • FAULTY CONNECTION AT RELAY, OPEN IN CKT 450 OR FAULTY RELAY.

CONTINUE TESTING OIL PRESSURE SWITCH.
OPEN IN CKT 806.
• ENGINE RUNNING.
• ENGINE AT NORMAL OPERATING TEMPERATURE.
• OIL PRESSURE NORMAL.
• DISCONNECT FUEL PUMP RELAY.
• WITH J 39200 CONNECTED TO GROUND, PROBE FUEL PUMP RELAY
HARNESS CONNECTOR TERMINAL " E " .
IS THERE B+ VOLTAGE?
YES NO
RECONNECT FUEL PUMP RELAY. OPEN IN CKT 440 OR 120 TO THE OIL PRESSURE
IGNITION "OFF." SWITCH OR FAULTY OIL PRESSURE SWITCH.
PROBE FUEL PUMP RELAY TERMINAL " E " WITH A TEST
LIGHT TO GROUND.
IS TEST LIGHT "ON"?
NO YES
H Z
NO TROUBLE FOUND. FAULTY OIL PRESSURE SWITCH.
10-29-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. PS 17142
TFT
SENSOR
TO BOOST TO E C T , IAT A N D PCM
SENSOR CRANKSHAFT
(A/T O N L Y ) (TURBO ONLY) POSITION S E N S O R
A
>-
A
452 BLK SENSOR GROUND
EGR CONTROL
433 G R Y / B L K EGR CONTROL
PRESSURE/BARO B
SENSOR PRESSURE/BARO SIGNAL
416 G R Y
EGR c SVOLT
REFERENCE
VALVE
^TOMCONNLID^J
PA/PB PINK 3 2 P I N I
TO BOOST
PC/PO PINK 24 PIN I TO E G R VENT
BC/BD BLUE 32 PIN I SOLENOID
SENSOR 11-3-93
(TURBO ONLY) PS 16975
EGR CONTROL PRESSURE/BARO SENSOR OUTPUT CHECK

An EGR control pressure/BARO sensor is used to monitor the amount of vacuum in the EGR circuit. It senses
the actual vacuum in the EGR vacuum line and sends a signal back to the PCM. The signal is compared to the
EGR duty cycle calculated by the PCM. On vehicles not equipped with EGR, this sensor is only used for a BARO
reading.
Chart Test Description: Number(s) below refer to 3. Check vacuum hose to sensor for leaking or
circled number(s) on the diagnostic chart. restriction. Be sure that no other vacuum devices
are connected to the sensor hose.
[T| Important
• Be sure to use the same diagnostic test equipment NOTICE: Make sure electrical connector remains
for all measurements. securely fastened.
1. Checks sensor output voltage to the PCM. This 4. Disconnect sensor from bracket and twist sensor
voltage, without engine running, represents a by hand (only) to check for i n t e r m i t t e n t
barometer reading to the PCM. connection. Output changes greater that .1 volt
• When comparing Tech 1 scan readings to a indicates a bad connector or connection. I f OK,
known good vehicle, it is important to compare replace sensor.
vehicles which use a sensor having the same
color insert or having the same "Hot Stamped"
3 digit number. Refer to figures on facing
page.
2. Applying 34 kPa (10" Hg) vacuum to the sensor
should cause the voltage to change. Subtract
second reading from the first. Voltage value
should be greater than 1.5 volts. When applying
vacuum to the sensor, the change in voltage should
be instantaneous. A slow voltage change indicates
a faulty sensor.
EGR CONTROL PRESSURE/BARO SENSOR

OUTPUT CHECK
© •
•
IF ANY DTC(s) ARE STORED, REFER TO THOSE CHARTS FIRST.
IGNITION "ON." ENGINE "OFF."
• TECH 1 SCAN TOOL SHOULD DISPLAY A SENSOR VOLTAGE.
• COMPARE THIS READING WITH THE READING OF A KNOWN GOOD VEHICLE.
SEE FACING PAGE TEST DESCRIPTION, STEP 1.
VOLTAGE READING SHOULD BE WITHIN ± .4 VOLT.
IS IT?
NO
X
© •
•
DISCONNECT AND PLUG VACUUM SOURCE TO SENSOR.
CONNECT A HAND VACUUM PUMP TO SENSOR.
REPLACE EGR
CONTROL
• START ENGINE. PRESSURE/BARO
• NOTE SENSOR VOLTAGE. SENSOR.
• APPLY 34 kPa (10" Hg) OF VACUUM AND NOTE VOLTAGE CHANGE.
SUBTRACT SECOND READING FROM THE FIRST. VOLTAGE VALUE
SHOULD BE GREATER THAN 1.5 VOLTS.
IS IT?
© NO TROUBLE FOUND. CHECK SENSOR VACUUM

SOURCE FOR LEAKAGE OR RESTRICTION.
© CHECK SENSOR CONNECTION.
IF OK, REPLACE EGR CONTROL
PRESSURE/BARO SENSOR.
m m
o X o
a IT
C B A
r 039 XXXX
IB—1 r
HOT-STAMPED •
NUMBER
I m
X
[9 m
\ X
X H o
hat ^#1
iC B A
COLOR *460 XXXX
KEYED INSERT
LS8963-6E LS 9045-6E
Figure 1 - Color Key Insert Figure 2 - Hot Stamped Number

10-28-93
TO
GAGES TO MIL A N D PCM
"SERVICE
IGNITION 20A THROTTLE
SOON" LAMP
l/P H A R N E S S
39 PNK/BLK — 1
(10 P I N )
W
*ON/OFF
B - 397 GRY REQUEST SIGNAL
RESUME/ACCELERATOR
C — 83 DK GRN
REOUEST SIGNAL
D - SET/COAST
84DKBLU
REQUEST SIGNAL
l/P H A R N E S S
CRUISE CONTROL (23 PIN)
P C M C O N N . ID
PA/PB PINK 3 2 PIN

PC/PD PINK 2 4 PIN 11-2-93
BGBD BLUE 3 2 PIN
N S 14322
CRUISE CONTROL SIGNAL DIAGNOSIS

The cruise on/off, set/coast and resume/accel signals are inputs to the fuel control portion of the PCM. These
inputs allow the PCM to control and hold a requested speed. I f cruise is inoperative, and no DTC(s) are stored,
check for faulty cruise switch, wiring harness for opens or faulty connections. The cruise control switch on the
clutch pedal stuck in the open position will cause a no cruise control complaint.
PCM
PRESSURE HIGH PRESSURE
CYCLING CUT-OUT
A/C CONTROL SWITCH SWITCH
SWITCH
66LTGRN
-e 603 DK GRY/WHT '59 DK GRN A/C SIGNAL
B 59 DK GRN
A T 150 BLK
- n
» Î pr.M
P nnNM
CM C in _
O N N . ID
A/C COMPRESSOR
CLUTCH I PA/PB PINK 3 2 P I N
I P C / P D PINK 2 4 PIN
| B C / B D B L U E 3 2 PIN J 12-10-93
PS 17591
A/C SIGNAL DIAGNOSIS

Turning "ON" the air conditioning supplies CKT 59 battery voltage to the A/C compressor clutch and to
terminal "PB4" of the PCM to increase and maintain idle speed.
The PCM does not control the A/C compressor clutch. Therefore, if A/C does not function, refer to the A/C
section of the service manual for diagnosis of the system.
RESTRICTED EXHAUST SYSTEM CHECK
Proper diagnosis for a restricted exhaust system is essential before any components are replaced. The
following procedure may be used for diagnosis:
DIAGNOSIS:
1. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler failure.
2. If there are no obvious reasons for the excessive backpressure, the catalytic converter is suspected to be
restricted and should be replaced using current recommended procedures. Refer to SECTION 6F of the
appropriate service manual.
3-9-93
8S 3 9 8 4
DIAGNOSTIC TROUBLE CODE (DTC) IDENTIFICATION

The MIL (Service Engine Soon) will be "ON" if an emission malfunction exists. If the malfunction clears, the
lamp will go "OFF" and the DTC will be stored in the PCM. Any DTCs stored will be cleared i f no problem
recurs within 50 engine starts.
Important
• All DTCs with the sign * are transmission related DTCs and have descriptions, diagnostic charts are in
SECTION 10A (4L60EV10B (4L80E). Remember, always start with the lowest numerical engine DTC
first. When diagnosing some engine DTCs, other transmission symptoms can occur.
DTC NUMBER AND NAME SECTION DTC NUMBER AND NAME SECTION
DTC 13 - Engine Shutoff Solenoid DTC 23 - Accelerator Pedal

Circuit Fault Position 1 Circuit Range Fault
DTC 14 - Engine Coolant *DTC 24 - Vehicle Speed Sensor 10A (4L60E)

Temperature (ECT) Sensor Circuit Circuit Low (Output Speed Signal) 10B (4L80E)
Low (High Temperature Indicated)
DTC 15 - Engine Coolant DTC 25 - Accelerator Pedal

Temperature (ECT) Sensor Circuit Position 2 Circuit High
High (Low Temperature Indicated)
DTC 16 - Vehicle Speed Sensor DTC 26 - Accelerator Pedal

Buffer Fault Position 2 Circuit Low
DTC 17 - High Resolution Circuit DTC 27 - Accelerator Pedal

Fault Position 2 Circuit Range Fault
DTC 18 - Pump Cam Reference *DTC 28 - Trans Range Pressure 10A (4L60E)
Pulse Error Switch Circuit 10B (4L80E)
DTC 19 - Crankshaft Position DTC 29 - Glow Plug Relay Fault

Reference Error
DTC 21 - Accelerator Pedal DTC 31-EGRControl

Position 1 Circuit High Pressure/Baro Sensor Circuit Low
(High Vacuum)
DTC 22 - Accelerator Pedal DTC 32 EGR Circuit Error
Position 1 Circuit Low
5-7-93
PS 17B14

Important
• A l l DTCs with the sign * are transmission related DTCs and have descriptions, diagnostic charts are in
SECTION 10A (4L60EV10B (4L80E). Remember, always start with the lowest numerical engine DTC
DTC 33 - EGR Control Pressure/Baro DTC 47 - Intake Air Temperature

Sensor Circuit High Sensor Circuit Low (High Temp
Indicated)
DTC 34 - Injection Timing Stepper DTC 48 - Intake Air Temperature

Motor Fault Sensor Circuit High (Low Temp
Indicated)
DTC 35 - Injection Pulse Width Error DTC 49 - Service Throttle Soon

(Response Time Short) Lamp Circuit Fault
DTC 36 - Injection Pulse Width Error DTC 51-PROM Error

(Response Time Long)
*DTC 37 - TCC Brake Switch Stuck 10A (4L60E) *DTC 52 - System Voltage High 10A(4L60E)
"ON" 10B (4L80E) Long 10B (4L80E)
*DTC 38 - TCC Brake Switch Stuck 10A (4L60E) *DTC 53 - System Voltage High 10A (4L60E)
"OFF" 10B (4L80E) 10B (4L80E)
*DTC 39 - TCC Stuck "OFF" 10B (4L80E) DTC 54 - PCM Fuel Circuit Error
DTC 41 - Brake Switch Circuit Fault 3 DTC 56 - Injection Pump

Calibration Resistor Error
DTC 42 - Fuel Temperature Circuit 3 DTC 57 - PCM 5 Volt Shorted
Low (High Temp Indicated)
*DTC 58 - Trans Fluid Temp Circuit 10A (4L60E)
DTC 43 - Fuel Temperature Circuit Low 10B(4L80E)
High (Low Temp Indicated)
*DTC 59 - Trans Fluid Temp Circuit 10A (4L60E)
DTC 44 - EGR Pulse Width Error High 10B (4L80E)
DTC 45 - EGR Vent Error DTC 61 - Turbo Boost Sensor Circuit

High
DTC 46 - Malfunction Indicator DTC 62 - Turbo Boost Sensor Circuit
Lamp Circuit Fault Low
11-2-93
PS 1 7 8 1 5 1

lamp will go "OFF" arid the DTC will be stored in the PCM. Any DTCs stored will be cleared if no problem
Important
All DTCs with the sign * are transmission related DTCs and have descriptions, diagnostic charts are in
SECTION 10A (4L60E)/10B (4L80E). Remember, always start with the lowest numerical engine DTC
DTC 63 - Accelerator Pedal •DTC 82 -1-2 Shift Solenoid Circuit 10A(4L60E)

Position 3 Circuit High 10B (4L80E)
DTC 64 - Accelerator Pedal •DTC 83 - TCC Pwm Solenoid
Position 3 Circuit Low Circuit 10B(4L80E)
DTC 65 - Accelerator Pedal 10B (4L80E)

Position 3 Circuit Range Fault •DTC 84 - Accelerator Pedal
Position Circuit Fault
*DTC 66 - 3-2 Control Solenoid 10A(4L60E)
Circuit •DTC 85 - Undefined Ratio Error 10B(4L80E)
•DTC 67 - TCC Solenoid Circuit 10A(4L60E) 10B (4L80E)

•DTC 86 - Low Ratio Error
*DTC 68 - Trans Component 10A(4L60E) 10B(4L80E)
Slipping 10B (4L80E) •DTC 87 - High Ratio Error
10A(4L60E) 3
•DTC 69 - TCC Stuck "ON" 10B (4L80E) DTC 88 - TDC Offset Error
3
DTC 71 - Set/Coast Switch Fault DTC 91 Cylinder Balance Fault
#1 Cyl
10A (4L60E) 3
•DTC 72 - Vehicle Speed Sensor 10B (4L80E) DTC 92 - Cylinder Balance Fault
Circuit Loss (Output Speed Signal) #2 Cyl
10A (4L60E) 3
•DTC 73 - Pressure Control Solenoid 10B (4L80E) DTC 93 - Cylinder Balance Fault
Circuit #3 Cyl
10B (4L80E) 3
•DTC 74 - Trans Input Speed Sensor DTC 94• Cylinder Balance Fault
Circuit #4 Cyl
10A(4L60E) 3
•DTC 75 - System Voltage Low 10B (4L80E) DTC 95 Cylinder Balance Fault
#5 Cyl
3
DTC 76 - Resume/Accel Switch Fault DTC 96 - Cylinder Balance Fault
#6 Cyl
3
DTC 78 - Wastegate Solenoid Fault DTC 97 - Cylinder Balance Fault
#7 Cyl
10A (4L60E) 3
•DTC 79 - Trans Fluid Over temp DTC 98- Cylinder Balance Fault
#8 Cyl
10A (4L60E) 3
•DTC 81 - 2-3 Shift Solenoid Circuit 10B (4L80E) DTC 99 - Accelerator Pedal
Position 2 (5 Volt Reference Fault)
5-7-93
PS 17660
3-3S DRIVEABILITY AND EMISSIONS (DIESEL)
ENGINE H A R N E S S
(15 PIN)
PCM
ENGINE S H U T - O F F
ENGINE S H U T - O F F SOLENOID
I SOLENOID CONTROL
— 981 B L U / W H T 1BC16
B ~ 339 PNK
1
PCM CONN. ID I
ALT
TO IGNITION SWITCH PA7PB P I N K 32 P I N I
20 A P C / P D P I N K 24 P I N I
B C / B D B L U E 32 PIN I
TO
FUEL DRIVER
SOLENOID
12-9-93
PS 17506
DTC 13
ENGINE SHUTOFF SOLENOID
CIRCUIT FAULT
When the ignition switch is in the "OFF" position, the engine shutoff solenoid is in the "No Fuel" position. By
providing a ground path, the PCM energizes the solenoid which then allows fuel to pass into the injection pump.
DTC 13 Will Set W h e n :

• Ignition voltage on CKT 981 when PCM has requested engine shutoff solenoid "ON."
OR
• No ignition voltage on CKT 981 when PCM has requested engine shutoff solenoid "OFF."
Action Taken {PCM will default to): A current and history DTC 13 will be stored.
DTC 13 Will Clear W h e n : The fault condition(s) no longer exist, and ignition switch is cycled "OFF" then
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: An open in CKT 981 or 339 will
refer to circled number(s) on the diagnostic chart. cause a DTC 13.
1. Check for open circuit from ignition switch to the Also a no start condition will exist. The Tech 1
solenoid. scan tool has the ability to turn the engine shutoff
2. Check CKT 981 from solenoid to PCM for open. solenoid "ON" and "OFF." This can be used as a quick
operational check.
DTC 13
CIRCUIT FAULT
© •
•
IGNITION "OFF."
DISCONNECT ENGINE SHUTOFF SOLENOID CONNECTOR.
• IGNITION "ON."
• PROBE ENGINE SHUTOFF HARNESS TERMINAL " B " WITH
TEST LIGHT CONNECTED TO GROUND.
IS TEST LIGHT " O N " ?
YES NO
© • PROBE ENGINE SHUTOFF

HARNESS TERMINAL "A" WITH
CHECK FOR OPEN OR SHORT TO
GROUND IN CKT 339.
TEST LIGHT CONNECTED TO B • .
IS TEST LIGHT "ON"?
YES NO
FAULTY ENGINE CHECK FOR OPEN IN

SHUTOFF CONNECTION CKT 981
OR OR
FAULTY ENGINE FAULTY PCM.
SHUTOFF SOLENOID.
4-22-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. NS14044
ENGINE HARNESS CONNECTOR (8 PIN)

PCM
ENGINE
COOLANT 410 YEL ECT SIGNAL
TEMPERATURE
(ETC) SENSOR TO EGR +
[ CONTROL
l PRESSURE/BARO
i SENSOR (LESS
1
THAN 8500 GVW)
INTAKE AIR SENSOR GROUND
TEMPERATURE
(IAT) SENSOR
IAT SIGNAL
TO BOOST SENSOR AND | PCM CONN. ID |

CRANKSHAFT POSITION**"
SENSOR BARO SENSOR f PA/PB PINK 32 PIN ]
(GREATER THAN 8500 G V W ) J PC/PD PINK 24 PIN J
1 1 11-4-93
BC/BD BLUE 32 P I N
NS 14045
DTC 14
ENGINE COOLANT TEMPERATURE (ECT) CIRCUIT LOW
(HIGH TEMPERATURE INDICATED)
The Engine Coolant Temperature (ECT) sensor is a thermistor that controls signal voltage to the PCM.
When the engine is cold, the sensor resistance is high, therefore the PCM will see high signal voltage. As the
engine warms, sensor resistance becomes less and voltage drops.
DTC 1 4 Will Set W h e n : Engine coolant temperature greater than 151°C (304°F) for 2 seconds.
Action Taken (PCM Will default to): The PCM will use 77°C (171°F) as measured engine coolant temp.
DTC 1 4 Will Clear W h e n : The fault condition(s) no longer exist.
DTC Chart Test Description: Number(s) below Diagnostic Aids: Check harness routing for a
refer to circled number(s) on the diagnostic chart. potential short to ground.
1. This step determines if DTC 14 is a hard failure or After engine is started, the coolant temperature
an intermittent condition. should rise steadily to about 85°C (185°F).
2. This test will determine i f CKT is shorted to The PCM default value will flash on the data
ground. screen intermittently.
Refer to "Intermittents" in SECTION 2.
The "Temperature to Resistance Value" scale at
the r i g h t may be used to test the intake a i r
temperature sensor at various temperature levels to
evaluate the possibility of a "skewed" (mis-scaled)
sensor. A"skewed" sensor could result i n poor
driveability complaints.
DTC 14
IF DTC 57 IS ALSO STORED, REFER TO THAT CHART FIRST.
© DOES TECH 1 SCAN TOOL DISPLAY ENGINE COOLANT

TEMPERATURE OF 130°C(266°F) OR HIGHER?
NO
i
© DISCONNECT ECT SENSOR.
TECH 1 SCAN TOOL SHOULD DISPLAY
DTC 14 IS INTERMITTENT. IF NO
ADDITIONAL DTCs WERE STORED, REFER
ENGINE COOLANT TEMPERATURE TO "DIAGNOSTIC AIDS" ON FACING PAGE.
BELOW -30°C(-22°F).
DOES IT?
YES NO
IT
REPLACE ECT SENSOR. CKT 410 SHORTED TO GROUND
OR
CKT 410 SHORTED TO SENSOR GROUND CIRCUIT
OR
FAULTY PCM.
DIAGNOSTIC AID
ENGINE COOLANT TEMPERATURE SENSOR
TEMPERATURE VS. RESISTANCE VALUES
(APPROXIMATE)
°C °F OHMS
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667 IF PCM IS FAULTY AND MUST BE REPLACED, "TDC
50 122 973 OFFSET" MUST BE PROGRAMMED INTO THE NEW PCM.
45 113 1188 REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION.
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. 10-29-93
NS14048

PCM
ENGINE
COOLANT 410 Y E L E C T SIGNAL
TEMPERATURE
(ETC) SENSOR TO EGR - TO TFT
CONTROL SENSOR
1 PRESSURE/BARO (A/TONLY)
i SENSOR (LESS
} THAN 8500 GVW)
TEMPERATURE
(IAT) SENSOR 472 TAN IAT SIGNAL
r ——. — — — -i
TO BOOST SENSOR AND | P C M C O N N . ID |
CRANKSHAFT POSITION *
SENSOR BARO SENSOR f P A / P B PINK 3 2 PIN ]
(GREATER THAN 0SOO GVW) P C / P D PINK 2 4 PIN
1 1
B C / B D B L U E 3 2 PIN 11-4-93
NS1404S
DTC 15
ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT HIGH
(LOW TEMPERATURE INDICATED)
engine warms, the sensor resistance becomes less and the voltage drops.

• Engine coolant temperature less than -36°C (-33°F).
• Engine running for at least 8 minutes.
Action Taken (PCM will default to):

• The PCM will use 18°C (64°F) as measured engine coolant temp.
• Idle increase.
DTC 15 Will Clear W h e n : The fault condition(s) no longer exist.
DTC Chart Test Description: Number(s) below Diagnostic A i d s : Check harness routing for a
refer to circled number(s) on the diagnostic chart. potential short to ground. After engine is started, the
1. This test determines if DTC 15 is a hard failure or ECT temperature should rise steady to about 85°C
an intermittent condition. (185°F). The default value will flash intermittently on
2. This test will determine i f CKT 410 is open, or a the data screen.
faulty PCM. The "Temperature to Resistance Value" scaled at
the right may be used to test the engine coolant sensor
at various temperature levels to evaluate the
possibility of a "skewed" (ims-scaled) sensor. A
"skewed" sensor could result in poor driveability
complaints.
DTC 15
© • DOES TECH 1 SCAN TOOL DISPLAY ECT OF -30°C (-22°F) OR LESS?
YES NO
• DISCONNECT ECT SENSOR. DTC 15 IS INTERMITTENT. IF NO

• JUMPER HARNESS TERMINALS TOGETHER. ADDITIONAL DTCs WERE STORED, REFER
• TECH 1 SCAN TOOL SHOULD DISPLAY 130°C (266°F) OR MORE. TO "DIAGNOSTIC AIDS" ON FACING PAGE.
DOES IT?
NO YES
I
© •
•
JUMPER CKT 410 TO GROUND.
TECH 1 SCAN TOOL SHOULD DISPLAY OVER 130°C (266°F).
FAULTY CONNECTION OR ENGINE
COOLANT TEMPERATURE SENSOR.
DOES IT?
YES NO
m m
OPEN ECT SENSOR GROUND CIRCUIT, FAULTY OPEN CKT 410. FAULTY
CONNECTION OR FAULTY PCM. CONNECTION AT PCM, OR
FAULTY PCM.
DIAGNOSTIC AID
(APPROXIMATE)
°C °F OHMS
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
IF PCM IS FAULTY AND MUST BE REPLACED, "TDC OFFSET" MUST
45 113 1188
40 104 1459 BE PROGRAMMED INTO THE NEW PCM.
35 95 1B02 REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION.
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
10-28-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. NS 14046
ENGINE PCM
- 822 LT GRN/BLK
-EB-,3SW&r*>—m
TO DLC <*T
GROUND
TO DLC 1 1
%
OUTPUT SPEED GROUND * - T O ANTILOCK

VSS INPUT C7
AND
VEHICLE SPEED
SENSOR
GROUND C8 450 BLK/WHT - J IS BRAKE
(VSS) IGNITION FEED 250 BRN . T O IGNITION
C9
15AMP SWITCH
VSS BUFFER VSS OUTPUT C10 696 WHT TO ANTILOCK
MODULE
VEHICLE SPEED
VSS OUTPUT C11 - 1586 BRN/WHT
SIGNAL
VSS INPUT C12
TRANSMISSION
TRANS. OUTPUT C13 437 BRN PC15 OUTPUT SPEED
r • - 1 SIGNAL
J PCM CONN. ID j VSS OUTPUT C14 834 BRN BD8 VEHICLE SPEED
SIGNAL
! PA/PB - PINK 32 PIN ! VSS OUTPUT C15 824 LT BLU/BLK - * - T O SPEEDO
m
i PC/PD • PINK - 24 PIN t
i BC/BD BLUE - 32 PIN i
i . . ~-i 821 PPUWHT - 11-30-93
NS 15750
DTC 16
VEHICLE SPEED SIGNAL BUFFER FAULT
The speed sensor circuit consists of a magnetic induction type sensor, a vehicle speed sensor buffer module
and wiring. Gear teeth pressed on the output shaft induce an alternating current in the sensor. This signal is
transmitted to the buffer. The buffer compensates for various axle ratios and converts the signal into a square
wave for use by the speedometer, cruise control, antilock brake and PCM. The buffer sends two different signals
to the PCM. The CKT 437 circuit relays the transmission output speed which is used to control shift points, line
pressure, TCC, DTC 24 and DTC 72. The CKT 834 circuit relays the vehicle speed which is used to control engine
operating functions and DTC 16. When DTC 24 or 72 is set, second gear only at maximum line pressure will
occur.

• Greater than 20 mph.
• 1000 to 4400 RPM.
• CKT 817 open or grounded.
• All conditions must be met for 2 seconds.
Action Taken (PCM will default to): No cruise control or fuel cutoff.
DTC 16 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled "OFF"
then "ON."
DTC Chart Test Description: Number(s) below 4. This tests for a signal from VSS buffer to the PCM.
refer to circled number(s) on the diagnostic chart.
1. This tests for B + at VSS buffer. Diagnostic Aids: Check connections at VSS buffer
2. This tests for proper ground path for vehicle speed and PCM. Refer to "4L80E or 4L60E Diagnostic
sensor signal buffer. Trouble Codes," Section "10" i f DTC 24 or DTC 72 is
3. This tests for vehicle speed sensor signal buffer also set.
signal to PCM.
DTC 16
VEHICLE SPEED SIGNAL
BUFFER FAULT
• INSTALL TECH 1.
• RECORD,THEN CLEAR DTC(s).
• RAISE DRIVE WHEELS.
• ENGINE OPERATING.
• TRANSMISSION IN ANY DRIVE RANGE.
WITH DRIVE WHEELS ROTATING. DOES "VEHICLE SPEED"
INCREASE WITH DRIVE WHEEL SPEED INCREASE?
NO YES
0 •
•
TRANSMISSION IN PARK.
BACKPROBE VSS BUFFER MODULE HARNESS
PROBLEM IS INTERMITTENT. REFER TO
"DIAGNOSTIC AIDS."
CONNECTOR TERMINAL "C9" WITHA TEST LIGHT TO
GROUND.
IS TEST LIGHT "ON"?
YES NO
© BACKPROBE VSS BUFFER MODULE HARNESS

CONNECTOR TERMINAL " C 9 " TO TERMINAL " C 8 *
REPAIR OPEN IGNITION FEED CIRCUIT
TO VSS BUFFER MODULE.
WITH A TEST LIGHT.
IS TEST LIGHT "ON"?
3L
YES NO
HZ 3Z
CONNECTOR TERMINAL "C7" TO TERMINAL
REPAIR OPEN GROUND CIRCUIT FROM
VSS BUFFER MODULE.
" C I 2 " WITH J 39200 DVM ON A/C SCALE.
TRANSMISSION IN ANY DRIVE RANGE WITH
DRIVE WHEELS ROTATING.
DOES VOLTAGE INCREASE ON J 39200 DVM
WITH DRIVE WHEEL SPEED INCREASE?
YES NO
HZ
©
n z
DOES TECH 1 DISPLAY TRANS CHECK CKTs 821 OR 822 FOR OPEN
OUTPUT SPEED (MPH) INCREASE SHORT TO GROUND OR FAULTY
WITH DRIVE WHEEL SPEED INCREASE? CONNECTIONS. IF OK, REPLACE VSS.
YES NO
HZ
CHECK CKT 834 FOR OPEN, SHORT. OR FAULTY CHECK VSS BUFFER CONNECTIONS.
CONNECTIONS AT VSS SIGNAL BUFFER CONNECTOR IF OK, REPLACE VSS BUFFER.
AND PCM CONNECTOR. IF OK, REPLACE PCM.
4-29-93
ENGINE HARNESS
P C M
CONNECTOR (15 PIN)
OPTICAL FUEL
TEMPERATURE SENSOR
\ 5 VOLT
—^^yJREFERENCE
M M SIGNAL
HIGH RESOLUTION SIGNAL
SENSOR GROUND
1578 Y E L
T v
987 WHT ™ 5VOLT

REFERENCE
p — — — — — — —^ -FUEL
| P C M C O N N . ID | TERMPERATURE
SIGNAL
FPA/PB PINK 3 2 P I N ]
P C / P D PINK 2 4 PIN J
[ B C / B D B L U E 32 PIN J 11-4-93
NS14321
DTC 17
HIGH RESOLUTION CIRCUIT FAULT
The optical sensor provides a high resolution signal to the PCM by counting pulses on the sensor disk located
in the injection pump. The high resolution is one of the most important inputs by the PCM for fuel control and
timing.
DTC 17 Will Set W h e n : 8 cam reference pulses without and increase in high resolution counts (internal to
PCM).
Action Taken (PCM will default to): Backup fuel.
DTC 17 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled ÔFF"
then "ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: When PCM is in backup fuel, fast
refer to circled number(s) on the diagnostic chart. idle and poor performance problems will exist. I f DTC
1. This step will determine i f there is a 5 volt 18 is also stored, there is a possible problem with CKTs
reference. 474 or 987. It is possible DTC 17 may set i f there is air
2. This step checks the ground circuit. in the fuel system, refer to SECTION 4.
3. This step will check to see i f the sensor is sending a
signal back to the PCM.
DTC 17
HIGH RESOLUTION
CIRCUIT FAULT
© •
•
IGNITION "OFF."
DISCONNECT OPTICAL/FUEL TEMPERATURE SENSOR.
• IGNITION "ON."
• PROBE TERMINAL "A" ON SENSOR HARNESS
CONNECTOR WITH J 3 9 2 0 0 CONNECTED TO GROUND.
IS THERE 5 VOLTS?
YES NO
© WITH TEST LIGHT CONNECTED

TO B + , PROBE SENSOR
CHECK FOR OPEN IN CKT 474
OR
HARNESS TERMINAL "D". FAULTY CONNECTIONS
FAULTY PCM.
YES NO
3= I E
© •
•
RECONNECT SENSOR.
DISCONNECT ENGINE SHUTOFF SOLENOID.
OR
• BACKPROBE PCM CONNECTOR TERMINAL "PD9" FAULTY CONNECTIONS
WITH J 39200 CONNECTED TO GROUND. OR
• CRANK ENGINE. FAULTY PCM.
IS THERE BETWEEN 2-3 VOLTS?
YES NO
HZ T
FAULTY PCM CONNECTION OPEN CKT 983
OR OR
FAULTY PCM. FAULTY OPTICAL/FUEL TEMPERATURE SENSOR
CONNECTION
OR
FAULTY OPTICAL/FUEL TEMPERATURE SENSOR.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. p$ 16762
ENGINE HARNESS
C O N N E C T O R (15 P I N )
PCM
OPTICAL FUEL
TEMPERATURE SENSOR
\ 5 VOLT
^ ^ J E F E R E N C E
- 474 GRY
- 442 P N K CAM SIGNAL
£. - 943 PPL HIGH RESOLUTION SIGNAL
E
F
987 W H T
1578 Y E L
987 W H T
F3 SENSOR GROUND
T V V ¥
5 V O L T
REFERENCE
—FUEL
I P C M C O N N . ID | TERMPERATURE
SIGNAL
J" P A / P B P I N K 3 2 P I N ]
P C / P D PINK 2 4 P I N J
1
B C / B D B L U E 3 2 PIN J 11-4-93
NS14321
DTC 18
PUMP CAM REFERENCE PULSE ERROR
The optical sensor also provides a Pump Cam signal to the PCM by counting pulses on the sensor disk located
in the injection pump. The Pump Cam reference pulse is one of the most important inputs by the PCM for timing
and start of injection.
DTC 18 Will Set W h e n : 8 cam reference pulses missed for every crankshaft position pulse.
DTC 18 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled "OFF" then
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: When the PCM is in backup fuel,
refer to circled number(s) on the diagnostic chart. rough idle and poor performance problems will exist.
1. This step determines i f it is the result of a hard If DTC 17 is stored, there is a possible problem with
failure or intermittent. CRTs 474 or 987.
2. This step checks 5 volt reference circuits.
3. This step checks ground circuit.
4. This step checks to see i f the optical/fuel
temperature sensor is sending a signal to the PCM
and to check CKT 982 for an open.
DTC 18
PUMP CAM REFERENCE
PULSE ERROR
© •
•
INSTALL SCAN T O O L
START ANO IDLE EN6INE.
DOES SCAN TOOL DISPLAY 8 CAM REFERENCE
PULSES MISSED?
YES NO
I
© IGNITION "OFF."
DISCONNECT OPTICAL/FUEL TEMPERATURE
DTC 18 IS INTERMITTENT.
IF NO ADDITIONAL DTC(s) ARE STORED,
SENSOR CONNECTOR. REFER TO "DIAGNOSTIC AIDS."
IGNITION "ON/* ENGINE "OFF."
PROBE SENSOR HARNESS TERMINAL "A" WITH
J 39200 TO GROUND.
IS THERE 5 VOLTS?
YES NO
© PROBE SENSOR HARNESS TERMINAL "D"

WITH A TEST LIGHT CONNECTED TO B + .
CHECK FOR OPEN IN CKT 474.
OR
IS TEST LIGHT "ON"? FAULTY CONNECTIONS.
OR
FAULTY PCM.
I YES NO
© •
•
RECONNECT SENSOR.
START AND IDLE ENGINE.
OR
• WITH SCAN TOOL, COMMAND 900 RPM. FAULTY CONNECTIONS
• WITH J 39200 ON HERTZ (Hz) SCALE, OR
BACKPROBE PCM TERMINAL "PD15". FAULTY PCM.
IS THERE 60 Hz ± 3 Hz)?
YES NO
X
OR OR
FAULTY PCM. FAULTY OPTICAL/FUEL TEMPERATURE SENSOR CONNECTION
OR
11-29-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. p$ | 6 9 S 2
TO ETC AND IAT SENSORS

CRANKSHAFT POSITION SENSOR PCM
643 YEL CRANKSHAFT
POSITION SIGNAL
416 QRY PC10 SVOLT

cj-^YrBf REFERENCE
TO EGR CONTROL
PRESSURE/BARO SENSOR
BOOST (LESS THAN 8 5 0 0 G V W )
SENSOR
(TURBO * 432 LT GRN BOOST SIGNAL
ONLY) 'IE! (TURBO O N L Y )
I I
[ - 5* EPifl 5 _ } BARO SENSOR

J PA/PB PINK 3 2 PIN ] ( G R E A T E R T H A N 3500 G V W )
J P C / P D PINK 2 4 PIN J
11-4-93
Ls?{|*L ItSJlfi?J NS14319
DTC 19
CRANKSHAFT POSITION REFERENCE ERROR
The crankshaft position sensor is a "Hall-effect" type sensor that monitors crankshaft position and speed.
There are four teeth 90° apart on the front of the crankshaft sprocket that induce a pulse i n the sensor which is
transmitted to the PCM.
DTC 19 Will Set W h e n : 8 crankshaft position pulses missed for every cam reference pulse.
Action T a k e n (PCM will default to): Backup fuel.
DTC 19 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled *OFF' then
"ON.*
refer to circled number(s) on the diagnostic chart. idle and poor performance will exist.
1. This step will determine i f DTC 19 is the result of a Check for good connection at crankshaft position
hard failure or an intermittent condition. sensor and at PCM.
2. This step checks the 5 volt reference.
3. This step checks the ground circuit.
4. This step checks the sensor and harness wiring.
DTC 19
CRANKSHAFT POSITION
REFERENCE ERROR
© •
•
INSTALL SCAN TOOL.
• DOES SCAN TOOL DISPLAY 8 CRANKSHAFT REFERENCE MISSED?
| YES NO
I
© •
•
IGNITION "OFF."
DISCONNECT CRANKSHAFT POSITION SENSOR.
• IGNITION "ON," ENGINE " O F F . " REFER TO "DIAGNOSTIC AIDS."
• PROBE SENSOR HARNESS TERMINAL " C " WITH
J 39200 TO GROUND.
IS THERE 5 VOLTS?
1
I YES NO
m
© PROBE SENSOR HARNESS TERMINAL " B "

WITH A TEST LIGHT CONNECTED TO B • .
OR
OR
FAULTY PCM.
1
! YES NO
I
© •
•
RECONNECT SENSOR.
DISCONNECT ENGINE SHUT OFF SOLENOID.
OR
• BACKPROBE PCM TERMINAL "PD13" WITH FAULTY CONNECTIONS.
J 39200 CONNECTED TO GROUND. OR
IS THERE 4 VOLTS?
X
YES NO
JO IE
OR OR
FAULTY PCM. FAULTY CONNECTIONS
OR
FAULTY CRANKSHAFT POSITION SENSOR.
10-28-93
PCM
ACCELERATOR Pf OAL
POSITION (APP) MODULI l/P HARNESS CONNECTOR
(10-PIN)
B02 JUU^SVOLT
997 WHT/BLK - 997 WHT/BLK m
REFERENCE
APP 1
SENSOR
992DKBLU - 992 DK BLU PC4 SENSOR SIGNAL
998 BRN 998 BRN PD4 E N S 0
3k$ * GROUND
996 TAN 996 TAN PB7 - M W ^ 5 VOLT
APP 2 REFERENCE
993 LT BLU 993 LT BLU
SENSOR pa SENSOR SIGNAL
999 PPL — — 999 PPL PD3 ~ j SENSOR GROUND
995 YEUBLK 995 YEUBLK PD11 JMl^- 5 VOLT
APP 3 REFERENCE
SENSOR — JL 994 DK GRN • 994 DK GRN PB10 SENSOR SIGNAL
961 GRY PD5 " 1 SENSOR GROUNO
l/P HARNESS (23-PIN)

A B C D E
K J H 0 F
r^reMCONN.ID^]
PA/PB PINK 32 PIN
PC/PD PINK 24 PIN
APP MODULE CONNECTOR ^ ^ L ^ B L ^ J 2 P J N J
11-8-93
NS14054
DTC 21
ACCELERATOR PEDAL POSITION (APP) 1 CIRCUIT HIGH
The Accelerator Pedal Position (APP) module provides a voltage signal that changes relative to accelerator
position. There are three sensors located within the APP module that are scaled differently.
DTC 21 Will Set W h e n : Voltage is greater than 4.75 volts for 2 seconds on APP 1 sensor.
Action Taken (PCM Will default to): The input from APP 1 sensor is ignored. A current and history DTC
will set but i t will not turn on the "Service Throttle Soon" lamp. The throttle will operate normally as long as
there is only one sensor malfunctioning. If two different APP sensors have a malfunction, the "Service Throttle
Soon" lamp will light and the PCM will limit power. I f three APP sensors have a malfunction present, the
"Service Throttle Soon" lamp will light and the PCM will only allow the engine to operate at idle.
"ON."
DTC Chart Test Description: Number(s) below Also, 90% pedal travel is acceptable for correct
refer to circled number(s) on the diagnostic chart. APP operation.
1. This step determines i f DTC 21 is the result of a Scan APP 1 sensor while depressing accelerator
hard failure or an intermittent condition. pedal with engine stopped and ignition "ON." Display
2. This step checks the PCM and wiring. should vary from about .74 volt when throttle was
3. This will check for an open in ground CKT 998. closed to about 3.7 volt when throttle is held at Wide
Open Throttle (WOT) position.
Diagnostic Aids: A scan tool reads APP 1 position A DTC 21 will result i f CKT 998 is open or CKT
in volts. Should read about .45 to .95 volt with throttle 992 is shorted to voltage.
closed and ignition "ON" or at idle. Voltage should Eefer to "Intermittent" in SECTION 2.
increase at a steady rate as throttle is moved toward
Wide Open Throttle (WOT).
DTC 21
ACCELERATOR PEDAL POSITION (APP) 1
CIRCUIT HIGH
© •
•
IGNITION "ON," ENGINE "OFF.**
DOES SCAN TOOL DISPLAY APP 1
VOLTAGE GREATER THAN 4 . 7 5 V ?
1
YES NO
© •
•
DISCONNECT APP MODULE.
DOES SCAN TOOL DISPLAY
ADDITIONAL DTCs WERE
APP 1 VOLTAGE OF . 2 5 V OR STORED, REFER TO "DIAGNOSTIC
LESS? AIDS" ON FACING PAGE.
YES NO
I T
© APP MODULE DISCONNECTED.

PROBE APP 1 HARNESS
CKT 992 SHORTED TO VOLTAGE
OR
TERMINAL "A" WITH TEST FAULTY PCM.
LIGHT CONNECTED TO B +.
TEST LIGHT SHOULD LIGHT.
1
TEST LIGHT "ON" TEST LIGHT " O F F "
I I
FAULTY CONNECTION OPEN SENSOR GROUND CKT 998
OR OR
FAULTY APP MODULE. FAULTY PCM.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. N S <| 5525
PCM
ACCELERATOR PEDAL
POSITION (APP) MODULE l/P HARNESS CONNECTOR
(10-PIN)
G BD2 i « A _ 5 VOLT
9S7 WHT/BLK 997 WHT/BLK m
REFERENCE
APP 1 — ^ •
F 992 OK BLU — — 992 OK BLU PC4 SENSOR SIGNAL
SENSOR
A 998 BRN 998 BRN PD4 ^ S E N S O R GROUND
0 996 TAN 996 TAN PB7 5 VOLT
f
APP 2 " REFERENCE

SENSOR C pa SENSOR SIGNAL
B 999 PPL — — 999 PPL PD3 ^ S E N S O R GROUND
E 995 YEUBLK PD11 4 A | ^ - 5 VOLT
995 YEUBLK
APP 3 " REFERENCE
994 OK GRN PB10
SENSOR JL " 994 DK GRN SENSOR SIGNAL
•
X 961GRY PD5 j ^ S E N S O R GROUND
t
A B C D E
K J H G F
[ PCMCONN.IO_]
f p A / P B PINK 3 2 P I N ]
• PC/PD PINK 24 PIN J
APP MODULE CONNECTOR [BC/BD BLUE 32 PIN J
11-8-93
NS14054
DTC 22
ACCELERATOR PEDAL POSITION (APP) 1 CIRCUIT LOW
DTC 22 Will Set W h e n : Voltage is less than .25 volt for 2 seconds on APP 1 sensor
Action Taken (PCM will default to): The input from APP 1 sensor is ignored. A current and history DTC
will set but it will not turn on the "Service Throttle Soon" lamp. The throttle will operate normally as long as
there is only one sensor malfunctioning. I f two different APP sensors have a malfunction, the "Service Throttle
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: A scan tool reads APP 1 position
refer to circled number(s) on the diagnostic chart. in volts. Should read about .45 to .95 volt with throttle
1. This step determines i f DTC 22 is the result of a closed and ignition "ON" or at idle. Voltage should
hard failure or an intermittent condition. increase at a steady rate as throttle is moved toward
2. This step checks the PCM and wiring. Wide Open Throttle (WOT).
3. This step will determine i f there is a faulty Also, 90% pedal travel is acceptable for correct
connection or sensor. APP operation.
4. This step will check the ground circuit. Scan TP sensor while depressing accelerator pedal
with engine stopped and ignition "ON." Display
should vary from about .74 volt when throttle is closed
to about 3.7 volts when throttle is held at Wide Open
Throttle (WOT) position.
A DTC 22 will result i f circuit is open.
DTC 22
CIRCUIT LOW
© THROTTLE CLOSED.
DOES SCAN TOOL DISPLAY APP 1 VOLTAGE
OF 25V OR L E S S ?
YES NO
© •
•
JUMPER CKTs 992 AND 997 TOGETHER.
• DTC 22 IS INTERMITTENT.
IF NO ADDITIONAL DTCs WERE STORED,
SCAN TOOL SHOULD DISPLAY APP 1 VOLTAGE REFER TO "DIAGNOSTIC AIDS."
GREATER THAN 4.0V.
DOES IT?
1 _
NO YES
© PROBE CKT 992 WITH A TEST LIGHT

CONNECTED TO B + .
© • POOR CONNECTION OR FAULTY
APP SENSOR.
SCAN TOOL SHOULD DISPLAY APP 1 VOLTAGE
GREATER THAN 4.0V.
DOES IT?
NO
YES
L
CKT 997 OPEN OR SHORTED TO GROUND
T
OR
OR FAULTY PCM CONNECTION
FAULTY CONNECTION OR
OR FAULTY PCM.
FAULTY PCM.
4-16-93
PCM
ACCELERATOR PEDAL
(10-PIN)
997 WHT/BLK 997 WHT/BLK BD2 m
REFERENCE
APP 1
992 DK BLU — — 992 DK BLU PC4 SENSOR SIGNAL
SENSOR
998 BRN 996 BRN PD4 ~1 SENSOR GROUND
996TAN 996 TAN PB7 5 VOLT
f l f
APP2 REFERENCE
SENSOR pa SENSOR SIGNAL
999 PPL — — 999 PPL PD3 " 1 SENSOR GROUND
99S YEUBLK 995 YEUBLK PD11 5 VOLT
f
APP 3 " REFERENCE

SENSOR 994 OK GRN " 994 DK GRN PB10 SENSOR SIGNAL
961GRY PD5 ~ j SENSOR GROUND
t
A B C D E
K 1 H G F
r^PCMCONNLID ]
f PA/PB PINK 3 2 P I N ]
P C / P D PINK 2 4 PIN J
APP MOOULE CONNECTOR • B C / B D B L U E 3 2 PIN J
11-8-93
NS 14054
DTC 23
ACCELERATOR PEDAL POSITION (APP) 1 CIRCUIT RANGE FAULT
pedal position. There are three sensors located within the APP module that are scaled differently.
DTC 23 Will Set W h e n : PCM has recognized a "skewed" (mis-scaled) sensor. The PCM compares all three
sensors to each other and determines if there is a 6% difference between APP 1 and APP 2 and a 10% difference to
APP 3.
will set but it will not turn on the "Service Throttle Soon" lamp. Throttle will operate normally as long as there is
only one malfunction present. I f there are two APP malfunctions present, the PCM will turn "ON" the "Service
Throttle Soon" lamp and limit power. I f a third APP malfunction is present, the "Service Throttle Soon" lamp
will be "ON" and only allow the engine to operate at idle.
"ON."
1. This step determines i f there is a good 5 volt closed and ignition "ON" or at idle. Voltage should
reference. increase at a steady rate as throttle is moved toward
2. This step will check for an open in the ground Wide Open Throttle (WOT).
circuit. Also, 90% pedal travel is acceptable for correct
APP operation.
Scan APP 1 sensor while depressing accelerator
pedal with engine stopped and ignition "ON." Display
should vary from about .74 volt when throttle was
closed to over about 3.7 volts when throttle is held at
Wide Open Throttle (WOT) position.
DTC 23
CIRCUIT RANGE FAULT
© •
•
• WITH J 39200 CONNECT TO GROUND, PROBE
HARNESS TERMINALS "G"« "D" AND " E " .
IS THERE 5.0 VOLTS ( ± .2) ON EACH CIRCUIT?
© •
I
• WITH TEST LIGHT CONNECTED TO
wr
B +, PROBE HARNESS TERMINALS
"A V ' B " AND " J " .
NO
OR
1
CKT(s) 997,996 OR 995 OPEN
SHORTED TO GROUND
IS TEST LIGHT "ON" (ALL OR
CIRCUITS)? FAULTY PCM.
X
YES NO
m IT
FAULTY CONNECTION OPEN SENSOR GROUND CKT(s)
OR 998,999,961
APP MODULE. OR
FAULTY PCM CONNECTION
OR
FAULTY PCM.
W
IF PCM IS FAULTY AND MUST BE REPLACED, TDC OFFSET" MUST BE PROGRAMMED INTO THE NEW PCM.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. ^15527
PCM
ACCELERATOR PEDAL
(10-PIN)
997 WHT/BLK 997 WHT/BLK BD2 J I M ^ S V O L T
™ REFERENCE
APP 1
992 OK BLU — — 992 DK BLU PC4
SENSOR SENSOR SIGNAL
998 BRN 998 BRN PD4 " 1 SENSOR GROUND
996 TAN 996 TAN PB7 - W ^ 5 VOLT
APP 2 1 , 1
REFERENCE
993 LT BLU
SENSOR 993 LT BLU
pa SENSOR SIGNAL
999 PPL — — 999 PPL PD3 ~ j SENSOR GROUND
995 YEUBLK 995 YEUBLK PD11 - 4 / W ^ S V O L T
T
APP 3 " REFERENCE

SENSOR 994 DK GRN - 994 DK GRN P810 SENSOR SIGNAL
961 GRY PD5 1 SENSOR GROUND
t
t/P HARNESS (23-PIN)
A B C D E
K J H G F
PCM CONN. ID 1
PA/PB PINK 3 2 PIN

P C / P D PINK 2 4 PIN !
APP MODULE CONNECTOR [ B C / B D BLUE 3 2 PIN J
11-8-93
NS 14054
DTC 25
there is only one malfunction present. I f two different APP sensors have a malfunction, the "Service Throttle
"ON."
1. This step determines if DTC 25 is a hard failure or Refer to SECTION 2 for "Intermittents."
an intermittent condition. Scan APP 2 signal while depressing accelerator
2. This will check for an open in ground CKT 999. pedal with engine stopped and ignition "ON." Display
3. This step checks the PCM and wiring. should vary from about 4.5 volts when throttle was
closed to about 1.5 volts when throttle is held at Wide
Diagnostic Aids: A Tech 1 scan tool reads APP 2 Open Throttle (WOT) position.
position in volts and should read about 4.5 volts with
throttle closed and ignition "ON" or at idle. Voltage
should decrease at a steady rate as throttle is moved
toward WOT.
DTC 25
© •
•
IGNITION " O N / ENGINE "OFF."
VOLTAGE GREATER THAN 4.75 VOLTS?
1
YES NO
X
© •
•
PROBE APP 2 HARNESS
TERMINAL " B " WITH TEST LIGHT STORED, REFER TO "DIAGNOSTIC
CONNECTED TO B +. AIDS" ON FACING PAGE.
IS TEST LIGHT "ON"?
YES NO
X
© JUMPER APP 2 HARNESS TERMINALS
" C " AND " B " TOGETHER.
CKT 999 OPEN
OR
DOES SCAN TOOL DISPLAY APP 2 FAULTY PCM CONNECTION
VOLTAGE LESS THAN .25 VOLTS? OR
FAULTY PCM.
TL
YES NO
XI X
FAULTY CONNECTION OPEN CKT 993 OR SHORTED
OR OR
APP MODULE. FAULTY PCM CONNECTION
OR
FAULTY PCM.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. m 1 5 5 2 8
PCM
ACCELERATOR PEDAL
(10-PIN)
G 997 WHT/BLK - 997WHT/BLK 8 0 2 JUUtA^SVOLT
m
REFERENCE
APP1 ^ — —
F 992 DK BLU - 992 DK BLU PC4 SENSOR SIGNAL
SENSOR
A 998 BRN 998 BRN PD4 H SENSOR GROUND
0 996 TAN 996 TAN PB7 - A / « ^ 5 VOLT
f
APR 2 REFERENCE
SENSOR 7" 993 LT BLU 993 LT BLU P O SENSOR SIGNAL
B 999 PPL — — 999 PPL PD3 "1 SENSOR GROUND
E 995 YEUBLK 99$ YEUBLK PD11 5 VOLT
APP 3 REFERENCE
SENSOR 994 OK ORN ' 994 DK GRN P310 SENSOR SIGNAL
•
"x 961 GRY PDS " ^ S E N S O R GROUND
t
A B C D E
K 1 H 0 F
|" PCM CONN. ID ]
f PA/PB PINK 32 PIN 1

J PG/PD PINK 24 PIN |
1
APP MODULE CONNECTOR [BC/BD BLUE 32PIN
11-8-93
NS 14054
DTC 26
DTC 26 Will Set W h e n : Voltage is less than .25 volt for 2 seconds on APP 1 sensor.
Action Taken (PCM will default to): The input from the sensor is ignored. A current and history DTC
there is only one malfunction present. If two different APP sensors have a malfunction, the "Service Throttle
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: A Tech 1 scan tool reads APP 2
refer to circled number(s) on the diagnostic chart. position in volts and should read about 4.5 volts with
1. This step determines i f DTC 26 is the result of a throttle closed and ignition "ON" or at idle. Voltage
hard failure or an intermittent condition. should decrease at a steady rate as throttle is moved
2. This step checks the PCM and wiring. toward WOT.
3. This will check the PCM and CKT 993. An open or short to ground in CKT 996 or 993 will
result in a DTC 26.
Refer to SECTION 2 for "Intermittents."
should vary from about 4.5 volts when throttle was
DTC 26
© DOES SCAN TOOL DISPLAY APP 2 LESS THAN . 2 5 VOLTS?
1
NO
© •
•
WITH J 39200 CONNECTED TO GROUND,
DTC 2 6 IS INTERMITTENT. IF NO ADDITION DTCs
WERE STORED REFER TO "DIAGNOSTIC AIDS"
PROBE HARNESS TERMINAL "D". ON FACING PAGE.
IS THERE 5 VOLTS ( ± .2 V)?
YES NO
X ZE
© • WITH J 3 9 2 0 0 CONNECTED TO GROUND,
PROBE HARNESS TERMINAL T .
CKT 9 9 6 OPEN OR SHORTED TO GROUND
OR
IS THERE 5 VOLTS ( i .2 V)? FAULTY PCM CONNECTION
OR
FAULTY PCM.
1
YES NO
X
FAULTY APP CONNECTION CKT 9 9 3 OPEN OR SHORTED TO GROUND
OR OR
FAULTY APP MODULE. FAULTY PCM CONNECTION
OR
FAULTY PCM.
4-16-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. HS 1 5 5 2 9
PCM
ACCELERATOR PEDAL
(10-PIN)
G 997 WHT/BLK 997 WHT/BLK BD2 J U U A — S V O L T
m
REFERENCE
APP1
F 992 OK BLU — — 992 OK BLU PC4 SENSOR SIGNAL
SENSOR
A 998 BRN 998 BRN PD4 ~% SENSOR GROUND
0 996 TAN 996 TAN PB7 5 VOLT
f , f
APP 2 REFERENCE
SENSOR C 993 LT BLU 993 LT BLU PQ SENSOR SIGNAL
B 999 PPL — — 999 PPL PD3 ~"—I SENSOR GROUND
E 99S YEUBLK PD11 -A/UULS.5VOLT
99S YEUBLK
APP 3 REFERENCE
994 OK GRN PB10
SENSOR JL - 994 DK GRN SENSOR SIGNAL
J1 961 GRY PD5 ^ S E N S O R GROUND
t
A B C 0 E
K J H G F
|" _ PCM CONN. ID ]
f p A / P B PINK 3 2 P I N ]
J PC/PD PINK 24 PIN J
11*93
NS140S4
DTC 27
sensors to each other (percentage to voltage chart) and determines if there is a 6% difference between APP 1 and
APP 2 and a 10% difference to APP 3.
only one malfunction present. I f there are two APP malfunctions present, the PCM will then turn "ON" the
"Service Throttle Soon" lamp and limit power. If a third APP malfunction is present, the "Service Throttle Soon"
lamp will be "ON" and will only allow the engine to operate at idle.
"ON."
DTC Chart Test Description: Number(s) below should decrease at a steady rate as throttle is moved
refer to circled number(s) on the diagnostic chart. toward WOT.
1. This step determines i f there is a good 5 volt Also, 90% pedal travel is acceptable for correct
reference. APP operation.
2. This step will check for an open in the ground Refer to SECTION 2 for "Intermittents."
circuits. Scan APP 2 sensor while depressing accelerator
Diagnostic Aids: A Tech 1 scan tool reads APP 2 should vary from about 4.5 volts when throttle was
position in volts and should read about 4.5 volts with closed to about 1.5 volts when throttle is held at Wide
throttle closed and ignition "ON" or at idle. Voltage Open Throttle (WOT) position.
DTC 27
CIRCUIT RANGE FAULT
© •
•
IGNITION "ON," ENGINE "OFF."
• WITH J 39200 CONNECT TO GROUND/PROBE
HARNESS TERMINALS " G " , "O" AND " E " .
YES NO
m
© WITH TEST LIGHT CONNECTED TO

B 4 - , PROBE HARNESS TERMINALS
CKT(s) 997,996 OR 995 OPEN
OR
"A", " B " AND " J " . SHORTED TO GROUND
YES NO
m I
OR 998,999,961
APP MODULE. OR
OR
FAULTY PCM.
4-16-93
WATER IN FUEL SENSOR
TO
PCM
FUEL HEATER
IGN
JUNCTION
*
GLOW PLUG
BLOCK •505 Y E L - PC13 RELAY CONTROL
B+ IN- -2RED- — 1 5 0 BLK-
"GLOWPLUG"
LEFT
GLOW
PLUGS
GLOW PLUG
- RELAY
CLUSTER BULKHEAD
CONNECTOR CONNECTOR
GLOW PLUG
- E D -
5 AMP
GLOW PLUG
-507 DK BLU SIGNAL
l/P ^MW—^
GLOW PLUG- CONNECTOR
LAMP
-509ORN/BLK—*
PCM CONN. ID
.J
PA/PB PINK 32 PIN !
PC/PD PINK 24 PIN i RIGHT
BC/BD BLUE 32 PIN i 11-1-93
FUSIBLE LINK GLOW
t. •mi
PLUGS NS14762
DTC 29
GLOW PLUG RELAY CIRCUIT FAULT
The glow plug system is used to assist in providing the heat required to begin combustion during engine
starting at cold ambient temperatures. The glow plugs are heated before and during cranking, as well as initial
engine operation. The PCM controls the glow plugs by sending a B + signal.

• Glow plugs commanded "ON" and "glow plug volts" is less than .8 volt.
OR
• Glow plugs "OFF" and "glow plug volts" is greater that. 8 volt.
OR
• "System voltage" exceeds "glow plug volts" by 2 volts.
Action Taken (PCM will default to): Hard start.

DTC Chart Test Description: Number(s) below 5. This step will determine if CKT 505 is open.
refer to circled number(s) on the diagnostic chart. 6. This step will check relay and wiring.
1 This step will determine i f DTC 29 is a hard
failure. Diagnostic Aids: I f glow plug relay was stuck in
2. The Tech 1 scan tool may not display system the "ON" position, check for proper operation of glow
voltage. The important thing is that the PCM is plugs, refer to SECTION 7. When glow plugs are
cycling voltage "ON" and "OFF" indicating that commanded "ON" by the Tech 1, an internal PCM
the PCM is OK. timer protects the glow plugs from damage by cycling
3. This step will check relay feed circuit. them "ON" for 3 seconds and the "OFF" for 12 seconds.
4. This step will check relay ground.
DTC 29
GLOW PLUG RELAY
CIRCUIT FAULT
© •
•
INSTALL TECH 1 SCAN TOOL.
• COMMAND GLOW PLUGS "ON."
• DOES "GLOWPLUG VOLTS" DISPLAY B +
WHEN GLOW PLUGS COMMANDED " O N " ?
NO YES
© •
•
COMMAND GLOW PLUGS "ON."
DOES SCAN TOOL DISPLAY "GLOW PLUG RELAY"
OTHER DTCs ARE STORED,
VOLTAGE CYCLING "ON" AND " O F F " ? REFER TO "DIAGNOSTIC AIDS."
YES NO
© •
•
DISCONNECT GLOW PLUG RELAY CONNECTOR.
OR
• WITH TEST LIGHT CONNECTED TO GROUND, PROBE PCM.
GLOW PLUG RELAY HARNESS TERMINAL "A".
IS TEST LIGHT "ON"?
3
YES NO
ZEZ
© • CONNECT TEST LIGHT BETWEEN GLOW PLUG HARNESS TERMINALS "A" AND " C "
IS TEST LIGHT "ON"?
OPEN CKT 39.
YES NO
© •
•
GLOW PLUG HARNESS STILL DISCONNECTED.
WITH TEST LIGHT CONNECTED TO GROUND, PROBE HARNESS TERMINAL " B "
OPEN CKT 150.

IS TEST LIGHT "ON"?
YES NO
r
© •
•
RECONNECT GLOW PLUG RELAY.
WITH TEST LIGHT CONNECTED TO GROUND, PROBE GLOW PLUG SIDE OF RELAY.
OPEN CKT 505
OR
• COMMAND GLOW PLUG "ON." FAULTY PCM CONNECTIONS
DOES TEST LIGHT COME "ON"? OR
PCM.
YES NO
nr
OPEN GLOW PLUG SIGNAL CIRCUIT OPEN CKT
OR OR
FAULTY PCM CONNECTION FAULTY CONNECTION
OR OR
FAULTY PCM. FAULTY GLOW PLUG RELAY.
PS 17109
TFT TO BOOST TO EOT, IAT AND PCM

SENSOR SENSOR CRANKSHAFT
(A/T ONLY) (TURBO ONLY) POSITION SENSOR
>-
A 452 BLK SENSOR GROUND
EGR CONTROL
PRESSURE/BARO B 433 GRY/BLK EGR CONTROL
416 GRY 5 VOLT
C
EGR REFERENCE
VALVE
_reMCONN.ID^ j
PA/PB PINK 32 PIN I
TO BOOST
PC/PO PINK 24 PIN I TO EGR VENT 11-3-93
SENSOR
DTC 31
EGR CONTROL PRESSURE/BARO SENSOR CIRCUIT LOW
(HIGH VACUUM)
A MAP sensor is used to monitor the amount of vacuum in the EGR circuit. It senses the actual vacuum in
the EGR vacuum line and sends a signal back to the PCM. This signal is used to control EGR duty cycle
calculated by the PCM.
DTC 31 Will Set W h e n : EGR pressure is less than 15 kPa for 2 seconds.
Action Taken (PCM will default to): The PCM will shut down the EGR system.
DTC 31 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled "OFF" the
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: With the ignition "ON" and the
refer to circled number(s) on the diagnostic chart. engine stopped, the EGR pressure is equal to
1. This step determines if DTC 31 is a hard failure or atmospheric pressure with the signal voltage being
an intermittent condition.. high. The information is used by the PCM as an
2. Jumpering harness terminals "B" to "C" (5 volts to indication of vehicle altitude. Comparison of this
signal circuit) will determine i f the sensor is at reading with a known good vehicle with the same
fault, or i f there is a problem with the PCM or sensor is a good way to check accuracy of a "suspect"
wiring. sensor. Readings should be the same ± .4 volt.
3. The Tech 1 scan tool may not display 5 volts. The An intermittent open in CKT 433 or CKT 416 will
important thing is that the PCM recognized the result in a DTC 31.
voltage as more than 4 volts, indicating that the
PCM and CKT 433 are OK.
DTC 31
(HIGH VACUUM)
* IF DTC 57 IS ALSO STORED, REFER TO THAT CHART FIRST.
© • ENGINE IDLING.
DOES TECH 1 DISPLAY EGR PRESSURE VOLTAGE BELOW 1.0 VOLT?
YES NO
I E
© IGNITION "OFF."
DISCONNECT SENSOR ELECTRICAL CONNECTOR.
DTC 31 IS INTERMITTENT. IF NO ADDITIONAL
DTCs WERE STORED, REFER TO "DIAGNOSTIC
JUMPER HARNESS TERMINALS " B " TO " C " . AIDS."
IGNITION "ON."
EGR PRESSURE VOLTAGE SHOULD READ OVER
4.0 VOLTS.
DOES IT?
NO YES
IT
© •
•
IGNITION "OFF."
REMOVE JUMPER WIRE.
FAULTY CONNECTION
OR
• PROBE TERMINAL " B " WITH A TEST SENSOR.
LIGHT TO BATTERY VOLTAGE.
• IGNITION "ON."
• TECH 1 SHOULD READ EGR
PRESSURE OVER 4 VOLTS.
DOES IT?
YES NO
zr
CKT 416 OPEN CKT 433 OPEN
OR OR
FAULTY PCM. CKT 433 SHORTED TO GROUND
OR
CKT 433 SHORTED TO SENSOR GROUND
OR
FAULTY PCM.
11-15-03
TO ECT, IAT, BOOST AND

CRANKSHAFT POSITION SENSORS PCM
TO
TO VACUUM
WASTEGATE PUMP
BOOST SOLENOID
(TURBO VEHICLE ONLY)
EGR
CONTROL
, BOOST
| PCM CONN. ID J CONTROL
| PA/PB - PINK - 32 PIN J
i PCPD - PINK - 24 PIN i 11-11-93
i BC/BD - BLUE • 32 PIN i NS14318
L, , I
DTC 32
EGR CIRCUIT ERROR
The PCM operates a solenoid to control the EGR valve. This solenoid is normally open. By providing a
ground path the PCM energizes the solenoid which then allows vacuum to pass to the EGR.
During normal operation, the PCM compares its desired EGR signal with the EGR pressure signal and makes
corrections in the duty cycle accordingly. I f there is a difference in the PCM command and what is at the EGR
valved sensed by the EGR control pressure/BARO sensor, the PCM makes minor adjustments to correct.

• RPM greater than 506.
• No DTC 31 or 33 stored.
• 50 kPa difference between desired EGR and EGR pressure for 25.5 seconds.
Action Taken (PCM will default to): The PCM will shut down the EGR.
DTC 32 Will Clear When: The fault condition(s) no longer exist, and the ignition switch is cycled "OFF" then
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: A vacuum leak or a pinched
refer to circled number(s) on the diagnostic chart. vacuum line may cause a DTC 32. Check all vacuum
1. This step determines if DTC 32 is a hard failure or lines and components connected to the hoses for leaks
an intermittent. or sharp bends. Check vacuum source to EGR
2. This step checks vacuum at EGR vent solenoid. solenoid. Also check for small leak in EGR valve.
3. This step checks the EGR valve.
DTC 32
EGR CIRCUIT ERROR
IMPORTANT:
THE PCM WILL SHUT DOWN THE EGR SYSTEM IN 15 SECONDS. TO PROPERLY DIAGNOSIS
EGR SYSTEM, IGNITION SHOULD BE CYCLED "ON" AND " O F F " BEFORE EACH PROCEDURE.
© •
•
INSTALL VACUUM GAGE IN PLACE OF EGR VALVE.
START ENGINE.
• AT IDLE, OSSERVE VACUUM
• VACUUM SHOULD BE ABOVE 50 kPa (15").
IS IT?
1
YES NO
IE
© •
•
DISCONNECT EGR VENT SOLENOID
ELECTRICAL CONNECTOR.
OBSERVE VACUUM GAGE AT IDLE.
CHECK VACUUM SOURCE
AT SOLENOID ASSEMBLY.
• THERE SHOULD BE NO VACUUM.
ABOUT 50 kPa BELOW 50 kPa

VACUUM PRESENT NO VACUUM (15") VACUUM. (15") VACUUM.
REPLACE EGR
VENT
SOLENOID.
© •
•
KEY "OFF."
INSTALL VACUUM PUMP
ON EGR VALVE.
CHECK FOR
PLUGGED
OR LEAKY VACUUM
CHECK FOR PLUGGED
OR LEAKY VACUUM
HOSE TO THE VACUUM
• PUMP UP TO 50 kPa (15") VACUUM HOSES. PUMP. IF OK, CHECK
AND OBSERVE EGR VALVE FOR IF OK, REFER TO VACUUM PUMP OUTPUT
MOVEMENT. "DIAGNOSTIC AIDS" AND REPAIR.
ON FACING PAGE.
NO EGR EGR VALVE

MOVEMENT. MOVES.
1
REPLACE EGR NO TROUBLE FOUND;
VALVE. SEE DIAGNOSTIC AIDS.
10-28-93
TFT TO BOOST TO ECT, IAT AND PCM

A
EGR CONTROL
PRESSURE/BARO
SENSOR
EGR
VALVE
>-
1
A
A
452 BLK
433 GRY/BLK
416 GRY
SENSOR GROUND
EGR CONTROL
PRESSURE/BARO SIGNAL
— 1VOLT
REFERENCE
PCM CONN. ID I
PA/PS PINK 32 PIN I

TO BOOST
PC/PD PINK 24 PIN I TO EGR VENT 11-3-93
SENSOR
DTC 33
EGR CONTROL PRESSURE/BARO SENSOR CIRCUIT HIGH
(LOW VACUUM)
A EGR control pressure/BARO sensor is used to monitor the amount of vacuum in the EGR circuit. It senses
the actual vacuum in the EGR vacuum line and sends a signal back to the PCM. The signal is used to control
EGR duty cycle calculated by the PCM.

• EGR vent "OFF."
• Desired EGR is less than or equal to 60 kPa.
• EGR pressure is greater than 101 kPa.
Action Taken (PCM will default to): PCM will shut off EGR system.
"ON."
DTC Chart Test Description: Number(s) below Comparison of the reading with a known good vehicle
refer to circled number(s) on the diagnostic chart. with the same sensor is a good way to check accuracy
1. This step determines if DTC 33 is a hard failure or of a "suspect" sensor. Readings should be the same ±
an intermittent condition. .4 volt.
2. This step simulates conditions for a DTC 31. If the A DTC 33 will result if CKT 452 is open or if CKT
PCM recognizes the change, the PCM and CKT 433 is shorted to voltage or to CKT 416.
433 and CKT 416 are OK. If DTC 33 is intermittent, refer to SECTION 2.
Diagnostic Aids: With the ignition "ON" and the NOTICE: Make sure electrical connector remains
engine stopped, the manifold pressure is equal to securly fastened.
atmospheric pressure with the signal voltage being
high. This information is used by the PCM as an • Refer to "EGR Control Pressure/BARO Sensor
indicator of vehicle altitude. Output Check" for further diagnosis.
DTC 33
(LOW VACUUM)
© •
•
ENGINE IDLING.
• DOES SCAN TOOL DISPLAY EGR PRESSURE
GREATER THAN 4 VOLTS?
YES NO
I
© •
•
IGNITION "OFF."
ADDITIONAL DTC(s) WERE STORED, REFER
• IGNITION "ON." TO "DIAGNOSTIC AIDS."
• SCAN SHOULD READ A VOLTAGE OF 1 VOLT OR LESS.
DOES IT?
YES NO
H
PROBE SENSOR HARNESS TERMINAL CKT 433 SHORTED TO VOLTAGE
" A " WITH A TEST LIGHT T O B + . OR
IS TEST LIGHT ON? SHORTED TO CKT 416
OR
FAULTY PCM.
YES NO
PLUGGED OR LEAKING SENSOR VACUUM HOSE OPEN CKT 452.

OR
FAULTY BARO SENSOR.
4-21-93
ENGINE HARNESS
CONNECTOR (15 PIN)
PCM
564 TAN/BLK 564 TAN/BLK PA9 ITS COIL 1 LOW

INJECTION
TIMING 565 RED/BLK 565 RED/BLK PA6 ITS COIL 1 HIGH
STEPPER
(ITS) 566 ORN/BLK 566 ORN/BLK PA16 ITS COIL 2 LOW
MOTOR 567 YEUBLK
567 YEUBLK PA11 ITS COIL 2 HIGH
,. — — — — — — — — .,
| PCM CONN. ID _ |
1
f PA/PB PINK 32 PIN .
1 1
PC/PD PINK 24 PIN
11-8-93
NS 14055
DTC 34
INJECTION TIMING STEPPER (ITS) MOTOR CIRCUIT FAULT
The PCM controls injection timing with the injection timing stepper motor. To increase injection timing the
PCM extends the stepper motor. To retard injection timing the PCM retracts the stepper motor.

• Engine operating at steady RPM.
• A 5° difference between measured and desired injection timing for 20.8 seconds.
Action Taken (PCM will default to): None.
DTC Chart Test Description: Number(s) below Diagnostic Aids: A hard start and possible poor
refer to circled number(s) on the diagnostic chart. performance condition might exist.
1. This step determines if DTC 34 is a hard failure or Measured injection timing will freeze at the point
an intermittent. of the fault.
2. This step checks for an open or short in CKTs 564
and 565.
and 567.
4. The important thing in this step is that the PCM is
sending a pulsing voltage, this will indicate that
the PCM is OK and that there is a problem with
the injection timing stepper motor.
DTC 34
© •
•
ENGINE AT OPERATING TEMPERATURE.
• S C A N INJECTION T I M I N G AT IDLE A N D A T 1500 RPM.
D O E S S C A N T O O L D I S P L A Y A 5° D I F F E R E N C E B E T W E E N
M E A S U R E D INJECTION TIMING A N D DESIRED INJECTION
TIMING A T IDLE O R A T 1500 RPM?
1
YES NO
H X
© •
•
IGNITION " O F F . "
DISCONNECT PCM.
• D T C 3 4 IS I N T E R M I T T E N T .
IF N O A D D I T I O N A L D T C ( s ) A R E S T O R E D ,
• MEASURE RESISTANCE BETWEEN PCM HARNESS TERMINAL REFER TO "DIAGNOSTIC AIDS."
"PA8" AND "PA9".
D O E S R E S I S T A N C E M E A S U R E B E T W E E N 10 A N D 60 OHMS?
YES NO
H m
© MEASURE RESISTANCE BETWEEN PCM HARNESS TERMINAL

"PA11"AND"PA10".
C H E C K F O R O P E N IN C K T 5 6 5 / 5 6 4
OR
D O E S R E S I S T A N C E M E A S U R E B E T W E E N 10 A N D 6 0 OHMS? FAULTY STEPPER MOTOR.
YES NO
H I E
© •
•
RECONNECT PCM.
DISCONNECT INJECTION TIMING STEPPER M O T O R .
C H E C K F O R O P E N IN C K T 5 6 7 / 5 6 6
OR
• START A N D IDLE ENGINE. FAULTY STEPPER MOTOR.
• U S I N G T E C H 1, C O M M A N D " T D C T I M E S E T " "ON."
• WITH J 39200 CONNECTED TO G R O U N D CHECK FOR A
PULSING V O L T A G E ON TERMINALS "A", " B " , " C " . "D"
D O E S V O L T A G E PULSE ON ALL CIRCUITS?
1
YES NO
HZ
F A U L T Y INJECTION PUMP. CHECK FOR A GROUNDED
CIRCUIT
OR
FAULTY CONNECTION
OR
FAULTY PCM.
IF P C M IS F A U L T Y A N D M U S T B E R E P L A C E D , " T D C O F F S E T " M U S T B E P R O G R A M M E D I N T O T H E N E W PCM.

R E F E R T O " O N - V E H I C L E S E R V I C E " IN T H I S S E C T I O N .
W H E N A L L D I A G N O S I S A N D REPAIRS A R E C O M P L E T E D , C L E A R DTC(s) A N D V E R I F Y P R O P E R O P E R A T I O N . PV16983

3-72 DRIVEABILITY A N D EMISSIONS (DIESEL)
ENGINE HARNESS PCM

CONNECTOR (15 PIN)

SOLENOID
» FUEL INJECT CONTROL
FUEL INJECT CONTROL
985 RED —I
FUEL INJECT SIGNAL
FUEL • S t a
SOLENOID
DRIVER
a 950 LT ORN PD2 CLOSURE GROUND
J
ENGINE
HARNESS 339 PNK
CONNECTOR
(S PIN)
J F/SOL
BLK TO
SOLENOID SWITCH
* •" ^ *ED
FUEL SOLENOID I
HARNESS CONNECTOR L« PCM CONN. ID
— — = „i
| PA/PB PINK 32 PIN I
J PG/PD PINK 24 PIN I
• BC/BD BLUE 32 PIN I
12-9-93
NS 14320
DTC 35
INJECTION PULSE WIDTH ERROR (RESPONSE TIME SHORT)
The fuel injector driver receives an inject command signal from the PCM and provides a current regulated
output to the fuel solenoid that controls injection. It also returns an injection pulse width signal back to the PCM
to inform i t when the fuel solenoid has actually seated. This injection pulse width signal is measured in micro
seconds.

• Battery voltage greater than 10 volts.
• Engine coolant temperature greater that 20°C (68°F).
• Injection pulse width less that 1.2 milliseconds.
Action Taken (PCM W i l l default to): Fixed injection pulse width value of 1.95.
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: The injection pulse width w i l l
refer to circled number(s) on the diagnostic chart. fluctuate slightly when throttle is depressed.
1. This step will determine if DTC 35 is the result of a
hard failure or an intermittent.
2. This will check CKT 985 for an open.
DTC 35
INJECTION PULSE WIDTH ERROR
(RESPONSE TIME SHORT)
© •
•
DOES SCAN TOOL DISPLAY INJECTION
PULSE WIDTH OF 1.95 MS?
YES NO
T i
© • SCAN INJECTION PULSE WIDTH WHILE
DEPRESSING ACCELERATOR.
ADDITIONAL DTCs ARE STORED,
• DOES INJECTION PULSE WIDTH FLUCTUATE? REFER TO "DIAGNOSTIC AIDS" ON
FACING PAGE.
i
YES NO
i
FAULTY FUEL SOLENOID CONNECTION OPEN CKT 985
OR OR
FAULTY FUEL SOLENOID. FAULTY CONNECTION
OR
FAULTY PCM.
12-2-93
ENGINE HARNESS PCM

CONNECTOR (16 PIN)
TO ENGINE SHUTOFF" 339 PNK

SOLENOID
FUEL INJECT CONTROL
QSD 985 RED

FUEL INJECT CONTROL
FUEL INJECT SIGNAL
FUEL
SOLENOID
DRIVER
• 950 LT GRN CLOSURE GROUND
ENGINE
HARNESS 339 PNK
CONNECTOR
(8 PIN)
7 F/SOL |~j
BLK TO
FUEL IGNITION 911 AAMP
20 MP •
SOLENOID SWITCH
RED -
FUEL SOLENOID
HARNESS CONNECTOR [ ^ P C M C O N N . ID ^ J
! P A / P B P I N K 32 PIN I
! P C / P D P I N K 24 PIN I
T B C / B 0^ B U J E J R PINI
12-9-93
NS 14320
DTC 36
INJECTION PULSE WIDTH ERROR (RESPONSE TIME LONG)
The fuel injection driver receives an inject command signal from the PCM and provides a current regulated
seconds.

• Coolant temperature greater than 20°C (68°F).
• Injection pulse width greater than 2.5 milliseconds.
Action Taken (PCM will default to): Fixed injection pulse width of 1.95.
then "ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: The injection pulse width will
refer to circled number(s) on the diagnostic chart. fluctuate when throttle is depressed.
1. This step determines if DTC 36 is a hard failure or A weak (mechanical failure) fuel solenoid will
an intermittent. result in a DTC 36.
2. This step sill determine i f the solenoid is at fault,
or if there is a problem with the PCM or wiring.
DTC 36
(RESPONSE TIME LONG)
© ENGINE IDLING.
1
YES NO
i
• DOES INJECTION PULSE WIDTH FLUCTUATE? REFER TO "DIAGNOSTIC AIDS" ON
FACING PAGE.
1
YES NO
i
OR OR
OR
FAULTY PCM.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION.
12-2-93
PS 16758
PCM
l/P HARNESS
CONNECTOR
(23 - P I N )
ECM-IQN
TO IGNITION - -439 PNK/BLK - H PM IGNITION FEED
SWITCH
t/P HARNESS
CONNECTOR
15 AMP (10-PIN) TO CHMSL
RELAY (P/U)
140 ORN
CRUISE CONTROL
820YELOR17 WHT [ T j # - 8 2820YEL—1PA7
l
BRAKE SWITCH
SIGNAL
STOPLAMP 439 PNK/BLK
SWITCH M.C. T C C BRAKE
420 PPL (A/T) -420 P P L - J B D 5 SWITCH SIGNAL
IV 420 PPL (M/T) —- 86 BRN —| P |" -86 BRN
fcf
N.C.
* FUSIBLE LINK CLUTCH PEDAL POSITION SWITCH
11-4-93
NS14053
DTC 41
BRAKE SWITCH CIRCUIT FAULT
The TCC normally closed brake switch supplies a B + signal on CKT 420 to the PCM. The circuit is opened
when the brakes are applied.
The stop lamp/cruise control normally open brake switch supplies a B + signal on CKT 820 to the PCM when
the brake is applied.

• Switches disagree for 10 consecutive minutes.
OR
• TCC and cruise control brake switches are not toggling "open" and "closed/' during 6 brake applications
on same ignition cycle.
Action Taken (PCM Will default to): An incorrect brake signal can affect TCC, fourth gear operation, in
hot mode and cruise control.
DTC Chart Test Description: Number(s) below Diagnostic Aids:

refer to circled number(s) on the diagnostic chart. • Refer to "PCM I n t e r m i t t e n t Diagnostic
1. This test checks for voltage at brake switch. Trouble Codes or Performance."
2. This test simulates brake switch closed or brakes • Check customer driving habits and/or unusual
"OFF." traffic conditions (i.e. stop and go expressway
3. This test checks for ignition feed to TCC brake traffic).
switch.
4. This test checks CKT 420 and simulates brakes
being applied.
DTC 41
INSTALL SCAN TOOL.
APPLY BRAKES.
DOES SCAN TOOL DISPLAY G C BRAKE SWITCH "CLOSED''
AND THEN "OPEN" WHEN BRAKE IS RELEASED?
NO YES
T JO
CHECK FUSE. APPLY BRAKES AGAIN.
I DOES SCAN TOOL DISPLAY TCC BRAKE SWITCH "OPEN"
© •
•
IGNITION STILL "ON."
DISCONNECT BRAKE SWITCH.
AND THEN "CLOSED" WHEN BRAKE IS RELEASED?
• WITH TEST LIGHT CONNECTED TO GROUND,

PROBE HARNESS TERMINAL "A".
IS TEST LIGHT "ON"?
X 1
YES NO NO YES
JO
© JUMPER HARNESS
TERMINALS "A" AND
OPEN IN CKT 140 CHECK FUSE.
I
IF NO OTHER DTCs ARE
STORED, REFER TO
" B " TOGETHER.
SCAN TOOL SHOULD
DISPLAY C/C BRAKE
© •
•
"DIAGNOSTIC AIDS" ON
FACING PAGE.
• WITH TEST LIGHT CONNECTED
SWITCH "CLOSED."
TO GROUND, PROBE HARNESS
DOES IT?
TERMINAL " C " .
IS TEST LIGHT "ON"?
1 1
NO YES YES NO
JO
OPEN CKT 820
OR
FAULTY
CONNECTION AT
© JUMPER HARNESS
TERMINALS " C AND
OPEN IN CKT 439
FAULTY PCM CONNECTION STOP LAMP "D" TOGETHER.

OR SWITCH SCAN TOOL SHOULD
FAULTY PCM OR DISPLAY TCC BRAKE
FAULTY STOP SWITCH "CLOSED."
LAMP SWITCH. DOES IT?
1
NO YES
X
OPEN CKT 420
JO
FAULTY CONNECTION
OR AT BRAKE SWITCH
FAULTY PCM CONNECTION OR
OR BRAKE SWITCH
FAULTY PCM
4-21-93
ENGINE HARNESS
CONNECTOR (15 PIN) PCM
OPTICAL FUEL
TEMPERATURE SENSOR
\ 5 VOLT
^^REFERENCE
474 GRY
442 PNK CAM SIGNAL
943 PPL HIGH RESOLUTION SIGNAL
907 WHT SENSOR GROUND
T W»sVOLT
REFERENCE
r — — — — — — — i —FUEL
SIGNAL
f PA/PB PINK 3 2 PIN ]
! P C / P D P I N K 2 4 PIN
1
BC/BD BLUE 32 PIN J 11-4-93
NS14321
DTC 42
FUEL TEMPERATURE CIRCUIT LOW
The fuel temperature sensor is a thermistor that controls signal voltage to the PCM. When the fuel is cold,
the sensor resistance is high, therefore the PCM will see high signal voltage. As fuel warms, sensor resistance
becomes less and voltage drops. The fuel temperature sensor is integrated with the optical sensor.
DTC 42 Will Set W h e n : Fuel temperature greater than 102°C (215°F) for 2 seconds.
Action T a k e n (PCM will default to): Poor idle quality during hot conditions.
DTC Chart Test Description: Number(s) below Diagnostic Aids: A scan tool reads fuel
refer to circled number(s) on the diagnostic chart. temperature in degrees centigrade. After engine is
1. This step determines if DTC 42 is a hard failure or started, the fuel temperature should rise steadily.
an intermittent condition. A faulty connection, or an open in CKTs 1578 or
2. This test will determine if CKT 1578 is shorted to 987 will result in a DTC 43.
ground. The "Temperature To Resistance Value" scale at
the right may be used to test the fuel sensor at various
temperature levels to evaluate the possibility of a
"skewed" (mis-scaled) sensor.
DTC 42
© DOES TECH 1 SCAN TOOL DISPLAY ENGINE FUEL

TEMPERATURE OF 102°C (215°F) OR HIGHER?
1
YES NO
i
© • DISCONNECT SENSOR.
FUEL TEMPERATURE BELOW -26°C (-15°F). TO "DIAGNOSTIC AIDS'* ON FACING PAGE.
DOES IT?
YES NO
FAULTY OPTICAL/FUEL TEMPERATURE SENSOR. CKT 1578 SHORTED TO GROUND

OR
OR
FAULTY PCM.
DIAGNOSTIC AID IF PCM IS FAULTY AND MUST BE REPLACED. "TDC

OFFSET" MUST BE PROGRAMMED INTO THE NEW
FUEL TEMPERATURE SENSOR PCM. REFER TO "ON-VEHICLE SERVICE" IN THIS
SECTION.
(APPROXIMATE)
°C °F OHMS
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
11-15-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED. CLEAR DTC(s) AND VERIFY PROPER OPERATION. NS 15533
ENGINE HARNESS
OPTICAL FUEL
TEMPERATURE SENSOR
\ 5 VOLT
— ^^_REFERENCE
/
A 474 GRY
442 PNK CAM SIGNAL
D 987 WHT SENSOR GROUND
E
v v v
p T 5YOLT
REFERENCE
—FUEL
SIGNAL
f P A / P B PINK 3 2 PIN ]
P C / P D PINK 2 4 PIN
8 C / B D B L U E 32 P I N 11-4-93
Ib mm mm, mm, mm, mm mm mm mm mi NS 14321
DTC 43
FUEL TEMPERATURE CIRCUIT HIGH

• Fuel temperature less than -14°C (6°F).
Action Taken (PCM Will default to): Poor idle quality during hot conditions.

1. This step determines i f DTC 43 is a hard failure or started, the temperature should rise steadily.
2. This test simulates a DTC 42. I f the PCM 987 will result in a DTC 43.
recognizes the low signal voltage (high temp) the The "Temperature To Resistance Value" scale at
PCM and wiring are OK. the right may be used to test the fuel sensor at various
3. This test will determine i f CKT 1578 is open. temperature levels to evaluate the possibility of a
There should be 5 volts at sensor connector i f "skewed" (mis-scaled) sensor.
measured with J 39200-DVM. This will determine
if there is a wiring problem or a faulty PCM.
DTC 43
© • DOES TECH 1 SCAN TOOL DISPLAY FUEL TEMP OF -14°C (6°F) OR LESS?
YES NO
HZ
© •
•
DISCONNECT SENSOR.
JUNIPER HARNESS TERMINALS T AND " F " TOGETHER.
DOES IT?
NO YES
© •
•
FAULTY CONNECTION
OR OPTICAL/FUEL
DOES IT? TEMPERATURE SfNSOR.
YES NO
Z E
OPEN SENSOR GROUND CIRCUIT, FAULTY OPEN CKT 1578, FAULTY
FAULTY PCM.
DIAGNOSTIC AID
FUEL TEMPERATURE SENSOR
(APPROXIMATE)
°c °F OHMS
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
5-7-93

TO SENSOR
VACUUM A * 452 BLK PD6
TO EGR CONTROL GROUND
WASTEGATE PUMP
PRESSURE/BARO B - 433 GRY/BLK - PCS
SENSOR MAP SIGNAL
C » 416 GRY -
5V REFERENCE
EGR VENT
CONTROL
EGR
CONTROL
BOOST
CONTROL
, PA/PB . PINK • 32 PIN (
i PCPD - PINK - 24 PIN i

i BC/BD . BLUE - 32 PIN i 11-11-93
i I NS 14318
DTC 44
EGR PULSE WIDTH ERROR
corrections in the duty cycle accordingly. If there is a difference in the PCM command and what is at the EGR
valve sensed by the EGR control pressure/BARO, the PCM makes minor adjustments to correct.

• Ignition voltage on CKT 435 when PCM is requesting EGR solenoid "ON."
OR
• No ignition voltage on CKT 435 when PCM is requesting EGR solenoid "OFF."
Action Taken (PCM w i l l default tdj: The PCM will shut down the EGR.
"ON."
refer to circled number(s) on the diagnostic chart. set a DTC 44.
1. This step determines if DTC 44 is a hard failure or
an intermittent.
2. This step checks to see i f PCM and wiring are OK.
3. This step checks voltage at EGR solenoid.
DTC 44
© •
•
INSTALL TECH 1 SCAN T O O L
• COMMAND EGR SOLENOID "ON" AND "OFF.'
DOES EGR PRESSSURE RESPOND TO EGR
SOLENOID COMMAND?
NO YES
I
© •
•
DISCONNECT EGR VENT.
CONNECT TEST LIGHT BETWEEN
ADDITIONAL DTC(s) ARE STORED,
HARNESS CONNECTOR TERMINALS. REFER TO "DIAGNOSTIC AIDS."
IS TEST LIGHT "ON"?
NO YES
IFAULTY
E CONNECTIONS
© • PROBE HARNESS TERMINAL "A" WITH
TEST LIGHT CONNECT TO GROUND. OR
• IGNITION "ON," ENGINE "OFF." FAULTY VENT SOLENOID.
~1
NO YES
n z
OPEN CKT 439. OPEN IN CKT 971
OR
FAULTY CONNECTIONS
OR
FAULTY PCM.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. p* 16753
T O ECT, IAT,B O O S T A N D
CRANKSHAFT POSITION SENSORS
PCM
TO SENSOR
PD6
TO VACUUM 452 BLK - GROUND
EGR CONTROL
WASTEGATE PUMP
PRESSURE/BARO J > B - 433 GRY/BLK - PCS
MAP SIGNAL
SENSOR
f— 416 GRY - PC10
5V REFERENCE
EGR EGR VENT TO BOOST AND

SOLENOID CRANKSHAFT
SOLENOID
POSITION SENSOR
Fi I- EGR VALVE
1
1 ZZ5T EGR VENT
A I A I B 971 W H T CONTROL
1 B B A
I I
KEY SW.
SOL
BOOST SOLENOID 539 LT BLU/BLK
(TURBO VEHICLE ONLY) 5A
EGR
435 GRY BD15 CONTROL
| P C M C O N N . ID J - 972 YEL H PA3 BOOST

CONTROL
J PA/PB - PINK - 3 2 PIN \
i PC/PD . PINK - 2 4 PIN i
i BC/BD - B L U E 3 2 PIN i 11-11-93
i «. . r NS 14318
DTC 45
EGR VENT ERROR
When the PCM recognizes the operating range for no EGR, the PCM energizes the EGR vent solenoid which
allows rapid venting of EGR vacuum. This solenoid is normally open.

• Ignition voltage on CKT 971 when PCM is requesting EGR vent "ON."
OR
• No ignition voltage on CKT 971 when PCM is requesting EGR vent "OFF."
Action Taken (PCM will default to): The PCM will shut "OFF" EGR system.
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: DTC 45 will set if CKT 971 or 539
refer to circled number(s) on the diagnostic chart. is open.
hard failure or an intermittent condition.
2. This step checks the PCM and wiring.
3. This step checks power and control circuit.
DTC 45
EGR VENT ERROR
© INSTALL TECH 1 SCAN TOOL.

COMMAND EGR VENT "ON" AND "OFF."
VENT COMMAND?
1
NO YES
© DISCONNECT EGR VENT.

DTC 4 5 IS INTERMITTENT. IF NO
IS TEST LIGHT "ON"?
NO YES
m
TEST LIGHT CONNECT TO GROUND.
FAULTY CONNECTIONS
OR
IS TEST LIGHT "ON"?
NO YES
n r
OPEN CKT 4 3 9 . OPEN IN CKT 971
OR
FAULTY CONNECTIONS
OR
FAULTY PCM.
4-29-93
PCM
MIL
TO GAUGES
IGNITION" 419 BRN/WHT
SWITCH 20 AMP SERVICE ENGINE SOON
MIL "SERVICE ENGINE
SOON" CONTROL
960 ORN
SERVICE THROTTLE SOON
"SERVICE THROTTLE
BULKHEAD SOON "LAMP CONTROL
CONNECTOR | PCM CONN. ID |
TO
CRUISE f PA/PB PINK 32 PIN "j
CONTROL PC/PD PINK 24 PIN
11-4-93
SWITCH [^/B^BLyEJ2PJNJ
NS14763
DTC 46
MIL "SERVICE ENGINE SOON" CIRCUIT FAULT
There should always be a MIL "Service Engine Soon" when the ignition is "ON" and the engine stopped. The
PCM will control the MIL and turn it "ON" by providing a ground path.

• Ignition voltage on CKT 419 when PCM is requesting MIL "ON."
OR
• No ignition voltage on CKT 419 when PCM is requesting MIL "OFF."
Action Taken (PCM will default to): No MIL
DTC Chart Test Description: Number(s) below Diagnostic Aids: Check for faulty bulb or fuse. An
refer to circled number(s) on the diagnostic chart. open in CKT 419 will cause a DTC 46 to set.
1. This test checks the a b i l i t y of the PCM to
command the MIL.
2. This test will determine i f there is an open in
ignition feed circuit or CKT 419.
DTC 46
© •
•
IGNITION "ON," ENGINE "OFF. 4
• USING A TECH 1, COMMAND

MIL "ON."
DOES MIL COME "ON"?
1
NO YES
I m
© •
•
IGNITION "OFF."
DISCONNECT 32 PIN (BLUE) PCM
CONNECTOR. REFER TO "DIAGNOSTIC AIDS" ON
• IGNITION "ON." FACING PAGE.
• CONNECT TEST LIGHT TO PCM
HARNESS TERMINAL "BC5" TO
GROUND.
DOES MIL COME "ON"?
CHECK:
- FUSE.
- FAULTY BULB.
- OPEN CKT 419.
- FAULTY CONNECTIONS.
12-16-93
PS167S2
PCM
ENGINE
TEMPERATURE
(ETC) SENSOR TO EGR -« TO TFT
CONTROL SENSOR
PRESSURE/BARO (A/T ONLY)
SENSOR (LESS
THAN 8500 GVW)
TEMPERATURE
(IAT) SENSOR 472 TAN — | P P 1 2 | (AT SIGNAL
r — — — — — — — — -|
I
CRANKSHAFT POSITION
(GREATER THAN 8500 GVW) PC/PD PINK 24 PIN 4 4_
BC/BD BLUE 32 PIN 11-4-93
1 J
NS 14045
DTC 47
INTAKE AIR TEMPERATURE (IAT) CIRCUIT LOW
The intake air temperature sensor is a thermistor that controls signal voltage to the PCM. When the air is
cold, the sensor resistance is high, therefore the PCM will see high signal voltage. As air warms, sensor
resistance becomes less and voltage drops.

• Engine coolant temperature less than 38°C (100°F).
• Intake air temperature is greater than 96°C (205°F) for 2 seconds.
Action Taken (PCM will default to): Poor performance during cold weather operation.

refer to circled number(s) on the diagnostic chart. potential short to ground in CKT 472.
1. This step determines if DTC 47 is a hard failure or Tech 1 scan tool displays intake air temperature in
an intermittent condition. degrees centigrade.
2. This test will determine i f CKT 472 is shorted to Refer to "Intermittents" in SECTION 2.
ground. The "Temperature to Resistance Value" scale at
sensor. A "skewed" sensor could result in poor
DTC 47
© DOES TECH 1 SCAN TOOL DISPLAY IAT OF 96°C (205*F) OR HIGHER?
X
YES NO
X H
© •
•
DISCONNECT SENSOR.
TECH 1 SCAN TOOL SHOULD
ADDITIONAL DTC(s) WERE
DISPLAY IAT TEMPERATURE STORED, REFER TO "DIAGNOSTIC
LESS THAN -26°C (-15°F). AIDS" ON FACING PAGE.
DOES IT?
YES NO
HZ I E
FAULTY CONNECTION OR IAT SENSOR. CKT 472 SHORTED TO GROUND
OR
FAULTY PCM CONNECTIONS
OR FAULTY PCM.
DIAGNOSTIC AID
INTAKE AIR TEMPERATURE SENSOR

(APPROXIMATE)
°C °F OHMS
100 212 177 .

90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
r *i
PCM
ENGINE
COOLANT 410 YEL E C T SIGNAL
TEMPERATURE
(ETC) SENSOR TO EGR TO TFT
! CONTROL SENSOR
S PRESSURE/BARO (ATT ONLY)
I SENSOR (LESS
' THAN 8500 GVW)
TEMPERATURE
(IAT) SENSOR
'"Hilt- 472 TAN IAT SIGNAL
p — — — — — — — — ,
CRANKSHAFT POSITION *
(GREATER THAN 8500 GVW) PC/PD PINK 24 PIN
1
BC/BD B L U E 3 2 PIN J 11-4-93
NS 14045
DTC 48
INTAKE AIR TEMPERATURE (IAT) CIRCUIT HIGH
DTC 48 Will Set W h e n : Intake air temperature less than -38°C (-39°F) for 2 minutes.
Action Taken (PCM will default to): Possible poor performance during cold weather operation.
an intermittent condition. degrees centigrade.
2. This test will determine if circuit 472 is shorted to Refer to "Intermittents" in SECTION 2.
ground. The "Temperature to Resistance Value" scaled at
3. This step will determine i f there is a wiring the right may be used to test the engine coolant sensor
problem or a faulty PCM. at various temperature levels to evaluate the
possibility of a "skewed" (mis-scaled) sensor. A
complaints.
DTC 48
© • DOES TECH 1 SCAN TOOL DISPLAY IAT -38°C (-39°F) OR COLDER?
YES NO
© •
•
DISCONNECT SENSOR.
JUMPER HARNESS TERMINALS
TOGETHER. STORED, REFER TO "DIAGNOSTIC
• TECH 1 SCAN TOOL SHOULD AIDS" ON FACING PAGE.
DISPLAY TEMPERATURE OVER
130°C(266°F).
DOES IT?
YES NO
m m
FAULTY CONNECTION OR SENSOR.
© •
•
130°C(266°F).
DOES IT?
DIAGNOSTIC AID
INTAKE AIR TEMPERATURE SENSOR YES NO

X
(APPROXIMATE) OPEN SENSOR OPEN CKT 472,
GROUND CIRCUIT, FAULTY CONNECTION
°C °F OHMS
FAULTY CONNECTION OR FAULTY PCM.
100 212 177 OR FAULTY PCM.
90 194 241
80 176 332
70 158 467
60 140 667
SO 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
4-23-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. N S 14051
PCM
MIL
TO GAUGES
IGNITION- i l l 419 BRN/WHT
SWITCH 20 AMP SERVICE ENGINE SOON
MIL "SERVICE ENGINE
$1
SOON" CONTROL
960 ORN 1 PAS

SERVICE THROTTLE SOON
SERVICE THROTTLE
SOON LAMP CONTROL
BULKHEAD
CONNECTOR | PCM CONN. ID |
TO
CRUISE f PA/PB PINK 32 PIN "J
CONTROL PC/PD PINK 24 PIN 11-4-93
SWITCH ^BC/BD^BLUE J 2 P I N J
NS 14763
DTC 49
"SERVICE THROTTLE SOON" LAMP CIRCUIT FAULT
There should be a "Service Throttle Soon" lamp when the ignition is "ON" and the engine "OFF" for 2
seconds. The PCM will control the "Service Throttle Soon" and turn i t "ON" by providing a ground path.

• Ignition voltage on CKT 960 when PCM is requesting "Service Throttle Soon" lamp "ON."
OR
• No ignition voltage on terminal "PA5" when PCM is requesting "Service Throttle Soon" lamp "OFF."
Action Taken (PCM Will default to): DTC 49 will not turn "ON" the MIL, but will set a current and history
DTC.
1. This test checks the ability of the PCM to
command the STS lamp.
DTC 49
© •
•
IGNITION "ON**, ENGINE "OFF".
• USING TECH 1, COMMAND "SERVICE
THROTTLE SOON" LAMP "ON."
DOES "SERVICE THROTTLE SOON"
COME ON?
YES
© •
•
IGNITION "OFF."
DISCONNECT 24 PIN (PINK) PCM CONNECTOR.
• IGNITION "ON." REFER TO "DIAGNOSTIC AIDS."
#
PROBE PCM HARNESS TERMINAL 'PA5".
IS SERVICE THROTTLE SOON LAMP "ON"?
CHECK:
FUSE.
FAULTY BULB.
OPEN CIRCUIT.
CKT 960 SHORTED TO VOLTAGE.
OPEN IGNITION FEED TO BULB.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. J1-1 -|3
NS14761
DTC 51
PROM ERROR
(FAULTY OR INCORRECT PROM)
CHECK THAT ALL PINS ARE FULLY INSERTED IN THE SOCKET. IF OK, REPLACE
PROM, CLEAR MEMORY AND RECHECK. IF DTC 51 REAPPEARS, REPLACE PCM.
DTC 54
PCM FUEL CIRCUIT ERROR
THIS DTC INDICATES THERE IS A FAULT IN THE FUELING CIRCUIT OF THE PCM.
* CHECK TO SEE IF A DTC 17 IS ALSO STORED, IF THERE IS REFER TO THAT
CHART FIRST, IF NOT, REPLACE PCM.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC{s) AND VERIFY PROPER OPERATION. 10-27-93
PS 20090
ENGINE HARNESS PCM

CONNECTOR (15 PIN)
TO ENGINE SHUTOFF* 339 PNK

SOLENOID . FUEL INJECT CONTROL
984 LT GRN
985 RED
4 98S RED
FUEL INJECT CONTROL
FUEL INJECT SIGNAL
FUEL 339 PNK
SOLENOID
BBEI
DRIVER
• 950 LT GRN PD2 CLOSURE GROUND
J
ENGINE
HARNESS 339 PNK
CONNECTOR
(8 PIN)
F/SOL
BLK TO
SOLENOID SWITCH
RED -
FUEL SOLENOID
HARNESS CONNECTOR PCM CONN. ID I
.-I
PA/PB PINK 32 PIN I
PC/PD PINK 24 PIN I
t B C / B D BLUE 32 PIN I
12-9-93
NS 14320
DTC 56
INJECTION PUMP CALIBRATION RESISTOR ERROR
The PCM uses a calibrated resistor mounted internally in the injection pump to determine fuel rates. The
resistor value is stored in the PCM memory. I f the PCM memory has been disturbed or the PCM has been
replaced, the PCM will relearn the resistor value on the next ignition cycle.
DTC 56 Will Set W h e n : PCM has lost its memory and is unable to read a resistor value on CKT 960 on the
next ignition cycle. Possible poor performance problem.
Action Taken (PCM Will default to): A current and history DTC will store and turn "ON" the MIL. The
PCM will default to the lowest fuel table.
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: Check connection at fuel injector
refer to circled number(s) on the diagnostic chart. driver. Clear DTC, and cycle ignition. I f DTC clears,
1. This step will determine if there is a problem with treat condition as an intermittent.
the connection at the fuel solenoid driver or a
faulty injection pump.
DTC 56
INJECTION PUMP CALIBRATION
RESISTOR ERROR
©I ARE THERE ANY OTHER ENGINE D T C s STORED?
YES NO
m
REFER TO APPLICABLE DTC CHART. FAULTY FUEL SOLENOID DRIVER
CONNECTION
OR
FAULTY INJECTION PUMP (REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE).
5-7-93
P S t 6 5 6
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. ?
ENGINE HARNESS PCM

CONNECTOR (15 PIN)
OPTICAL FUEL
TEMPERATURE SENSOR
A 474 QRY •
JL 474 QRY — PD10 W
5 VOLT
REFERENCE
B 442 PNK • r 982 PNK P015 CAM SIGNAL
943 PPL ' 983 PPL — PD9 HIGH RESOLUTION SIGNAL
D 987 WHT ' 4-987 W H T - P014
FH
SENSOR GROUND
E 1578 YEL 1578 YEL - PB11
5 VOLT
F 987 WHT REFERENCE
FUEL
TEMPERATURE
TFT TO BOOST TO EOT, IAT AND SIGNAL
A
SENSOR GROUND
EGR CONTROL EGR CONTROL
PRESSURE/BARO
W 5 VOLT
REFERENCE
' r — — — — — — «i TO CRANKSHAFT
POSITION SENSOR
| PA/PB PINK 32 PIN |

TO BOOST
I PC/PD PINK 24 PIN . TO EGR VENT
SENSOR
1
3C/BD BLUE 32 PIN 1
SOLENOID
(TURBO ONLY)
12-9-93
PS 20236
DTC 57
PCM 5 VOLT SHORTED
The 5 volt reference is a non-varying calculated voltage.
DTC 57 Will Set W h e n : 5 volt reference is less than 1 volt.
Action Taken (PCM Will default to): Backup fuel, no EGR and no turbo boost.
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: During the time the failure is
refer to circled number(s) on the diagnostic chart. present, the setting of additional DTCs that share a
1. Checks to confirm that a DTC is still present. 5 volt reference may also set.
2. Checks to determine i f there is a 5 volt reference
from the PCM.
3. Checks to determine i f there is a short-to-ground
in CKT 416 or CKT 474, or a short-to-ground in
the PCM.
DTC 57
PCM 5 VOLT SHORTED
© •
•
INSTALL SCAN TOOL.
• RECORD AND CLEAR DTCs.
• CRANK ENGINE FOR 15 SECONDS OR START UP.
DOES DTC 57 RESET?
1
YES NO
I
• IGNITION "ON," ENGINE "OFF." DTC 57 IS INTERMITTENT.
• DISCONNECT EGR CONTROL PRESSURE/BARO SENSOR. REFER TO "DIAGNOSTIC AIDS.'
• WITH J 39200 CHECK VOLTAGE BETWEEN HARNESS
CONNECTOR PIN " C " AND GROUND.
IS VOLTAGE LESS THAN 4 VOLTS?
NO
© •
•
DISCONNECT PCM 32 PIN PINK CONNECTOR ONLY.
RECONNECT EGR CONTROL PRESSURE/BARO SENSOR.
REPLACE EGR CONTROL
• WITH TEST LIGHTCONNECTED TO B + , PROBE PCM
TERMINALS "PCtO" AND "PD10".
IS TEST LIGHT "ON," IN EITHER CIRCUIT?
NO YES
Jl
REPLACE PCM. SHORT TO GROUND
IN CKT 416 OR 474.
11-1-93

CRANKSHAFT POSITION SENSOR
PCM
843 YEL PD13 CRANKSHAFT
POSITION SIGNAL
416 QRY PC10 5 VOLT

REFERENCE
TO EQR CONTROL
BOOST (LESS THAN 8500 GVW)
SENSOR
(TURBO ' 432 LT GRN PC7 BOOST SIGNAL
ONLY) (TURBO ONLY)
I J
7CM CONOID"] BARO SENSOR

• I
PA/PB PINK 32 PIN (GREATER THAN 8500 GVW)
PC/PD PINK 24 PIN 11-4-93
BC/BD_BLUE J32PINJ
t
NS14319
DTC 61
TURBO BOOST SENSOR CIRCUIT HIGH
The PCM sends a 5 volt reference signal to the boost sensor. As manifold pressure changes, the electrical
resistance of the boost sensor also changes. By monitoring the sensor output voltage, the PCM detects how much
pressure is being produced by the turbocharger in the intake manifold. The PCM uses the boost sensor to control
turbo boost and fuel at different loads.

• Boost signal voltage greater than 3.9 volts.
• RPM less than 3500.
Action Taken (PCM Will default to): No turbo boost. Poor performance.

refer to circled number(s) on the diagnostic chart. engine stopped, boost pressure is equal to atmospheric
1. This step will determine if DTC 61 is the result of a pressure.
hard failure or an intermittent condition. Comparison of this reading with a known good
2. This step simulates conditions for a DTC 62. If the vehicle using the same sensor is a good way to check
PCM recognizes the change, the PCM and CKT accuracy of a "suspect" sensor. Readings should be the
432 are OK. same ± .4 volt.
3. This step will check for an open in ground circuit. Very little boost can be attained by revving the
engine in neutral.
DTC 61
© ENGINE IDLING.
DOES TECH 1 DISPLAY BOOST SENSOR
YES NO
I T
© •
•
IGNITION "OFF."
DISCONNECT BOOST SENSOR.
ADDITIONAL DTC(s) ARE STORED, REFER TO
• IGNITION "ON." "DIAGNOSTIC AIDS" ON FACING PAGE.
• TECH 1 SHOULD DISPLAY BOOST VOLTAGE OF
1 VOLT OR LESS.
DOES IT?
1
YES NO
X
© • PROBE HARNESS TERMINAL "A" WITH A
TEST LIGHT TO B + .
CHECK CKT 432
SHORTED TO VOLTAGE
• TEST LIGHT SHOULD LIGHT. OR
DOES IT? FAULTY PCM.
X
YES NO
I
PLUGGED SENSOR FITTING OPEN CKT 452.
OR
FAULTY BOOST SENSOR.
10-28-93

CRANKSHAFT POSITION SENSOR PCM
EHHHl 643 YEL PD13 CRANKSHAFT
POSITION SIGNAL
416 QRY PC10 5 VOLT

REFERENCE
TO EQR CONTROL
BOOST (LESS THAN 8500 GVW)
SENSOR
(TURBO ' 432 LT GRN — PC7 BOOST SIGNAL
ONLY) (TURBO ONLY)
r ———— i
| PCM CONN. ID |
BARO SENSOR
f PA/PB PINK 32 PIN ] (GREATER THAN 8500 GVW)
PC/PD PINK 24 PIN
1 11-4-93
[BC/BD BLUE 32 PIN
NS14319
DTC 62
TURBO BOOST SENSOR CIRCUIT LOW
pressure is being produced by the turbocharger i n the intake manifold. The PCM uses the boost sensor to control
DTC 62 Will Set W h e n ; Boost signal voltage less than .8 volt.
Action T a k e n (PCM Will default to): No turbo boost, poor performance.
DTC 62 Will Clear W h e n : The fault eondition(s) no longer exist.
416 and CKT 432 are OK. same ± .4 volt.
Very little boost can be attained by revving the
engine i n neutral.
DTC 62
* IF DTC 57 IS A t S O STORED, REFER TO THAT CHART FIRST.
© ENGINE IDLING.
VOLTAGE LESS THAN .8 VOLT?
YES NO
© •
•
IGNITION "OFF."
• JUMPER HARNESS TERMINALS " B " AND " C " TOGETHER. "DIAGNOSTIC AIDS".
• IGNITION "ON."
DOES BOOST VOLTAGE READ GREATER THAN 4.0 VOLTS?
1
NO YES
I E
• IGNITION " O F F . * FAULTY CONNECTION
• REMOVE JUMPER WIRE. OR SENSOR.
• IGNITION "ON."
• PROBE TERMINAL " B " WITH TEST LIGHT TOB + .
• TECH 1 SHOULD READ OVER 4 VOLTS.
DOES IT?
1_
YES NO
• Z 3 _
OPEN CKT 416 CHECK FOR OPEN IN CKT 432
OR OR
OR
OR
FAULTY PCM.
PCM
ACCELERATOR PEDAL
(10-PIN)
997 WHT/BLK - 997 WHT/BLK 8D2 ^ A A * - . 5 V O L T
w
REFERENCE
APP 1
SENSOR 992 DK BLU - 992 OK BLU PC4 SENSOR SIGNAL
998 BRN 998 BRN PD4 " t SENSOR GROUND
996 TAN 996 TAN PB7 - W ^ SVOLT
APP 2 "* REFERENCE
SENSOR 993 LT BLU 993 LT BLU PC3 SENSOR SIGNAL
999 PPL — — 999 PPL PD3 ~1 SENSOR GROUND
995YEL/BIK — 995 YEUBLK PD11 5 VOLT
APP 3 REFERENCE
SENSOR 994 DK GRN - 994 DK GRN P810 SENSOR SIGNAL
961 GRY PD5 ~ j SENSOR GROUND

E -
t
A B C D E
K 1 H 0 F P ——————— — i
1 PCM CONN. ID |
f PA/PB PINK 32 P I N ]
J PC/PD PINK 24 PIN
11-22-93
NS 14054
DTC 63
will set but it will not turn "ON" the "Service Throttle Soon" lamp. The throttle will operate normally as long as
"ON."
refer to circled number(s) on the diagnostic chart. in volts. Should read about 4.0 volts with throttle
1. This step will determine if DTC 63 is the result of a closed and ignition "ON" or at idle. Voltage should
hard failure or an intermittent condition. decrease at a steady rate as throttle is moved toward
3. This will check for an open in ground CKT 994 and Also, 90% pedal travel is acceptable for correct
PCM. APP operation.
DTC 63
CIRCUIT HIGH
© •
•
IGNITION "ON." ENGINE "OFF.**
VOLTAGE GREATER THAN 4.75V?
YES NO
' • z T :
© •
•
PROBE APP 3 HARNESS TERMINAL " J "
WITH TEST LIGHT CONNECTED TO B • . TO "DIAGNOSTIC AIDS" ON FACING PAGE.
YES NO
m JE
" K " AND " J " TOGETHER.
CKT 961 OPEN
OR
FAULTY PCM.
YES NO
JO I
FAULTY APP CONNECTION OPEN CKT 994 OR SHORTED
OR OR
OR
FAULTY PCM.
4-23-93
m 1 5 5 3 7
PCM
ACCELERATOR PEDAL
(10-PIN)
997 WHT/BLK 997 WHT/BLK BD2 - A M / L - 5 V O L T
m
REFERENCE
APP 1
SENSOR 992 DK BLU — — 992 DK BLU PC4 SENSOR SIGNAL
998 BRN 998 BRN P04
1 SENSOR GROUND
99STAN 99S TAN PB7 -MffZ 5 VOLT
APP 2 REFERENCE
993 LT BLU
SENSOR 993 LT BLU pa SENSOR SIGNAL
999 PPL — — 999 PPL PD3
"1 SENSOR GROUND
995 YEUBLK 995 YEUBLK PD11 5 VOLT
APP 3 REFERENCE
SENSOR
—-m :
994 DK ORN ' 994 DK GRN
9S1 GRY
PB10 SENSOR SIGNAL
PD5 j SENSOR GROUND
t
A B C D E
K J H 0 F
I PCM CONN. ID ]
f PA/PB PINK 32 PIN ]

PC/PD PINK 24 PIN J
APP MODULE CONNECTOR 1
BC/BO BLUE 32 PIN J
11-22-93
NS 14054
DTC 64
Soon" lamp will light and the PCM will limit power. If three APP sensors have a malfunction present, the
"ON."
1. This step will determine if DTC 64 is the result of a Scan APP 3 sensor while depressing accelerator
3. This will check the PCM and CKT 994. closed to about 2.0 volts when throttle is held at Wide
in volts. Should read about 4.0 volts with throttle 994 is shorted to ground.
closed and ignition "ON" or at idle. Voltage should Refer to "Intermittents," in SECTION 2.
decrease at a steady rate as throttle is moved toward
DTC 64
CIRCUIT LOW
© DOES SCAN TOOL DISPLAY APP 3 LESS THAN .25 VOLTS?
1
YES NO
IE
© •
•
DTC 26 IS INTERMITTENT. IF NO ADDITION DTCs
WERE STORED REFER T O ' DIAGNOSTIC AIDS"
PROBE HARNESS TERMINAL " E " . ON FACING PAGE.
IS THERE 5 VOLTS (+..2V)?
YES NO
I
© • WITH J 39200 CONNECTED TO GROUND,
PROBE HARNESS TERMINAL "K".
OR
IS THERE 5 VOLTS ( ± .2 V)? FAULTY PCM CONNECTION
OR
FAULTY PCM.
YES NO
FAULTY APP CONNECTION CKT 944 OPEN OR SHORTED TO GROUND

OR OR
OR
FAULTY PCM.
IF PCM IS FAULTY AND MUST BE REPLACED, "TDC OFFSET** MUST BE PROGRAMMED INTO THE NEW PCM.
4-23-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. PS17S0S
PCM
ACCELERATOR PEOAL
POSITION (APP) M O D U L E l/P H A R N E S S C O N N E C T O R
(10-PIN)
997 WHT/BLK - 997WHT/BLK B02 ^ J U A ^ S V O L T
M
REFERENCE
APP 1
992 OK BLU - 992 DK BLU PC4 SENSOR SIGNAL
SENSOR
9 9 8 BRN 9 9 8 BRN PD4 H J E N S O R GROUND
996 TAN — 996 TAN PB7 - A M ^ = 5 VOLT

APP 2 REFERENCE
SENSOR
9 9 3 LT BLU 9 9 3 LT BLU
pa SENSOR SIGNAL
9 9 9 PPL — — 9 9 9 PPL PD3 "1 SENSOR GROUND
995 YEUBLK 99S YEUBLK PD11 ÂWUE-SVOLT

APP 3 REFERENCE
^ — ^ \ —
SENSOR 994 OK ORN ' 994 DK GRN PB10
SENSOR SIGNAL
961 G R Y PD5 ^ S E N S O R GROUND
l/P H A R N E S S ( 2 3 - P I N )
A B C D E
K J H G F
r^PCMCONN.ID_]
f PA/PB PINK 3 2 P » N ]
P C / P D P I N K 2 4 PIN
APP MODULE CONNECTOR [ B C / B O B L U E 32 PINJ
11-22-93
NS14054
DTC 65
APP 2 and a 10 difference to APP 3.
will set but it will not turn "ON" a "Service Throttle Soon" lamp. Throttle will operate normally as long as there
is only one malfunction present. I f there are two APP malfunctions present the PCM will then turn "ON" the
"Service Throttle Soon" lamp and limit power. If a third APP malfunction is present the "Service Throttle Soon"
lamp will be "ON" and only allow the engine to operate at idle.
"ON."
1. This step determines i f there is a good 5 volt Scan APP 3 sensor while depressing accelerator
reference. pedal with engine stopped and ignition "ON." Display
2. This step will check the ground circuits. should vary from about 4.0 volts when throttle was
Diagnostic Aids: A scan tool reads APP 3 position Open Throttle (WOT) position.
in volts. Should read about 4.0 volts with throttle
closed and ignition "ON" or at idle. Voltage should
decrease at a steady rate as throttle is moved toward
DTC 65
CIRCUIT RANGE FAULT
© •
•
HARNESS TERMINALS " G " , "D" AND " E " .
YES NO

B + , PROBE HARNESS TERMINALS
CKT(s) 997,996 OR 995 OPEN
OR
1
YES NO
I
OR 998,999,961
APP MODULE. OR
OR
FAULTY PCM.
4-16-93
TO
GAGES TO MIL AND PCM
-•"SERVICE
SOON" LAMP
l/P HARNESS
39 PNK/BLK - 1
(10 PIN)
"ON/OFF"
f- 397 GRY REQUEST SIGNAL
RESUME/ACCELERATOR
- 83 DK GRN
REOUEST SIGNAL
D _ 84 DK BLU SET/COAST
REQUEST SIGNAL
l/P HARNESS
i PCM CONN. ID
i..
! PA/PB PINK • 32 PIN
i PC/PD PINK 24 PIN 11-2-93
i BC/BD BLUE 32 PIN NS 14322
i
DTC 71
SET/COAST SWITCH FAULT
The cruise "ON/OFF," "set/coast" and "resume/accel" switches are inputs to the fuel control portion of the
PCM. These inputs allow the PCM to control and hold a requested speed. CKT 84 supplies ignition voltage to the
PCM when set/coast is depressed.

• Cruise control "ON."
• Ignition voltage on terminal "BD15" for more than 25.5 seconds.
Action Taken (PCM Will default to): The PCM will disallow all cruise inputs. TCC shift schedules may be
affected.
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: Check for a set/coast switch stuck
refer to circled number(s) on the diagnostic chart. in the engage position or CKT 84 shorted to voltage.
1. This step determines if the cruise control switch is
OK.
2. This step determines i f the PCM or switch is at
fault.
DTC 71
© •
•
DISCONNECT PCM 32 PIN BLUE CONNECTOR.
• CRUISE SWITCH "ON."
• PROBE TERMINAL "BD15" ON THE PCM HARNESS
WITH A TEST LIGHT CONNECTED TO GROUND.
NOTE TEST LIGHT.
1
TEST LIGHT "OFF" TEST LIGHT "ON"
1 i
© WITH PROBE STILL CONNECTED, ENGAGE AND RELEASE

SET/COAST SWITCH.
OR
DOES TEST LIGHT COME "ON" AND GO "OFF" WHEN FAULTY CRUISE SWITCH.
SET/COAST BUTTON IS RELEASED?
NO YES
FAULTY CRUISE SWITCH. FAULTY PCM CONNECTION.

OR
FAULTY PCM.
10-28-93
TO .
-•"SERVICE
SOON** LAMP
l/P HARNESS
39 PNK/BLK (10 PIN)
"ON/OFF"
- 397 GRY — BD3 REQUEST SIGNAL
RESUME/ACCELERATOR
C — 83 DK GRN BD11
REOUEST SIGNAL
SET/COAST
84 DK BLU BD15
REQUEST SIGNAL
l/P HARNESS
i PCM CONN. ID
! PA/PB PINK - 32 PIN
i PC/PD PINK - 24 PIN i 11-2-93
i BC/BD BLUE - 32 PIN i NS 14322
I
DTC 76
RESUME/ACCEL SWITCH FAULT
PCM.

Action Taken (PCM will default to): The PCM will disallow all cruise inputs. TCC shift schedules may be
affected.
"ON."
1. This step determines i f CKT 83 is shorted to
voltage.
fault.
DTC 76
© •
•
• PROBE TERMINAL "BD11" ON THE PCM
HARNESS WITH A TEST LIGHT CONNECTED TO
GROUND.
NOTE TEST LIGHT.
3
I I
© WITH PROBE STILL CONNECTED, ENGAGE AND

RELEASE RESUME/ACCEL SWITCH.
OR
DOES TEST LIGHT COME "ON" AND GO "OFF" FAULTY CRUISE SWITCH.
WHEN RESUME/ACCEL SWITCH IS RELEASED?
NO YES
m
FAULTY CRUISE SWITCH. FAULTY PCM CONNECTION
OR
FAULTY PCM.
11-2-93

TO SENSOR
VACUUM PD6
TO 452 BLK - GROUND
PUMP EGR CONTROL
WASTEGATE PRESSURE/BARO PCS
433 GRY/BLK - MAP SIGNAL
SENSOR
f — 416 GRY - PC10
5V REFERENCE
EGR EGR VENT TO BOOST AND

SOLENOID SOLENOID CRANKSHAFT
POSITION SENSOR
A EGR VENT
PA4
CONTROL
B
I
BOOST SOLENOID
(TURBO VEHICLE ONLY)
EGR
BD15 CONTROL
r 1
PA3 BOOST
J PCM CONN. ID J CONTROL
! PA/PB . PINK - 32 PIN j
i PC/PD . PINK 24 PIN i 11-11-93
i BC/BD • BLUE 32 PIN i
i . i NS 14318
DTC 78
WASTEGATE SOLENOID FAULT
The PCM operates a solenoid to control boost. This solenoid is normally open. By providing a ground path the
PCM energizes the solenoid which then allows vacuum to pass to the wastegate valve.
During normal operation, the PCM compares its wastegate duty cycle signal with the boost signal and makes
corrections in the duty cycle accordingly.

• Fuel rate greater than 20 mm.
• Boost pressure greater than or less than desired (internal to PCM).
Action Taken (PCM W i l l default to): Boost will shut down. Reduce maximum fuel.
1. This step will check for a good vacuum source. lines and components connected to the hoses for leaks
2. This step will check for a faulty vacuum line or or sharp bends.
pump. Check vacuum source. A possible DTC 32 w i l l
3. This step checks the solenoid wiring. store i f there is a problem with the vacuum source.
DTC 78
© •
•
INSTALL VACUUM GAGE IN PLACE OF WASTEGATE.
OBSERVE VACUUM AT IDLE.
IS IT?
YES
m
• DISCONNECT ELECTRICAL CONNECTOR.
• OBSERVE VACUUM GAGE AT IDLE.
IS THERE VACUUM?
1
YES
T
NO
© DISCONNECT WASTEGATE
SOLENOID CONNECTOR.
CHECK FOR PLUGGED
OR LEAKY VACUUM
CONNECT TEST LIGHT BETWEEN HOSE TO THE
FAULTY SYSTEM OK, REFER TO
HARNESS CONNECTOR VACUUM PUMP.
WASTEGATE SECTION 6J FOR
TERMINALS. IF OK, CHECK
SOLENOID. FURTHER DIAGNOSIS.
IGNITION "ON,** ENGINE "OFF." VACUUM PUMP
IS TEST LIGHT "ON**? OUTPUT AND REPAIR.
YES NO
I
CONNECT TEST LIGHT FAULTY SOLENOID
BETWEEN HARNESS CONNECTION
TERMINAL "A" AND GROUND. OR
IS TEST LIGHT "ON"? FAULTY SOLENOID.
NO YES
OPEN CKT 972 OPEN CKT 439.

OR
OR
FAULTY PCM.
10-29-93
PCM
ACCELERATOR PEDAL
(10-PIN)
0 997 WHT/BLK 997 WHT/BLK BD2 - A / U ^ S V O L T
m
REFERENCE
APP 1
F 992 OK BLU — — 992 DK BLU PC4 SENSOR SIGNAL
SENSOR
A 998 BRN 998 BRN PD4 ~ j SENSOR GROUND
D 996 TAN 996 TAN PB7 5 VOLT
1 , 1
APP 2 REFERENCE
SENSOR T 993 LT BLU 993 LT BLU PC3
SENSOR SIGNAL
B 999 PPL — — 999 PPL PD3 ^ S E N S O R GROUND
E 995 YEUBLK 995 YEUBLK POtf - W W ^ 5 VOLT
APP 3 REFERENCE
994 DK GRN ' 994 DK GRN P810
SENSOR JL SENSOR SIGNAL
J 961 GRY PD5
-DQ- - | _ S E N S O R GROUND
t
A B C D E
K J H G F
J PCM CONN. ID ]
f PA/PB PINK 3 2 PIN 1

J PC/PD PINK 2 4 PIN
APP MODULE CONNECTOR [BC/BD BLUE 3 2 PIN J
11-22-93
NS14054
DTC 84
ACCELERATOR PEDAL POSITION (APP) CIRCUIT FAULT
DTC 84 Will Set W h e n : PCM has recognized an intermittent APP fault and there are no other current APP
faults stored.
Action Taken (PCM will default to): When DTC 84 is set, a current and history DTC will set, but will not
light the "Service Throttle Soon" lamp, and the vehicle will operate at limited power.
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: Check for faulty connections at
refer to circled number(s) on the diagnostic chart. APP module, PCM and I/P connector.
an intermittent condition.
DTC 84
ACCELERATOR PEDAL POSITION (APP)
CIRCUIT FAULT
• C H E C K C O M P L E T E APP HARNESS F O R INTERMITTENT SHORTS OR OPENS.

• IF O K . R E P L A C E A P P MODULE.
• IF D T C R E S E T S . R E P L A C E P C M .
IF P C M I S F A U L T Y A N D M U S T B E R E P L A C E D . " T D C O F F S E T " M U S T B E P R O G R A M M E D I N T O T H E N E W PCM.
5-7-93
P S 1 6 7 5 7
W H E N A L L D I A G N O S I S A N D R E P A I R S A R E C O M P L E T E D , C L E A R DTC(s) A N D V E R I F Y P R O P E R O P E R A T I O N .
DTC 88
TDC OFFSET ERROR
DTC 88
TDC OFFSET ERROR
THIS DTC INDICATES THERE IS A PUMP TIMING PROBLEM.
• THIS DTC WILL SET IF TDC OFFSET IS GREATER THAN 12.0°, OR THE PCM HAS LOST MEMORY (TDC
OFFSET IS STORED IN PCM MEMORY).
• CHECK INJECTION PUMP TIMING, IF OK, REFER TO "ON-VEHICLE SERVICE" TDC OFFSET.
3-17-93
DTC 91
CYLINDER BALANCE FAULT
• DIAGNOSE ALL OTHER DTC(s) BEFORE PROCEEDING.

• DTC 9 1 INDICATES THERE IS A POSSIBLE MECHANICAL OR FUEL DELIVERY PROBLEM WITH
CYLINDER #7.
• DTC 9 1 WILL NOT TURN ON THE MIL, BUT WILL BE STORED AS A CURRENT AND HISTORY DTC.
CHECK: FOR BASIC ENGINE MECHANICAL OR CYLINDER FUEL

DELIVERY FAILURES. (LOW COMPRESSION, FAULTY
NOZZLE, FUEL LEAK, RESTRICTED HIGH PRESSURE LINE, E T C . . )
DTC 92

CYLINDER # 2 .
* CHECK: FOR BASIC ENGINE MECHANICAL OR CYLINDER FUEL

NOZZLE, FUEL LEAK, RESTRICTED HIGH PRESSURE LINE, ETC..)
DTC 93

CYLINDER # 6 .

11-3-93
PS 16755
DTC 94

• DTC 94 INDICATES THERE IS A POSSIBLE MECHANICAL OR FUEL DELIVERY PROBLEM WITH
CYLINDER # 5 .
• DTC 94 WILL NOT TURN ON THE MIL, BUT WILL BE STORED AS A CURRENT AND HISTORY DTC.
CHECK : FOR BASIC ENGINE MECHANICAL OR CYLINDER FUEL

DTC 95

CYLINDER # 4 .
• DTC 95 WILL NOT TURN ON THE MIL, BUT WILL BE STORED AS A CURRENT AND HISTORY D T C

DTC 96

CYLINDER # 3 .

11-3-93
PS 20091
DTC 97

• DTC 97 INDICATES THERE ISA POSSIBLE MECHANICAL OR FUEL
DELIVERY PROBLEM WITH CYLINDER # 1 .
• DTC 97 WILL NOT TURN ON THE MIL BUT WILL BE STORED AS
(
A CURRENT AND HISTORY DTC.

DELIVERY FAILURES (LOW COMPRESSION, FAULTY NOZZLE,
FUEL LEAK, RESTRICTED HIGH PRESSURE LINE, E T C ) .
DTC 98

• DTC 98 INDICATES THERE IS A POSSIBLE MECHANICAL OR FUEL
• DTC 98 WILL NOT TURN ON THE MIL, BUT WILL BE STORED AS
A CURRENT AND HISTORY D T C

11-4-93
PS 20092
PCM
ACCELERATOR PEDAL
(10-PIN)
G 997 WHT/BLK 997 WHT/BLK BD2 - j y U A _ 5 V O L T
REFERENCE
APP 1
SENSOR F 992 OK BLU — — 992 OK BLU PC4 SENSOR SIGNAL
A 998JRN - — 998 BRN PD4 ^ S E N S O R GROUND

oT 996 TAN 996 TAN PB7 5 VOLT
1
APP 2 REFERENCE
SENSOR c 993 LT BLU 993 LT BLU pa SENSOR SIGNAL
i 999 PPL — — 999 PPL PD3 " 1 SENSOR GROUND
E 995 YEUBLK PD11 - W ^ -5 VOLT
995 YEUBLK
APP 3 REFERENCE
SENSOR 994 OK ORN ' 994 DK CRN PB10 SENSOR SIGNAL
j X 9 6 ! GRY PD5 -j SENSOR GROUND
t
A B C D E
K J H 0 F
I P C M C O N N . ID "J
f P A / P B PINK 3 2 P I N ]
J P C / P D PINK 2 4 PIN !
APP MODULE CONNECTOR J B C / B D B L U E 32 PIN J
m mm mm mm mm mm mm mm mm J 11-22-93
N S 14054
DTC 99
ACCELERATOR PEDAL POSITION (APP) 2 5 VOLT REFERENCE FAULT
DTC 99 Will Set W h e n : Reference voltage on APP 2 below 4.8 volts for 2 seconds.
Action Taken (PCM W i l l default to): If DTC 99 is present, the PCM will turn "ON" the "Service Throttle
Soon" lamp and limit power.
"ON."
DTC Chart Test Description: Number(s) below A short to ground in CKT 996 will result in a DTC
refer to circled number(s) on the diagnostic chart. 99.
1. This step will determine i f there is a good 5 volt Refer to SECTION 2 for "Intermittents."
reference. Scan APP 2 signal while depressing accelerator
position in volts. It should read about 4.5 volts with closed, to about 1.5 volts when throttle is held at Wide
toward Wide Open Throttle (WOT).
DTC 99
5 VOLT REFERENCE FAULT
© •
•
• WITH 139200 CONNECTED TO GROUND,
PROBE APP HARNESS TERMINAL "D".
IS THERE LESS THAN 4.8 VOLTS?
YES NO
CKT 996 SHORTED TO GROUND DTC 99 IS INTERMITTENT. IF NO OTHER

OR DTC(s) ARE STORED, REFER TO
FAULTY PCM. "DIAGNOSTIC AIDS" ON FACING PAGE.
4-23-93
l/P HARNESS CONNECTOR (23 PIN) PCM

' 451 WHT/BLK DIAGNOSTIC
REQUEST
SYSTEM GROUND
E 0 C B A
O
0 H J K L M
SYSTEM GROUND
SERIAL DATA
IGNITION FEED
BATTERY FEED
IN-LINE FUSE HOLDER

ACCELERATOR
PEDAL
POSITION P\i3 ^ E©3~
(APP)
MODULE 20 AMP
G — 997 WHT/BLK — 997 WHT/BLK — BDF2 5V REFERENCE
APP 1
SENSOR S * - ^ — F 992DK8LU ' " 992 DK BLU PC4 APP 1 SIGNAL
A 998 BRN 998 BRN - PD4 GROUND
D | — 998 TAN 996 TAN PB7 5V REFERENCE

APP 2
SENSOR C 993 LT BLU 993 LT BLU - PC3 APP 2 SIGNAL
999 PPL — 999 PPL — PD3 GROUND
B
E
995 YEUBLK - 99S YEUBLK — PD11 5V REFERENCE
APP 3 PB10 APP 3 SIGNAL
SENSOR 994 DK GRN 994 DK GRN
K
961 GRY PD5 GROUND
J l/P HARNESS
OPTICAL/ ENGINE HARNESS
CONNECTOR
FUEL TEMP (23 PIN) * C CONNECTOR (15 PIN)
SENSOR 474 GRY • 474 GRY PD10 5V REFERENCE
TBD PNK - 982 PNK — PD15 CAM SIGNAL
943 PPL - 983 PPL — PD9 HI RES. SIGNAL
987 WHT
1S78 YEL
987 WHT
z 987 WHT — PD14 SENSOR GROUND
PB11 FUEL TEMPERATURE

SIGNAL
11-5-93
REFER TO PCM CONNECTOR TERMINAL END VIEW FOR PCM CONNECTOR COLOR NS 14200
Figure 3-9-PCM Wiring Diagram 6.5L Diesel (1of7)


PCM
ENGINE
COOIANT rfTjpÔYEL ECT SIGNAL
TEMPERATURE
(ECT) SENSOR

TEMPERATURE
(IAT) SENSOR
IAT SIGNAL
CRANKSHAFT
POSITION SIGNAL
5V REFERENCE
BOOST SIGNAL
(TURBO ONLY)
BARO SIGNAL
(TURBO, GREATER
THAN 8500 GVW)
INJECTION ITS COIL 1 LOW

TIMING ITS COIL 1 HIGH
STEPPER
(ITS) ITS COIL 2 LOW
MOTOR
ITS COIL 2 HIGH
ENGINE SHUT-OFF
SOLENOID CONTROL
FUEL INJECT CONTROL

FUEL INJECT CONTROL
FUEL INJECT SIGNAL
CLOSURE GROUND
11-5-93
Figure 3-10 - PCM Wiring Diagram 6.5L Diesel (2 of 7)

TO WATER IN
FUEL SENSOR
PCM
•A
TO GAUGES
IGNITION -*»-TO FUEL HEATER
SWITCH 20 AMP
JUNCTION — 3 9 PNK/BLK -
BLOCK GLOW PLUG
— 5 0 5 YEL PC13 RELAY CONTROL
B+ • * —• 2 RED
1
—150BLK-—
ENGINE
-=r GROUND
LEFT
GLOW
PLUGS
"GLOW PLUG 503 ORN

LAMP BULKHEAD
CONNECTOR
GLO PLUG
81 503 ORN
SAMP
-507 DK BLU - ~|P88 GLOW PLUG SIGNAL

W
CONNECTOR
(23 PIN)
-509 O R N / B L K — i ^ L
RIGHT -=Sr
GLOW -
PLUGS
l/P HARNESS
CONNECTOR
(23 PIN)
ECM-1GN
TO IGNITION -439 PNK/BLK- IGNITION FEED
SWITCH
TOCHMSL
a
B+«*- l/P HARNESS
CONNECTOR
15 AMP (10 PIN) TOCHMSL
RELAY (P/U)
-140 ORN
N.oN£ CRUISE CONTROL
-820 YEL OR 17 WHT - — M H - 8 2 0 YEL BRAKE SWITCH SIGNAL
STOP
LAMP -439 PNK/BLK —
SWITCH ».c.JZ
420PPL(A/T) * El- -420 PPL BD5
TCCBRAKE
SWITCH SIGNAL
T x
~ 4 2 0 1PPL ( M / T H j — 8 6 BRN -86 BRN
N.C
FUSIBLE LINK CLUTCH PEDAL POSITION SWITCH
REFER TO PCM CONNECTOR TERMINAL END VIEW FOR PCM CONNECTOR COLOR 11-5-93
NS 14203
Figure3-11-PCM Wiring Diagram 6.5L Diesel (3 of 7)

822 LT GRN/BLK
TO P/N- ENGINE PCM
- S - i SWITCH GROUND
TO OLC
OUTPUT SPIED VSS INPUT C7 GROUND ANTILOCK

AMD
VEHICLE SPEED GROUND C8 - 450 8LK/WHT J
SENSOR BRAKE
(VSS) IGNITION FEED TO IGNITION
C9 - 250 BRN
15 AMP SWITCH
VSS BUFFER VSS OUTPUT C10 - 696 WHT TO ANTILOCK
MODULE
VEHICLE SPEED
C11 - 1586 BRN/WHT {PD8
VSS OUTPUT SIGNAL
VSS INPUT C12 TRANSMISSION
SIGNAL
VSS OUTPUT C14 h 834 BRN BDF8 VEHICLE SPEED
SIGNAL
VSS OUTPUT C15 " 824 LT BLU/BLK -TOSPEEDO
821 PPUWHT -
PRESSURE HIGH PRESSURE
CYCLING CUTOUT
A/C CONTROL SWITCH
SWITCH SWITCH
TO^- 66 LT GRNI — ^ — 59 OK GRN A/C SIGNAL

IGNIT10N 603 DK GRY/WHT
SWITCH
8 59 DK GRN
A 150 BLK
A/C COMPRESSOR
CLUTCH l/P BULK HEAD
CONNECTOR (23 PIN)
MIL
T
I 1
MIL "SERVICE
r— 39 PNK/BLK 419 BRN/WHT ENGINE SOON"
"SERVICE CONTROL
ENGINE
SOON''
GAUGES
TO «*-
IGNITION
SWITCH
20AMP
39 PNK/BLK
"SERVICE
THROTTLE S O O N '
0 960 ORN "SERVICE THROTTLE
SOON " LAMP
CONTROL
LAMP
39 PNK/BLK
l/P HARNESS
CONNECTOR
(10 PIN)
CRUISE —
CONTROL T
SWITCH 1w W <
CRUISE "ON/OFF-
— 3 9 7 GRY REQUEST SIGNAL
1 RESUME/ACCELERATE
83 DK GRN REQUEST SIGNAL
84DK8LU SET/COAST
REQUEST SIGNAL
HHTîi
11-5-93
REFER TO PCM CONNECTOR TERMINAL END VIEW FOR PCM CONNECTOR COLOR NS14202

TFT TO BOOST TO ECT, IAT AND PCM

EGR CONTROL SENSOR GROUND

PRESSURE BARO EGR CONTROL
5V REFERENCE
EGR
VALVE
Z 3
EGR VENT
SOLENOID CONTROL
(VEHICLES LESS THAN
8500 GVW)
EGR SOLENOID
CONTROL
(VEHICLES LESS
THAN 8500 GVW)
SOL
LT BLU/BLK-
SWITCH 5 A M P
l/P HARNESS
CONNECTOR
TO 4 (23 PIN)
VACUUM ^
PUMP
WASTEGATE
I VACUUM
ACTUATOR
VALVE
WASTEGATE WASTEGATE SOLENOID

SOLENOID 972 YEL
CONTROL (TURBO ONLY)
(TURBO 539 LT BLU/BLK
ONLY)
11-8-93
REFER TO PCM CONNECTOR TERMINAL AND END VIEW FOR PCM CONNECTOR COLOR
NS15523

PCM
4 WHEEL DRIVE
LOW SWITCH
N.O.
TORQUE
CONVERTER
CLUTCH
(TCC)
SOLENOID
3-2
CONTROL
SOLENOID
1-2 SHIFT
SOLENOID CONTROL
2-3 SHIFT
SOLENOID CONTROL
TRANSMISSION
RANGE
PRESSURE
SWITCH
VEHICLES WITH 4L60E TRANSMISSION

11-30-93
Figure 3-14-PCM Wiring Diagram 6.5L Diesel (6of 7)

PCM
4 WHEEL DRIVE
4 WHEEL DRIVE LOW SIGNAL
LOW SWITCH N.O.
TRANSMISSION TRANSMISSION INPUT

• 1230 CRY/RED — PC12
INPUT SPEED L ~ SPEED SIGNAL (HIGH)
SENSOR •1231 DK BLU/WHT • PD12 TRANSMISSION INPUT
SPEED SIGNAL (LOW)
TO EGR CONTROL TO ECT, IAT,
PRESSURE/BARO SENSOR CRANKSHAFT
(LESS THAN 8500 GVW) POSITION AND
BOOST SENSOR
A
TO BARO
TRANSMISSION SENSOR
CONNECTOR (GREATER
THAN 8500
GVW)
TRANSMISSION
FLUID SENSOR GROUND
TEMPERATURE
(TFT) TRANSMISSION
SENSOR FLUID
TEMPERATURE
(TFT) SIGNAL
TORQUE TCC SOLENOID
CONVERTER CONTROL (PWM)
CLUTCH
(TCC)
SOLENOID
1-2 SHIFT
SOLENOID
1-2 SHIFT
SOLENOID
CONTROL
2-3 SHIFT
SOLENOID
CONTROL
PRESSURE
CONTROL
PRESSURE SOLENOID
CONTROL (LOW)
SOLENOID
(PCS) PRESSURE
CONTROL
SOLENOID
(HIGH)
RANGE
SIGNAL "A**
TRANSMISSION
RANGE RANGE
PRESSURE SIGNAL " B "
SWITCH
RANGE
SIGNAL " C "

11-30-93
REFER TO PCM CONNECTOR TERMINAL END VIEW FOR PCM CONNECTOR COLOR. NS 14803

PCM Connector and Driveability Symptoms Identification

This PCM voltage chart is for use with a J 39200 to further aid in diagnosis. These voltages were derived
from a known good vehicle. The voltages you get may vary due to low battery charge or other reasons,
butthey should be very close.
The "B + " symbol indicates a nominal system voltage of 12-14 volts.
THE FOLLOWING CONDITIONS MUST BE MET BEFORE TESTING:
• Engine at operating temperature • Engine idling (for "Engine Operating" column)
• Test terminal not grounded • Scan tool not installed
PINK 24 PIN PA/PB CONNECTOR
NORMAL VOLTAGE
PIN PIN CKT WIRE DTC(s) POSSIBLE
FUNCTION # COLOR KEY ENGINE AFFECTED SYMPTOMS
-ON" OPERATING
A1 IGNITION FEED 439 PNK/BLK B+ B+ - NO START
3-2 CONTROL SOLENOID CONTROL L\ B+ B+ r d

A2 897 WHT 66 3 GEAR ONLY
A3 WASTEGATE SOLENOID CONTROL • 972 YEL B+ B+ 62 NO TURBO

BOOST
A4 EGR VENT SOLENOID CONTROL (VIN P, VIN S) 971 LTBLU B+ B+ 31.45 NO EGR
A5 SERVICE THROTTLE SOON LAMP CONTROL 960 YEL (4) (4) 49 NO SERVICE
THROTTLE
SOON LAMP
A6 NOT USED - - - -
A7 CRUISE CONTROL BRAKE SWITCH SIGNAL 820 YEL 0 0 37,38,41 NO BRAKE
LIGHTS
A8 ITS COIL 1 HIGH 565 RED/BLK .9V B+ 34 POOR

PERFORMANCE
A9 ITS COIL t LOW 564 TAN/BLK B+ ,9V 34 POOR

PERFORMANCE
A10 ITS COIL 2 LOW 566 ORN/BLK B+ .9V 34 POOR

PERFORMANCE
A11 ITS COIL 2 HIGH 567 YEL/BLK JV B+ 34 POOR

PERFORMANCE
A12 DIAGNOSTIC REQUEST 451 WHT/BLK 5V 5V NONE -
(1) VARIES.
BACK VIEW
(2) OPEN CIRCUIT. OF
(3) GROUNDED CIRCUIT. CONNECTOR
(4) OPEN/GROUNDED CIRCUIT.

(5) LESS THAN 1 VOLT.
(6) LESS THAN .5 VOLT (500 mV).
A 4L60E.
• TURBO CHARGED.
VEHICLE: OKTRUCK
ENGINE: 6.5L DIESEL VINP(L49)
24 PIN A-B
VIN S (L56) CONNECTOR
VINF(L65J (PINK)
TRANSMISSION: 4L60E, 4L80E AND MANUAL
10-28-93
NS 14549
Figure 3-16 - K M Connector Terminal End View (1 of 6)


from a known good vehicle. The voltages you get may vary due to fow battery charge or other reasons,
but they should he very close.
NORMAL VOLTAGE
"ON" OPERATING
B1 WOT USED
- - - - - -
B2 NOT USED
- - - - - -
B3 NOT USED
- - - - - -
B4 A/C SIGNAL 59 DK GRN 0*21 0*A NONE A/C STATUS
B5 NOT USED - - - - - -
B6 NOTUSED
- - - - - -
B7 APP 2 SENSOR 5V REFERENCE 996 TAN 5v 4.3v 25,26,27,84. POOR
99 PERFORMANCE
B8 GLOW PLUG SIGNAL 507 DK BLU B+ 0 29 HARD START
B9 NOT USED
- - - - - -
B10 APP 3 SENSOR SIGNAL 994 DKGRN 4v 4v 64,65,84 POOR
PERFORMANCE
B11 FUEL TEMP SIGNAL 1578 YEL (2) 1.5v(2) 42,43 POOR
PERFORMANCE IN
COLD TEMPS
B12 IAT SIGNAL 472 TAN (2) 1.6v(2) 47,48 POOR

PERFORMANCE IN
COLD TEMPS
(1) VARIES. BACK VIEW

(2) VARIES WITH TEMPERATURE. OF
CONNECTOR
(3) OPEN CIRCUIT.
(4) GROUNDED CIRCUIT.
* LESS THAN .5 VOLT (500 mV).
A B4- WITH A/C "ON."
VEHICLE: C/K TRUCK

ENGINE: 6.5L DIESEL VINP(L49) |H
VIN S (L56 24 PIN A-B
CONNECTOR
VINF(L65 (PINK)
10-28-93
NS 14550
Figure 3-17 - PCM Connector Terminal End View (2 of S)


but they snould be very close.
PINK 32 PIN PC/PD CONNECTOR
NORMAL VOLTAGE
PIN PIN CKT WIRE ENGINE
DTC(S) POSSIBLE
FUNCTION # COLOR KEY AFFECTED SYMPTOMS
OPERATIN
"ON"
G
C1 SYSTEM GROUND 450 WHT/BLK 0* 0* NONE -

C2 FUEL INJECT SIGNAL 985 RED 5.6V 4.0V NONE NONE
C3 APP S E N S O R 2 S I G N A L 993 LT B L U 4.3V 4.3V 26,27,84 POOR P E R F O R M A N C E
C4 APP SENSOR 1 SIGNAL 992 DK B L U .5V .5V 22,23,84 POOR P E R F O R M A N C E
C5 E G R C O N T R O L P R E S S / B A R O S I G N A L ( V I N P, V I N S ) 433 GRY/BLK 4.8V 3.2V 31,33 NO EGR

B A R O S I G N A L (VIN F )
C6 PRESSURE CONTROL SOLENOID (HIGH) A • 1228 RED/BLK 0* 6.3V 73 HARSH SHIFT
a BOOST SIGNAL • 432 LTGRN 1.4V 1.4V 61,62 NO TURBO BOOST
C8 ECT SIGNAL 410 YEL 3.4V 3.0V (3) 14.15 EARLY T C C

(3)
C9 TRANSMISSION FLUID T E M P E R A T U R E (TFT) 1227 BLK/YEL 3.5V 2.8V 58,59,79 EARLY T C C

SIGNAL A •
C10 C R A N K S H A F T P O S I T I O N EGR C O N T R O L 416 GRY 5V 5V 19,31 BACK UP F U E L , NO

PRESS/BARO A N D BOOST S E N S O R 5 VOLT EGR
REFERENCE
C11 PRESSURE CONTROL SOLENOID (LOW) A • 1229 LT B L U / 0* 1.5V 73 HARSH SHIFT

WHT
C12 TRANS INPUT SPEED SIGNAL (HIGH) • 1230 GRY/RED 0* 0* 74 N O T C C A P P L Y N O 4th

G E A R IN H O T M O D E
C13 G L O W PLUG RELAY CONTROL 505 YEL B + 0 29 HARDSTART
C14 SERIAL DATA 1061 ORN/BLK 5V 5V NONE NO SCAN T O O L DATA
C15 TRANSMISSION O U T P U T S P E E D SIGNAL 437 BRN 0* 0* 24,72 2 n d

GEAR O N L Y
CIS NOT USED - - - - - -

BACK VIE:w
(1) V A R U S FROM 0 TO B A T T E R Y V O L T A G E , D E P E N D I N G ON P O S I T I O N OF D R I V E WHEELS. OF
(2) VARIES. CONNEC1roR
(3) VARIES WITH TEMPERATURE.
(4) O P E N CIRCUIT.
(5) G R O U N D E D CIRCUIT.
(6) O P E N / G R O U N D E D CIRCUIT.
"•DO
(8) B + WHEN G L O W PLUG LAMP "ON."
* LESSTHAN.5VOLT(500ir,V). CON N ^ C T O T ( P I N K)
m
A 4L60E.
_ mwmm
• 4L80E. VEHICLE: C/K TRUCK

• TURBOCHARGED. ENGINE: 6.5L DIESEL VINP(L49)
VINSCLSl) : : S D
VIN F a f f ) : : H D
TRANSMISSION: 4L60E, 4L80E AND MANUAL 10-28-93
NS14551
Figure 3-18 - PCM Connector Terminal End View (3 of 6)


but they should be very close.
NORMAL VOLTAGE
PIN PIN CKT WIRE ENGINE DTC(s) POSSIBLE
FUNCTION # COLOR KEY AFFECTED SYMPTOMS
"ON" OPERATIN
G
01 SYSTEM GROUND 551 TAN/WHT 0* 0* NONE -
02 CLOSURE GROUND 950 LT GRN (4) (4) NONE NO START
03 APP2 SENSORGROUND 999 PPL 0 o 26.27,84 POOR PERFORMANCE
04 APP 1 SENSOR GROUND 998 BRN 0 0 22,23,84 POOR PERFORMANCE
05 APP 3 SENSOR GROUND 961 RED 0 0 64,65,84 POOR PERFORMANCE
Di ECT, IAT. CRANKSHAFT POSITION, TFT AND 452 BLK 0* 0* 14,47,19.58 FAST IDLE, BACK UP
EGR CONTROL PRESSURE SENSOR GROUND FUEL
07 NOT USED - - - - - -
D8 VEHICLE SPEED SIGNAL 1586 BRN/WHT 0* 0* 16 FUELCUTOFF
09 HIGH RESOLUTION SIGNAL 983 PPL 5V 2.5V 17 BACK UP FUEL
D10 OPTICAL SENSOR 5V REFERENCE 474 GRY 5V SV 17,18 BACK UP FUEL
D11 APP 3 SENSOR 5V REFERENCE 995 YEL/BLK 5V 5V 64,65,84 POOR PERFORMANCE
D12 TRANSMISSION INPUT SPEED SIGNAL (LOW) • 1231 DK BLU/ 0* 0* 74 NO TCC APPLY, NO
t h
- WHT 4 GEAR IN HOT
MODE
D13 CRANKSHAFT POSITION SIGNAL 643 YEL 5V 4.5V 19 BACK UP FUEL
D14 OPTICAL SENSOR GROUND 987 GRN/WHT 0* 0* 17,18 BACK UP FUEL
D15 OPTICAL SENSOR CAM SIGNAL 442 PNK .2V .5V 18 BACK UP FUEL
D16 NOT USED - - - - - -
BACK VIEW
(1) VARIES FROM OTO BATTERY VOLTAGE, DEPENDING ON POSITION OF DRIVE WHEELS. OF
(2) VARIES. CONNECTOR
(3) OPEN CIRCUIT.
• 4L80E.
VEHICLE: C/K TRUCK

ENGINE: 6.5L DIESEL VINP(L49
~~ VIN S (L56
VINF(L65
32 PIN C D
CONNECTOR (PINK) 5 _ g 3
NS 14552

The "B * " symbol indicates a nominal system voltage of 12-14 volts.
• Engine at operating temperature •Engine idling (for "Engine Operating" column)
BLUE 32 PIN BC/BD CONNECTOR
NORMAL VOLTAGE
PIN PIN CKT DTC(s) POSSIBLE
WIRE COLOR KEY ENGINE A FFECTED SYMPTOMS
FUNCTION #
"ON" OPERATING
a BATTERY FEED 440 ORN B+ B+ NONE NO START
C2 FWD LOW SWITCH A « 1493 DK BLU B+ B + NONE -

a NOT USED - - - - - -
C4 NOT USED - - - - - -
C5 MIL 'SERVICE ENGINE SOON" CONTROL 419 BRN/WHT (5) (5) 46 NO MIL
C6 TCC SOLENOID CONTROL A 422 TAN/BLK B+ B + 67,69 POOR FUEL

ECONOMY
a 1-2 SHIFT SOLENOID 1222 LT GRN B+ .4V 82 NO 3 ^ / 4 ^ GEAR

CONTROL A •
C8 RANGE 1224 PNK B+ B + 24,28,72

SIGNAL " A " 4*
C9 RANGE 1225 DK BLU 0 0 24,28,72 -

SIGNAL " B " A «
C10 RANGE 1226 RED B+ B+ 24.28,72 -

SIGNAL " C A «
C11 TCC SOLENOID CONTROL (PWM) • 1350 TAN/BLK B+ ,4V 67-4L60E -

8E-4L80E
C12 NOT USED - - - - - -

C13 2-3 SHIFT SOLENOID CONTROL A« 1223 YEL/BLK B+ .4V 81 -
C14 FUEL INJECT CONTROL 984 LTGRN 0 1.9 V NONE NONE
C15 EGR SOLENOID CONTROL (VIN P AND S) 435 GRY B+ 9.5V 32,44 NO EGR
C16 ENGINE SHUT-OFF SOLENOID CONTROL 981 DK BLU/WHT (5) (5! 13 NO START
(1) VARIES. BACKVIEW OF

CONNECT!DR
(2) READS BATTERY VOLTAGE IN GEAR.
(3) OPEN CIRCUIT. j \ Ap i\
(4) GROUNDED CIRCUIT. : i

-oo-
(6) LESS THAN 1 VOLT. --act
A 4L60E. 1
• 4L80E.
VEHICLE: C/K TRUCK =sa-

ENGINE: 6.5L DIESEL V I N P (L49)
VINS(L56)
VINF(L65) 32PINC-D
ION N ECTOR
< 11-8-93
TRANSMISSION: 4L60E, 4L80E AND MANUAL (BLUE) NS 14553


BLUE 32 PIN BC/BD CONNECTOR
NORMAL VOLTAGE
PIN PIN CKT WIRE DTC($) POSSIBLE
-ON" OPERATING
01 NOT USED - - - - - -
D2 APP 1 SENSOR 5V REFERENCE 997 WHT/BLK 5V 5V 21,22,23, POOR
84 PERFORMANCE
03 CRUISE "ON/OFF" REQUEST SIGNAL 397 GRY (4) (4) NONE NO CRUISE
04 NOT USED - - - - - -
05 TCC BRAKE SWITCH 420 PPL B+ B+ 37,38,41 NO TCC
86
D6 NOT USED - - - - - -
07 NOT USED - - - - -
08 VEHICLE SPEED SIGNAL 834 BRN * * 16 NO CRUISE
D9 NOT USED - - - - - -
D10 NOT USED - - - - - -
011 RESUME/ACCEL REQUEST SIGNAL 83 DK GRN B+ B+ 76 NO CRUISE
D12 NOT USED - - - -

013 FUEL INJECT CONTROL 984 LTGRN 0 1.9V NONE NONE
014 NOT USED - - - - - -

015 SET/COAST REQUEST SIGNAL 84 DK BLU B+ B+ 71 NO CRUISE
D16 NOT USED - - - - - -
(1) VARIES.
BACK Vli:w
(3) GROUNDED CIRCUIT. CONNECI roR

* LESS THAN .5 VOLT (500 ftiV).
# MANUAL TRANSMISSION.
i=s§
A 4L60E.
• 4L80E. mlnn
II
m
wmm
- T
VEHICLE: C/K TRUCK

ENGINE: 6.5L DIESEL VINP(L49
VINS(L56
VIN F (L65! 32 PIN C D
TRANSMISSION: 4L60E,4L80 E AND MANUAL c o
f*X O R
10-29-93
(BLUE) N S 1 4 554
Figure 3-21 - PCM Connector Terminal End View (S of 6)
ON-VEHICLE SERVICE
WIRE HARNESS If this happens, to the wrong terminal pair, it is
possible to damage certain components. Always use
The PCM harness electrically connects the PCM to jumper wires between connectors, for circuit checking.
the various solenoids, switches, and sensors in vehicle NEVER probe through the Weather-Pack seals. Use
engine transmission and passenger compartment. tachometer adapter J 35812, or equivalent, which
Wire harnesses should be replaced with proper provides an easy hook up of the tach. lead. The
part number harnesses. When signal wires are connector test adapter kit J 35616, or equivalent,
spliced, into a harness, use wire w i t h high contains an assortment of flexible connectors, used to
temperature insulation only. probe terminals during diagnosis. Fuse remover and
With the low current and voltage levels found in test tool BT 8616, or equivalent, is used for removing a
the system, i t is important that the best possible bond fuse and to adapt fuse holder, with a meter, for
at all wire splices be made by soldering the splices, as diagnosis.
shown in Figure 3-22. When diagnosing, open circuits are often difficult
Molded on connectors r e q u i r e complete to locate by sight, because oxidation, or terminal
replacement of the connector. This means splicing a misalignment are hidden by the connectors. Merely
new connector assembly into the harness. wiggling a connector on a sensor, or in the wiring
Replacement connectors and terminals are listed harness, may correct the open circuit condition. This
in Group 8.965, of the Standard Parts Catalog. should always be considered, when an open circuit, or
failed sensor is indicated. Intermittent problems may,
CONNECTORS AND TERMINALS also, be caused by oxidized or loose connections.
Before making a connector repair, be certain of the
Use care, when probing a connector or replacing type of connector. Weather-Pack and Compact Three
terminals in them. I t is possible to short between connectors look similar, but are serviced differently.
opposite terminals.
TWISTED/SHIELDED CABLE TWISTED LEADS

DRAIN WIRE
Z OUTER JACKET
MYLAR
1. REMOVE OUTER JACKET. 1. LOCATE DAMAGED WIRE.

2. UNWRAP ALUMINUM/MYLAR TAPE. DO NOT 2. REMOVE INSULATION AS REQUIRED.
REMOVE MYLAR.
SPLICE AND SOLDER
3. UNTWIST CONDUCTORS. STRIP INSULATION AS 3. SPLICE TWO WIRE TOGETHER USING SPLICE
CLIPS AND ROSIN CORE SOLDER.
NECESSARY.
DRAIN WIRE
Z 2
4. SPLICE WIRES USING SPLICE CLIPS AND ROSIN CORE
SOLDER. WRAP EACH SPLICE TO INSULATE.
4. COVER SPLICE WITH TAPE TO INSULATE
5. WRAP WITH MYLAR AND DRAIN (UNINSULATED) WIRE. FROM OTHER WIRES.
2
5. RETWIST AS BEFORE AND TAPE WITH
z LQ3
6. TAPE OVER WHOLE BUNDLE TO SECURE AS BEFORE.
ELECTRICAL TAPE AND HOLD IN PLACE.
4S 0570-6E
Figure 3-22 - Wire Harness Repair

Micro-Pack To remove a terminal;

Slide the seal back on the wire.
Refer to Figure 3-23 and repair procedure for Insert tool (3) BT-8518, or J 35689, or
replacement of a Micro-Pack terminal. equivalent, as shown in insert "A" and "B," to
release the terminal locking tab (2).
3. Push the wire and terminal out through the
connector.
If reusing the terminal, reshape the locking tang
(2).
Weather-Pack
A Weather-Pack connector can be identified by a

rubber seal, at the rear of the connector. This
connector, which is used in the engine compartment,
protects against moisture and dirt, which could create
oxidation and deposits on the terminals. This
protection is important, because of the very low
voltage and current levels found in the electronic
1 CABLE 3 LOCKING TANG
system.
2 TERMINAL 4 TOOL J 33095/BT8234-A Repair of a Weather-Pack terminal is shown in
7S3548-6E
Figure 3-25. Use tool J M28742, or BT-8234-A to
Figure 3-23 - Micro-Pack Connector remove the pin and sleeve terminals.
Metri-Pack If removal is attempted with an ordinary pick,
there is a good chance that the terminal will be bent,
Some connectors use terminals called Metri-Pack or deformed. Unlike standard blade type terminals,
Series 150 (Figure 3-24). These may be used at the these terminals cannot be straightened once they are
coolant sensor, as well as TBI/CPI units. bent.
They are also called "Pull-To-Seat" terminals, Make certain that the connectors are properly
because, to install a terminal on a wire, the wire is seated and all of the sealing rings in place, when
first inserted through the seal (5) and connector (4). connecting leads. The hinge type flap provides a
The terminal is then crimped on the wire and the backup, or secondary locking feature for the connector.
terminal pulled back into the connector to seat i t in They are used to improve the connector reliability by
place. retaining the terminals, i f the small terminal lock
tangs are not positioned properly.
Weather-Pack connections cannot be replaced with
standard connections. Instructions are provided with
Weather-Pack connector and terminal packages.
1. METRI-PACK SERIES 3. TOOL J 35689 OR BT-8446

150 FEMALE TERMINAL 4. CONNECTOR BODY
2. LOCKING TANG 5. SEAL
2-5-90
•7S3213-6E
Figure 3-24 - Metri-Pack Series 150 Terminal Removal

1. OPEN SECONDARY LOCK HINGE ON CONNECTOR. Compact Three

FEMALE MALE
CONNECTOR CONNECTOR The Compact Three connector, which looks similar
to a Weather-Pack connector, is not sealed and is used
where resistance to the environment is not required.
SECONDARY- This type of connector, most likely, is used at the air
LOCK HINGE control solenoid. Use the standard method, when
REMOVE TERMINAL USING TOOL. repairing a terminal. Do not use the Weather-Pack
144 PUSH TO
RELEASE
terminal tool J 28742, or BT-8234-A, as these w i l l
damage the terminals.
TERMINAL TOOLJ28742/BT8234-A
POWERTRA1N CONTROL MODULE (PCM)
CUT WIRE IMMEDIATELY BEHIND CABLE SEAL.
Service of the PCM should normally consist of

WIRE
either replacement of the PCM or a PROM change.
SEAL
If the diagnostic procedures call for the PCM to be
4. REPLACE TERMINAL replaced, the PROM and PCM should be checked first
A. SLIP NEW SEAL ONTO WIRE. to see if they are the correct parts. If they are, remove
B. STRIP 5mm (.2*) OF INSULATION FROM WIRE.
C. CRIMP TERMINAL OVER WIRE AND SEAL. the PROM from the faulty PCM and install i t i n the
new service PCM. THE SERVICE PCM WILL NOT
CONTAIN A PROM. DTC 51 indicates the PROM is
SEAL
installed improperly or has malfunctioned. When
DTC 51 is obtained, check the PCM installation for
bent pins or pin not fully seated in the socket. I f it is
5. PUSH TERMINAL AND CONNECTOR AND
ENGAGE LOCKING TANGS. installed correctly and DTC 51 is still displayed,
6. CLOSE SECONDARY LOCK HINGE. replace the PROM.
7S 3542-6E
Figure 3-25 - Weather-Pack Terminal Repair Important

• When replacing the production PCM with a service
PCM, a DTC 88 will be stored. It is important to
program "TDC Offset" into the service PCM. Refer
to "TDC Offset Program Procedure."
[T"| Important
PCM (controller), i t is important to transfer the
broadcast code and production PCM number to the
service PCM label. Please Do Not record on PCM
cover. This will allow positive identification of
PCM parts throughout the service life of the
vehicle.
[ T | Important
• To prevent internal PCM damage, the ignition
must be "OFF" when disconnecting or
reconnecting power to PCM (for example, battery
cable, PCM pigtail, PCM fuse, jumper cables, etc.).
The ignition should be "OFF" for at least 39
seconds before disconnecting power to the PCM.
1 l/P HARNESS ENGINE HARNESS
2 PCM
PS 17680
Figure 3-26 - Powertrain Control Module

[+*| Install or Connect

1. PROM in PROM socket.
Important
Gently press down on PROM.
2. Access cover on PCM.

3. PCM in passenger compartment.
4. Connectors to PCM.
Functional Check
1. Turn ignition "ON."

2. Enter diagnostics mode.
A. DTC 12 should flash three times (if no other
Figure 3-27 - PCM and PROM DTCs are present). This indicates the PROM
is installed properly, and the PCM is
PCM OR PROM REPLACEMENT functioning.
Figure 3-26 B. If DTC 51 occurs, or if the MIL (Service Engine
Soon) is "ON" constantly with no DTC(s), the
* | Remove or Disconnect PROM is not fully seated or is defective.
1. Negative battery cable. • If not fully seated, press firmly on the ends
2. Connectors from PCM. of the PROM.
3. PCM mounting hardware. • I f it is necessary to remove the PROM,
4. PCM from passenger compartment. follow the previous removal instructions.
5. PCM access cover (Figure 3-27).
6. PROM. TDC OFFSET PROGRAM PROCEDURE
[ V I Important This procedure allows the PCM memory to be

• A replacement Powertrain Control Module (PCM) updated with the correct TDC offset for the vehicle.
is supplied without a PROM, so care should be DTC 88 will be stored until this procedure has
used when removing it from the defective PCM been completed.
because i t will be reused in the new PCM. Set up:
• Battery is fully charged.
NOTICE: To prevent possible electrostatic • Engine operating at idle.
discharge to the PCM or PROM, do not touch the • Vehicle at operating temperature.
component leads, and do not remove integrated • Connect Tech 1 scan tool.
circuit from carrier. • Select "OUTPUT TESTS" and "INJ. PUMP."
• Activate "TDC LEARN."
Using two fingers, grasp the PROM at both ends
and lift it up out of the socket. Do not remove the cover NOTICE: It takes PCM 20 seconds to learn TDC
of the PROM. Use of unapproved PROM removal offset.
methods may cause damage to the PROM or socket.
• Verify "TDC OFFSET" in data list.
Inspect • DTC 88 will be stored if procedure has not been
done correctly.
For alignment notches of the PROM and carefully
set it aside. NOTICE: I f the PCM fails to program the TDC
OFFSET, do the following:
IF PCM IS BEING REPLACED • Check all PCM connections.
• Check Techline terminal/equipment for latest
Remove or Disconnect software version.
1. New PCM from its packaging and check the • Try again to program the PCM. If it fails again
service number to make sure it is the same as the replace the PCM. Refer to "PCM Replacement."
defective PCM.
2. Access cover.
1 FRONTCOVER
1 ENGINE COOLANT TEMPERATURE SENSOR
2 CRANKSHAFT POSITION SENSOR
2 CROSSOVER THERMOSTAT HOUSING 3 BOLT
NS15745 NS15749
Figure 3-28 - Engine Coolant Temperature (ECT) Figure 3-29 - Crankshaft Position Sensor
Sensor
PCM SENSORS AND INPUT SWITCHES Figure 3-29
Engine Coolant Temperature (ECT) Sensor 4»+ Remove or Disconnect
Figure 3-28
1. Negative battery cable.
NOTICE: Care must be taken, when handling 2. Sensor electrical connector.
sensor. Damage to sensor w i l l affect proper 3. Sensor bolt.
operation of the fuel control system. 4. Sensor from engine.
4*+ Remove or Disconnect | ¥ | Inspect

1. Negative battery cable. • Sensor O-ring for wear, cracks or leakage. Replace
2. Drain cooling system below level of sensor. if necessary. Lube new O-ring with engine oil
3. Electrical connector releasing locking tab. before installing.
4. Sensor.
Install or Connect
Install or Connect 1. Sensor in engine.
1. Sensor in engine. 2. Sensor bolt, tighten to 25 N-m (17 lb. ft.).
2. Electrical connector. 3. Sensor electrical connector.
3. Refill coolant system. 4. Negative battery cable.
Important
Accelerator Pedal Position (APP) Module "The procedure, called the "TDC Offset Program
Procedure," utilizes the capabilities of the Tech 1
Refer to SECTION 4 for replacement. scan tool. This procedure must be done when a
crankshaft position sensor is replaced. Refer to
Optical/Fuel Temperature Sensor "TDC Offset Program Procedure."
These sensors are only serviceable with electronic

fuel injection pump. Refer to SECTION 4.
1 IAT SENSOR (TYPICAL)

7S3263-6E
Figure 3-30 - IAT Sensor
Intake Air Temperature (IAT) Sensor 1 PLENUM PANEL
Figure 3-30 2 SENSOR PS 17309
Figure 3-31 - EGR Control Pressure/BARO Sensor

01. Negative
Remove or Disconnect
battery cable.
2. Electrical connector releasing locking tab.
3. IAT sensor.
Install or Connect
1. IAT sensor.
2. Electrical connector.
EGR Control Pressure/BARO Sensor

Figure 3-31
Other than checking for loose hoses and electrical

connections, the only service possible is unit
replacement if diagnosis shows sensor to be faulty.
2. Vacuum harness assembly. (If equipped.)
3. Electrical connector releasing locking tab. 1 BOOST SENSOR
4. Bolts or release lock tabs and remove sensor.
2 SOLT
Install or Connect
1. Bolts (3.5 N-m 27 lb. in.) or snap sensor on 3 SEAL
bracket. NS15746
3. Vacuum harness. (If equipped.)
Boost Sensor 1. Negative battery cable.
Figure 3-32 2. Vacuum harness assembly.
Other t h a n checking for loose e l e c t r i c a l 4. Bolts.
replacement i f diagnosis shows sensor to be faulty.
[nHh| Install or Connect

1. Bolts (3.5 N m 27 lb. in.).
3. Vacuum harness.
Wastegate Solenoid
Figure 3-34
1. Negative battery cables.
2 Electrical connector from the solenoid.
3 Vacuum hoses.
4. Wastegate solenoid.
•#4- Install or Connect

1 Wastegate solenoid.
2. Vacuum hoses.
3. Electrical connector from the solenoid.
5. Perform "On-Board Diagnostic (OBD) System 1 CONTROL MODULE
Check."
2 INSTRUMENT PANEL
Vehicle Speed Sensor (VSS) 3 VSS BUFFER MODULE

MS 12398
Refer to SECTION 10 for on-vehicle service of the Figure 3-33 - VSS Buffer Module
transmission mounted VSS.
VSS Buffer Module

Figure 3-33
The VSS buffer module is mounted i n the

instrument panel. Refer to SECTION 8C of the
appropriate service manual for on-vehicle service.
Brake Switches
Refer to SECTION 5 of the appropriate service

manual for on-vehicle service of the brake (stoplamp)
switches.
1 WASTEGATE SOLENOID
Cruise Control Switches
PS 17583
The cruise control switches are part of the multi- Figure 3-34 - Wastegate Solenoid
function turn signal lever. Refer to SECTION 3F of
the appropriate service manual.
PARTS INFORMATION
PART NAME GROUP
Module, Eng. Cont. 3.670

PROM,ECM 3.670
Sensor, Engine Coolant Temp 3.682
BLANK
G
DRIVEABILITY
AND
EMISSIONS
(DIESEL)
SECTION 3
SECTION 3
CONTENTS
General Description 3-3 PROM 3-17
Powertrain Control Module (PCM) 3-3 Fuel Control 3-17
PCM Learning Ability 3-3 PCM Sensors and Input Signals 3-17
Electrostatic Discharge Damage 3-4 Engine Coolant Temperature (ECT)
PCM Function 3-4 Sensor 3-17
MEMORY 3-4 Accelerator Pedal Position (APP)
ROM 3-4 Module 3--17
RAM . 3-4 Pump Cam Signal 3--18
PROM 3-5 Fuel Temperature Sensor 3--18
PCM Sensors and Input Signals 3-5 Crankshaft Position Sensor 3--18
Engine Coolant Temperature (ECT) Intake Air Temperature (IAT) Sensor . . 3--18
Sensor 3-5 EGR Control Pressure/BARO Sensor . . . 3--18
Accelerator Pedal Position (APP) Vehicle Speed Sensor (VSS) 3--18
Module 3-!5 Fuel Inject Signal 3-18
Optical Sensor 3- •5 Brake Switches 3-18
High Resolution Signal 3- •5 Glow Plug Signal 3-18
Pump Cam Signal 3- •5 Cruise Control 3-18
Fuel Temperature Sensor 3- -6 A/C Request Signal 3-19
Crankshaft Position Sensor 3- •6 Automatic Transmission Sensors
Intake Air Temperature (IAT) Sensor . . . 3- -6 and Signals 3-19
EGR Control Pressure/BARO Sensor . . . . 3 -6 CHART A-1
Vehicle Speed Sensor (VSS) 3- 7 No MIL (Service Engine Soon) 3-20
Vehicle Speed Signal (VSS) Buffer CHART A-2
Module 3 7 No Scan Data or Will Not Flash MIL
Fuel Inject Signal 37 or MIL (Service Engine Soon)
Brake Switch Signals 3- •7 "ON" Steady 3-22
Glow Plug Signal 3 •7 CHART A-3
Cruise Control Signals 3- •7 Engine Cranks But Will Not Run 3-24
A/C Request Signal 3 •7 CHART A-5 3-27
Automatic Transmission Sensors EGR Control Pressure/BARO Sensor
and Signals 3 •7 Output Check 3-28
Diagnosis 38 Cruise Control Signal Diagnosis 3-30
Diagnostic Information 3 •8 A/C Signal Diagnosis 3-31
Malfunction Indicator Lamp (MIL) Restricted Exhaust System Check 3-32
"Service Engine Soon" 3'•8 Diagnostic Trouble Code (DTC)
"Service Throttle Soon" Lamp 3 •8 Identification 3-33
On-Board Diagnostic (OBD) System Check . 3 •8 DTC 13 - Engine Shutoff Solenoid Circuit
On-Board Diagnostic (OBD) System Check Fault
3-36
(With Tech 1 Scan Tool) 3•10 DTC 14 - Engine Coolant Temperature (ECT)
Typical Tech 1 Engine Data Values . . . . . . 3 •12 Sensor Circuit Low (High Temperature
Engine Tech 1 Data Definitions 3 •13 Indicated)
3-38
Tech 1 Scan Tool 3•15 DTC 15 - Engine Coolant Temperature (ECT)
PCM Information Modes 3- •15 Sensor Circuit High (Low Temperature
Normal (Open) Mode 3 •15 Indicated)
3-40
Diagnostic Mode 3 •15 DTC 16 - Vehicle Speed Signal
Reading Diagnostic Trouble Codes ... 3- 15 Buffer Fault 3-42
DTC12 3- 15 DTC 17-High Resolution Circuit Fault ... 3-44
Clearing Diagnostic Trouble Codes . . . . 3- 16 DTC 18 - Pump CAM Reference Pulse
Intermittents 3- 16 Error 3-46
Scan Tool Use with Intermittents . . . 3- 16
T100-GM CAMS 3- 16
PCM Diagnosis 3 17

Error . 3-48 Circuit High 3-100
Circuit High 3-50 Circuit Low 3-102
Circuit Low . . . . . . . . . . . . . . . . . . 3-52 Circuit Range Fault 3-104
DTC 23 - Accelerator Pedal Position (APP) 1 DTC 71 - Set/Coast Switch Fault 3-106
Circuit Range Fault . . . . . . . . . . . . . 3-54 DTC 76 - Resume/Accel Switch Fault . . . . 3-108
DTC 25 - Accelerator Pedal Position (APP) 2 DTC 84 - Accelerator Pedal Position (APP)
Circuit High 3-56 Circuit Fault 3-110
DTC 26 - Accelerator Pedal Position (APP) 2 DTC 88-TDC Offset Error . . . . . . . . . . . 3-112
Circuit Low 3-58 DTC 91 - Cylinder Balance Fault . . . . . . . 3-113
DTC 27 - Accelerator Pedal Position (APP) 2 DTC 92 - Cylinder Balance Fault . 3-113
Circuit Range Fault 3-60 DTC 93 - Cylinder Balance Fault . . . . . . . 3-113
DTC 29 - Glow Plug Relay Circuit Fault • • • 3-62 DTC 94 - Cylinder Balance Fault 3-114
DTC 31 - EGR Control Pressure/BARO DTC 95 - Cylinder Balance Fault . . . . . . . 3-114
Sensor Circuit Low (High Vacuum) . . . 3-64 DTC 96 - Cylinder Balance Fault . . . . . . . 3-114
DTC 32 - EGR Circuit Error . . . . . 3-66 DTC 97 - Cylinder Balance Fault 3-114
DTC 33 - EGR Control Pressure/BARO DTC 98 - Cylinder Balance Fault 3-114
Sensor Circuit High (Low Vacuum) . . . 3-68 DTC 99 - Accelerator Pedal Position (APP) 2
DTC 34 - Injection Timing Stepper (ITS) Motor 5 Volt Reference Fault 3-116
Circuit Fault . • . • 3-70 PCM Wiring Diagram (1 of 6) . . . . . . . . 3-118
DTC 35 - Injection Pulse Width Error PCM Connector Terminal End View
(Response Time Short) . . . . . . . . . . . 3-72 (1of6) 3-124
DTC 36 - Injection Pulse Width Error On-Vehicle Service 3-131
(Response Time Long) 3-74 Wire Harness 3-131
DTC 41 - Brake Switch Circuit Fault .... 3-76 Connectors and Terminals 3-131
DTC 42 - Fuel Temperature Circuit Low Micro-Pack 3-132
(High Temperature Indicated) • 3-78 Metri-Pack 3-132
DTC 43 - Fuel Temperature Circuit High Weather-Pack 3-132
(Low Temperature Indicated) . . . . . . 3-80 Compact Three . . . . . . . . . . . . . . . 3-133
DTC 44- EGR Pulse Width Error . . . . . . . 3-82 Powertrain Control Module (PCM) . . . . . 3-133
DTC 45- EGR Vent Error . . . . . . . . . . . 3-84 PCM or PROM Replacement . . . . . . . . . 3-134
DTC 46-MIL "Service Engine Soon" If PCM Is Being Replaced . . . . . . . . . . . 3-134
Circuit Fault 3-86 Functional Check . . . . . . . . . . . . . . 3-134
DTC 47 - Intake Air Temperature (IAT) TDC Offset Program Procedure 3-134
Circuit Low (High Temperature PCM Sensors and Input Switches 3-135
Indicated) • 3-88 Engine Coolant Temperature (ECT)
DTC 48 - Intake Air Temperature (IAT) Sensor 3-135
Circuit High (Low Temperature Accelerator Pedal Position (APP)
Indicated) 3-90 Module . . . . . . . . . . . . . . 3-135
DTC 49 - "Service Throttle Soon" Optical/Fuel Temperature Sensor . . . . 3-135
Lamp Circuit Fault 3-92 Crankshaft Position Sensor 3-135
DTC 51 - PROM Error (Faulty or Intake Air Temperature (IAT) Sensor . . 3-136
Incorrect PROM) •• • 3-94 EGR Control Pressure/BARO Sensor . . . 3-136
DTC 54 - PCM Fuel Circuit Error 3-95 Vehicle Speed Sensor (VSS) 3-136
DTC 56 - Injection Pump Calibration VSS Buffer Module . . . . . . . . . . . . . 3-136
Resistor Error c 3-96 Brake Switches 3-137
DTC 57 - PCM 5 Volt Shorted 3-98 Cruise Control Switches 3-137
Parts Information 3-137
GENERAL DESCRIPTION
The control module system has a computer,. operational problems, alert the driver through the
Powertrain Control Module (PCM) to control fuel MIL (Service Engine Soon), and store one or more
delivery, timing, and some emission control systems. DTCs which identify the problem areas to aid the
The control module system, monitors a number of technician in making repairs. See diagnosis section
engine and vehicle functions (Figure 3-1) and controls for more information.
the following operations: The PCM is designed to process the various input
• Fuel control. information (Figure 3-1) and then sends the necessary
• Fuel injection timing. electrical responses to control fuel delivery, timing and
• Exhaust gas recirculation. other emission control systems. The input information
• Transmission shift and shift quality functions. has an interrelation to more than one output,
Specific transmission control diagnostics are therefore, i f the one input failed i t could affect more
covered in SECTION 10 of this service manual. than one system's operation.
POWERTRAIN CONTROL MODULE (PCM) PCM Learning Ability

Figure 3-2
The PCM has a "learning" ability which allows i t
The diesel Powertrain Control Module (PCM) is to make corrections for minor variations in the fuel
located in the passenger compartment and is the system to improve driveability. I f the battery is
control center of the control module system. The PCM disconnected to clear DTCs, or for repair, the
used on the electronic fuel injected 6.5L diesel is "learning" process has to begin all over again.
referred to as PCME. A change may be noted i n the vehicle's
The PCM constantly looks at the information from performance. To "teach" the vehicle, make sure the
various sensors, and controls the systems that affect engine is at operating temperature, and drive at part
vehicle performance. The PCM performs the throttle, w i t h moderate acceleration and idle
diagnostic function of the system. I t can recognize conditions, until normal performance returns.
OPERATING CONDITIONS SENSED
A/C Status Exhaust Gas Recirculation (EGR) Operation

Vehicle Speed (VSS) Injection Timing
Engine Coolant Temperature (ECT) Fuel Control
Crankshaft Position - Idle Speed and Quality
Engine Speed (RPM) Diagnostics
Injection Pump Timing - Malfunction Indicator Lamp (MIL)
- Pump Cam Reference Signal POWERTRAIN - "Service Throttle Soon* Lamp
Boost Pressure CONTROL
- Data Output
System Voltage MODULE
(PCM) Turbo Boost
Accelerator Pedal Position (APP) Transmission Functions
EGR Control Pressure - Electronic Automatic Transmission
Barometric Pressure (BARO) Glow Plug System
Intake Air Temperature (IAT) Cruise Control
Brake Switch
Transmission Functions
Fuel Temperature
Cruise Control Request
3-11-93
* All systems not used on all engines. PS 17155



discharge. It is possible for less than 100 volts of static
PS 17313
components. By comparison, i t takes as much as 4,000 Figure 3-2 - Powertrain Control Module
volts for a person to even feel the zap of a static PCM FUNCTION
discharge.
There are several ways for a person to become The PCM supplies a buffered 5 or 12 volts to power
statically charged. The most common methods of various sensors or switches. This is done through
charging are by friction and by induction. An example resistances in the PCM which are so high i n value that
of charging by friction is a person sliding across a car a test light will not light when connected to the circuit.
seat, in which a charge of as much as 25,000 volts can In some cases, even an ordinary shop voltmeter will
build up. Charging by induction occurs when a person not give an accurate reading because its resistance is
with well insulated shoes stands near a highly charged too low. Therefore, the use of a 10 megohm input
object and momentarily touches ground. Charges of impedance digital voltmeter is necessary to assure
the same polarity are drained off, leaving the person accurate voltage readings.
highly charged with the opposite polarity. Static The input/output devices i n the PCM include
charges of either type can cause damage, therefore, i t analog to digital converters, signal buffers, counters,
is important to use care when handling and testing and special drivers. The PCM controls output circuits
electronic components. such as the inject solenoids, etc. by controlling the
ground circuit through transistors or a device called a
NOTICE: To prevent possible Electrostatic driver in the PCM.
Discharge damage:
• Do Not touch the PCM connector pins or MEMORY
soldered components on the PCM circuit board.
• When handling a PROM, Do Not touch the There are three types of memory storage within
component leads, and Do Not remove integrated the PCM: ROM, RAM and PROM.
circuit from carrier.
• Be sure to follow the guidelines listed below if ROM
servicing any of these electronic components.
1. Do not open the replacement part package Read Only Memory (ROM) is a permanent memory
until i t is time to install the part. that is physically soldered to the circuit boards within
2. Avoid touching electrical terminals of the part. the PCM. The ROM contains the overall control
3. Before removing the part from its package, algorithms. Once the ROM is programmed, it cannot
ground the package to a known good ground on be changed. The ROM memory is non-volatile, and
the vehicle. does not need power to be retained.
4. Always touch a known good ground before
handling the part. This step should be RAM
repeated before installing the part i f the part
has been handled while sliding across the seat, Random Access M e m o r y ( R A M ) is the
while sitting down from a standing position, or microprocessor "scratch pad." The processor can write
while walking a distance. into, or read from this memory as needed.
This memory is volatile and needs a constant supply of

voltage to be retained. I f the voltage is lost, the
memory is lost.
PROM
Figure 3-2
Programmable Read Only Memory (PROM) is the

portion of the PCM that contains the different engine
1 HARNESS CONNECTOR
calibration information that is specific to year, model
and emissions. 2 LOCKING TAB
The PROM also contains specific calibration 3

SENSOR 5S1640-6E
information used to allow fuel delivery i f other parts of
the PCM are damaged. The PROM is a non-volatile Figure 3-3 - Engine Coolant Temperature (ECT)
memory that is read only by the PCM. Sensor
While one PCM part number can be used by many The PCM supplies a 5 volt signal to the Engine
vehicle lines, a PROM is very specific and must be Coolant Temperature (ECT) sensor through a resistor
used for the right vehicle. For this reason, i t is very in the PCM and measures the voltage. The voltage
important to check the latest parts book and service will be high when the engine is cold, and low when the
bulletin information for the correct part number when engine is hot. By measuring the voltage, the PCM
replacing a PROM. knows the engine coolant temperature. Engine
A PCM used for service comes without a PROM. coolant temperature affects fuel control and the glow
The PROM should be retained w i t h the vehicle plug system.
PCM must be carefully removed and installed in the Accelerator Pedal Position (APP) Module
new PCM, refer to "On-Vehicle Service/' Figure 3-4
PCM SENSORS AND INPUT SIGNALS The APP module contains three potentiometers (a
device for measuring an unknown voltage or potential
In addition to the PCM, the control module system difference by comparison to a standard voltage). Each
has some or all of the following information sensors: of the APP sensors send a varying voltage to the PCM.
• Engine Coolant Temperature (ECT) sensor. By monitoring the output voltage from the Accelerator
• Accelerator Pedal Position (APP) module. Pedal Position (APP) module, thfe PCM can determine
• Optical sensor. fuel delivery based on the accelerator pedal position
• Fuel temperature sensor. (driver demand).
• Intake Air Temperature (IAT) sensor. Optical Sensor ^
• EGR control pressure sensor.
• Barometric Pressure (BARO) sensor. The optical sensor sends what is called a high
• Vehicle Speed Sensor (VSS). resolution signal and a pump cam signal to the PCM.
And some or all of the following input signals:
• Fuel inject signal. High Resolution Signal
• Brake switch signals.
• Glow plug signal. The PCM uses this signal to determine injection
• Cruise control signals. timing and for fuel control and is one of the most
• A/C signal. important inputs to the PCM.
Pump Cam Signal
Engine Coolant Temperature (ECT) Sensor
Figure 3-3 The pump cam signal reference pulses are used by
the PCM to calculate injection timing and is one of the
The Engine Coolant Temperature (ECT) sensor is most important inputs to the PCM.
a thermistor (a resistor which changes value based on
temperature) mounted in the engine coolant stream.
The crankshaft position sensor provides a signal

which the PCM uses as reference to calculate RPM and
crankshaft position.

Figure 3-6
The Intake A i r Temperature (IAT) sensor is a

thermistor (a resistor which changes value based on
temperature) mounted in the intake manifold.
Low temperature produces a high resistance
The control module supplies a 5 volt signal to the
sensor through a resistor in the control module and
measures the voltage. The voltage will be high when
the intake air is cold, and low when the air is hot. By
measuring the voltage, the control module knows the
intake air temperature.
The IAT signal is used by the control module to
control fuel.
PS 16763
Figure 3-4 - Accelerator Pedal Position (APP) Module

7S3263-6E

Figure 3-7
On vehicles equipped with EGR, the EGR control

pressure/BARO sensor, mounted on the left side of the
cowl, is used to monitor the amount of vacuum in the
PS 17515 EGR circuit. It senses the actual vacuum i n the EGR
Figure 3-5 - Optical/Fuel Temperature Sensor vacuum line and sends a signal back to the PCM. The
signal is compared to the desired EGR calculated by
Fuel Temperature Sensor the PCM. If there is a difference in the PCM command
Figure 3 - 5 and what is at the EGR valve sensed by the EGR
control pressure/BARO sensor on vehicles not equip
The fuel temperature sensor is part of the with EGR this sensor is used only to measure BARO,
optical/fuel temperature sensor. The PCM uses the the PCM makes minor adjustments to correct. When a
fuel temperature signal for fuel control. major difference is sensed, the PCM recognizes a fault
and sends a maximum EGR signal. This sensor is also
used to measure barometric pressure (BARO) under
certain conditions, which allows the PCM to
automatically adjust for different altitudes.
Brake Switch Signals
The TCC normally closed brake switch supplies a

B + signal into the PCM. The signal voltage is opened
when the brakes are applied.
The cruise control normally open brake switch
supplies a B + signal to the PCM when the brake is
applied. These signals are used by the PCM to control
transmission and cruise control functions. The brake
switches are part of the stoplamp switch.
G l o w Plug Signal
1 SENSOR The glow plug system is used to assist in providing

the heat required to begin combustion during engine
6S2648-6E
starting at cold ambient temperatures. The glow plugs
are heated before and during cranking, as well as
Figure 3-7 - EGR Control Pressure/BARO Sensor initial engine operation. The PCM monitors the glow
The control module uses the boost pressure signal plug relay output.
to control fuel delivery.
Cruise Control Signals
The cruise control switches are part of the
The VSS is attached to the output shaft housing. multifunction turn signal lever. These switches
This device contains a permanent magnet surrounded enable the driver to control the cruise on/off, set/coast
by a coil of wire producing a magnetic field which is and resume/accel signals. These signals are inputs to
interrupted by rotor teeth pressed on an output shaft. the fuel control portion of the PCM and allow the PCM
As the rotor interrupts the magnetic field an AC to maintain a desired vehicle speed under normal
voltage is generated in the circuit. driving conditions.
Vehicle Speed Signal (VSS) Buffer Module A/C Request Signal
The VSS buffer module is an electronic device. This signal indicated that the A/C compressor
The VSS buffer module process inputs from the vehicle clutch is engaged. The PCM uses this signal to adjust
speed sensor and outputs various signals. The VSS the idle speed.
buffer module outputs a 4000 pulse per mile signal.
This signal is used by the PCM to determine vehicle Automatic Transmission Sensors a n d Signals
cruise control and fuel cutoff. The VSS buffer module Refer to SECTION 10 of this service manual for a
is matched to the vehicle based on transmission, final description of automatic transmission sensors and
drive ratio and tire size. The VSS buffer module is signals.
located behind the instrument panel.
Fuel Inject Signal
The fuel injector driver receives an inject

regulated output to the fuel solenoid that controls
injection. It also returns an injection pulse width
signal back to the PCM to inform i t when the fuel
solenoid has actually seated.
DIAGNOSIS
DIAGNOSTIC INFORMATION When the light remains "ON" while the engine is
running, or when a malfunction is suspected due to a
The diagnostic "tree" charts and functional checks driveability or emissions problem, an "On-Board
in this manual are designed to locate a faulty circuit or Diagnostic (OBD) System Check" must be performed.
component through logic based on the process of This check will expose malfunctions which may not be
elimination. detected if other diagnostics are performed
The charts are prepared with the requirements prematurely.
that the vehicle functioned correctly at the time of
assembly and that there are no multiple failures. "Service Throttle S o o n " Lamp
The PCM performs a continual self-diagnosis on
certain control functions. This diagnostic capability is This light is on the instrument panel and has the
complemented by the diagnostic procedures contained following functions:
i n t h i s m a n u a l . The PCM's language f o r • I t informs the driver that a problem has
communicating the source of a malfunction is a system occurred i n the Accelerator Pedal Position
of Diagnostic Trouble Codes (DTC). The DTCs are two (APP) circuit and the vehicle should be taken
digit numbers that can range from 12 to 99. When a or service as soon a reasonably possible.
malfunction is detected by the PCM, a DTC is set and • I f APP DTCs are stored by the PCM, the MIL
the Malfunction Indicator Lamp (MIL) is illuminated. will display these. The "Service Throttle Soon"
Lamp will not display DTCs.
Malfunction Indicator Lamp (MIL) " S e r v i c e As a bulb and system check, the light will come
Engine S o o n " "ON" with the key "ON" for 2 seconds. When the
engine is started, the light will turn "OFF." I f the
This light is on the instrument panel and has the light remains "ON," the self-diagnostic system has
following functions: detected a problem. If the problem goes away, the light
• I t informs the driver that a problem has will go out in most cases after 10 seconds, but a DTC
occurred and that the vehicle should be taken will remain stored in the PCM.
or service as soon as reasonably possible. When the light remains "ON" while the engine is
• It displays DTCs stored by the PCM which help running, or when a malfunction is suspected, an
the technician diagnose system problems. "On Board Diagnostic (OBD) System Check" must be
As a bulb and system check, the light will come performed. This check will expose malfunctions which
"ON" with the key "ON" and the engine not running. may not be detected if other diagnostics are performed
When the engine is started, the light will turn "OFF." prematurely.
If the light remains "ON," the self-diagnostic system
has detected a problem. I f the problem goes away, the ON-BOARD DIAGNOSTIC ( O B D ) S Y S T E M
light will go out in most cases after 10 seconds, but a CHECK
DTC will remain stored in the PCM.
After the visual/physical underhood inspection,
the on-board diagnostic system check, is the starting
point for all diagnostic procedures or finding the
cause of an emission test failure.
BLANK
l/P JUMPER HARNESS PCM

— 1061 ORN/BLK SERIAL DATA
DIAGNOSTIC
DATA LINK " 451 WHT/BLK REQUEST
CONNECTOR
TO WATER 551 TAN/WHT SYSTEM GROUND
IN FUEL
F E D C B A
o o SENSOR T Q F U E L
G H >\K L M BULKHEAD HEATER ENGINE

CONNECTOR GROUNDS
TO SIR DERM 450 BLK/WHT SYSTEM GROUND
ECMI
IGNITION
439 PNK/BLK IGNITION FEED
SWITCH
10 AMP
ECMB
B + ~«- [g]- 440 ORN BATTERY FEED
BULK HEAD
10 AMP CONNECTOR
MIL
CAGES
TO MIL "SERVICE
IGNITION' 39 PNK/BLK 419 BRN/WHT ENGINE SOON"
SWITCH 20 AMP "SERVICE CONTROL
ENGINE PCM CONN. ID i
TO "SERVICE SOON" -4
THROTTLE SOON" ! PA/PB - PINK - 32 PIN i
AND CRUISE t
J PGPD - PINK - 24 PIN i 1-13-94
CONTROL SWITCH i BC/BD - BLUE - 32 PIN i PS 17639

by a control module system malfunction. It must be the starting point for any driveability complaint diagnosis,
chart and using it properly will reduce diagnostic time and prevent the unnecessary replacement of good parts
Chart Test Description: Number(s) below refer to Comparison of actual control system data with the
circled number(s) on the diagnostic chart. Typical Tech 1 Data Values is a quick check to
1. When the ignition switch is cycled to "ON," the determine if any parameter is not within limits. A
MIL should turn "ON" briefly, then "OFF" briefly, base engine problem (i.e., advanced cam timing
then remain "ON" steady. This sequence will may substantially alter sensor values).
determine that the vehicle diagnostics are
operational. NOTICE: The PCM utilizes a 24 pin "Pink"
2. This step will isolate i f the customer complaint is connector, a 32 pin "Pink" connector and a 32 pin
a MIL or driveability problem. "Blue" connector. The 24 pin "Pink" connector is
3. Although the control module is powered up; a labeled "A" and "B", the 32 pin "Pink" connector is
symptom could exist because of a system fault. labeled "C" and "D" and the 32 pin "Blue"
4. Use Tech 1 to aid diagnosis, therefore, serial data connector is labeled "C" and " D " . When
must be available. referencing PCM connector pin outs, the "Blue"
5. This step will isolate if the customer complaint is a PCM connector will be referred to as the "E" and
MIL or driveability problem with no MIL. "F".
6. Although the PCM is powered up, a "Cranks But
Will Not Run" symptom could exist because of a
PCM or system problem.

CHECK
• IGNITION "ON." ENGINE "OFF."

I 1
©[ STEADY LIGHT
•
©[ NO LIGHT FLASHING LIGHT
© WITH TECH 1 SCAN TOOL PERFORM

ON-BOARD DIAGNOSTIC SYSTEM CHECK
[ REFER TO J
i CHART A-1. i
CHECK FOR GROUNDED
DIAGNOSTIC TEST CKT 4S1.
OR
T E R M I N A L ' B ' TO " A " .
DOES MIL FLASH?
| YES NO
11
©[ DOES TECH 1 DISPLAY SCAN DATA? ! REFER TO CHART A-2. !
YES NO
zxz
©I ARE ANY DTCs DISPLAYED? i REFER TO CHART A-2. \
YES NO
©
3 Z
6 1 DOES ENGINE START? REFER TO 'TYPICAL TECH 1 DATA VALUES" AND
COMPARE SCAN DATA.
YES NO
X
• REFER TO APPLICABLE DTC CHART. {REFER TO CHART A-3. |
11-1-93
PS 17310
functioning properly and no DTG(s) displayed, the "Typical Tech 1 Engine Data Values" may be used for
Only the parameters listed below are used i n this manual for diagnosing. I f a scan tool displays other
Systems." I f all varies are within the range illustrated, refer to "Symptoms," section.

Idle / Lower Radiator Hose H o t / C l o s e d Throttle / Park or Neutral / Accessories Off
ENG COOL TEMP. C7F° o o o
85 C-105 C(185°F-221 F)
BARO kPa/Volts 70 -100/3.5-4.5 (varies with altitude)
DESIRED EGR kPa/Volts 50-100 kPa/2.8 - 3.0V (varies)
EGR DUTY CYCLE Percentage 35-100% (may vary)
o
FUEL TEMPERATURE C7F° 2rC-43 C(70°F-110°F)
THROTTLE ANGLE Percentage 0%-100%
MPH km/h 0-98
SYSTEM VOLTAGE Volts 12.0-14.5
ENG SHUTOFF On/Off On
CRANK REF MISSED Counts 0 (missed)
CAM REF MISSED Counts 0 (missed)
Drive 4, Drive 3,
Drive 2, Low,
Park/Neut Park/Neut
TIME FROM START Hrs/M ins/Sec Varies
12-7-93
PS 17640

"Transmission.* This information will assist in emission or driveability problems. The displays can be viewed
while the vehicle is being driven. Always perform the "On-Board Diagnostic (OBD) System Cheek" first. The
"OBD System Check" will confirm proper systemoperation.
ENGINE DATA
input (low resolution circuit). I t should remain close to throttle demanded by the driver. Should read about
desired idle under various engine loads with engine .35-.95 volts at idle to above 4.0 volts at Wide Open
DESIRED IDLE • Range 0-3187 RPM - The idle speed ACCELERATOR PEDAL POSITION (APP 2) - Range 0-5
ENG COOL TEMP - Range -40°C to 151°C, -40°F to 304°F ACCELERATOR PEDAL POSITION (APP 3) - Range 0-5
mounted in the coolant pump and sends engine throttle demanded by the driver. Should read about
the sensor warms (internal resistance decreases), the missed. At idle i t should read 0.
voltage signal w i l l decrease and the PCM w i l l
INTAKE AIR TEMP - Range -40*C to 151°C -40°F to
f position. The scan tool will display the number of cam
304°F - The PCM converts the resistance of the intake pulses missed. A t idle it should read 0.
Temperature (IAT) is used by the PCM to adjust fuel FUEL TEMP - Range -40°C to 151*C, -40°F to 304*F -
delivery and spark timing according to incoming air There is a thermistor located in the high resolution
density. sensor that determines fuel temperature. When the
sensor is cold (internal resistance high) the PCM
BARO - Range 10-105 kPa/0.00-5.00 Volts - The BARO monitors a high signal voltage which i t interprets as
reading displayed is determined from the MAP sensor low fuel temperature. As the sensor warms (internal
at ignition "ON," engine "OFF," and WOT conditions. resistance low) the voltage signal will decrease and the
The BARO reading displayed represents barometric PCM will interpret the low voltage as warm fuel.
pressure and is used to compensate for altitude
differences. FUEL RATE - Range 0-80 mm - This reading is
THROTTLE ANGLE - Range 0 -100% - Computed by the fuel the PCM is requesting.
PCM from APP module voltage (throttle position) and
should display 0% at idle and 100% at wide open
at idle.
glow plug relay. The PCM will cycle the voltage "ON" solenoid. When engine load is increased, injector pulse
and "OFF." Cycling timing will increase when engine width will fluctuate.
EGR DUTY CYCLE - Range 0-100% - The PCM cycles
GLOW PLUG VOLTS - Range 0-25.5 Volts - This is used the EGR solenoid valve "ON" and "OFF." The "ON"
by the PCM to determine if there is voltage coming out time (duty cycle) of the EGR solenoid valve, expressed
of the relay and going towards the glow plugs. During as a percent, determines how much the exhaust gas is
normal operation the volts reading will be lower than recirculated.
glow plug relay voltage because of the high resistance
in the glow plugs. A/C REQUEST - Tech 1 displays "YES"/"NO" -
Represents if the A/C request from the control head is
DESIRED INJECTION TIMING - Range 0-25.5 Degrees - being received by the PCM.
The amount of injection timing requested by the PCM.
PARK/NEUTRAL POS - Tech 1 displays - "P-N"-- or -"R-
MEASURED INJECTION TIMING - Range 0-25.0 Degrees DL" - "P-N"-- displayed indicates that the gear select
- Current actual injection timing. lever is in park or neutral.
TDC OFFSET - Range ±2.02 Degrees - The PCM has CRUISE CONTROL - Tech 1 Displays "OFF"/"ON" - This
the ability to determine the amount of offset needed to will indicate when the cruise control has been enabled.
bring the engine to top dead center. This is used by the This signal is used by the PCM to adjust TCC
PCM to determine proper injection timing and fuel engagement scheduling, and to operate PCM cruise
delivery. This value may be displayed as a positive or fuel.
negative number.
1 - 2 SHIFT SOL - Tech 1 displays "ON"/"OFF" - When
EGR DESIRED POSITION - Range 10-103 kPa - The PCM the transmission in in first or fourth gear, the Tech 1
command for EGR vacuum that is desired. should display "ON." When the transmission is i n
second or third gear, the Tech 1 should indicate "OFF."
EGR ACTUAL POSITION - Range 10-103 kPa - Current
actual EGR vacuum. 2 - 3 SHIFT SOL - Tech 1 displays "ON"/"OFF" - When
4WD LOW SWITCH - Indicator to PCM when driver the Tech 1 should indicate " O N . " When the
selects 4WD. transmission is in third or fourth gear, the Tech 1
parameter. It is computed by timing pulses coming C/C BRAKE SWITCH - Tech 1 displays "OPEN"/
TCC BRAKE SWITCH - Tech 1 displays "CLOSED"/
ID is used when it is necessary to replace the PROM. disengagement switch.
PROMs. PROM ID should not be confused with "Part TIME FROM START - Range 0:00:00-18:12:15
Number." HR/MIN/SEC - A measure of how long the engine has
been operating. When the ignition is cycled to "OFF"
12-9-93
PS 17676
TECH 1 SCAN TOOL PCM INFORMATION MODES
essential tool. Although, the term scan tool w i l l
continue to be used for simplicity's sake, we On engines that can be monitored in the "Open"
terminal " M " (Figure 3-8). This data is transmitted at
high frequency which requires a scan tool for When the diagnostic terminal is grounded with the
enter what is called the diagnostic mode. In this mode
the PCM will-
OR
Display any stored DTC by flashing the MIL.
TERMINAL IDENTIFICATION Each DTC will be flashed three times.
• GROUND EBCM DIAGNOSTIC

TERMINAL (ANTILOCK)
• K M DIAGNOSTIC
TERMINAL
E AND C DATA (RADIO) The means of communicating with the control
FUEL PUMP PRIME PCM SERIAL Figure 3-8) located under the instrument panel and is
DATA 3-9-93
8S3967-6E
sometimes covered by a plastic cover labeled
"DIAGNOSTIC CONNECTOR." The DLC is used in
Figure 3-8 - Data Link Connector (DLC) the assembly plant to receive engine information to
With an understanding of the data which the scan determine proper operation before it leaves the plant.
the scan tool can be very useful in obtaining be displayed either through the Tech 1 scan tool, a
problem is in a particular circuit. Diagnostic tree grounded. The DLC terminal " B " (diagnostic
scan tool when it is applicable. connecting i t to terminal "A" (internal control module
The kev to using the scan tool successfully for pause, flash-flash, long pause, flash, pause, flash-flash,
diagnosis lies in the technician's ability to understand long pause, flash, pause, flash-flash."
the system being diagnosed, as w e l l as an
understanding of the scan tool's limitations.
DTC 12 indicates that the control module diagnostic Scan Tool Use With Intermittents
system is operating properly. I f the DTC 12 is not
indicated, and a fault is present within the diagnostic In some scan tool applications, the data update
system itself, i t should be addressed by consulting the rate makes the tool less effective than a voltmeter,
appropriate diagnostic chart in this section. such as when trying to detect an intermittent problem
The malfunction indicator lamp will indicate a which lasts for a very short time. However, the scan
Diagnostic Trouble Code (DTC) three times i f a DTC is tool allows manipulation of w i r i n g harnesses or
present, or i t will simply continue to output DTC 12. I f components under the hood with the engine not
more than one diagnostic trouble code has been stored running, while observing the scan tool readout.
ini the control module memory, the DTC(s) will be The scan tool can be plugged in and observed while
displayed from the lowest to the highest with each driving the vehicle under the condition when the MIL
DTC being displayed three times. "Service Engine Soon" light turns "ON" momentarily
or when the engine driveability is momentarily poor.
Clearing Diagnostic Trouble Codes I f the problem seems to be related to certain
parameters that can be checked on the scan tool, they
To clear the DTC(s) from the memory of the control should be checked while driving the vehicle. I f there
module, either to determine i f the malfunction will does not seem to be any correlation between the
occur again or because repair has been completed, the problem and any specific circuit, the scan tool can be
Tech 1 scan tool should be used to clear the DTC(s). I f checked on each position, watching for a period of time
a scan tool is not available the following must be to see i f there is any change i n the readings that
performed when all repairs have been completed. This indicates intermittent operation.
will allow all DTC(s) to be cleared. The scan tool is also an easy way to compare the
1. Ignition "OFF." operating parameters of a poorly operating engine
2. Ground diagnostic terminal "A" to "B" of DLC. with those of a known good one. For example, a sensor
3. Ignition "ON." may shift in value but not set a DTC. Comparing the
4. Fully apply brake pedal. sensor's readings with those of a known good vehicle
5. Fully apply accelerator pedal. may uncover the problem.
" 6. Check MIL (Service Engine Soon) for DTC 12. The scan tool has the ability to save time i n
7. Release brake pedal. diagnosis and prevent the replacement of good parts.
8. Release accelerator pedal. The key to using the scan tool successfully for
9. Check MIL (Service Engine Soon) for DTC 12. diagnosis lies in the technician's ability to understand
10. Remove jumper from DLC connector. the system he is trying to diagnose as well as an
11. Turn ignition "OFF." understanding of the scan tool operation and
limitations. The technician should read the tool
NOTICE: To prevent control module damage, the manufacturer's operating manual to become familiar
key must be "OFF" when disconnecting or with the tool's operation.
reconnecting module power.
T 1 0 0 - G M CAMS
Intermittents
The T100-GM CAMS (Computerized Automotive
Corresponding DTC will be stored in the memory Maintenance System) is a computerized technician's
of the PCM as a history DTC until DTCs have been terminal unit. When connected to a vehicle, performs
cleared. When unexpected DTCs appear during the engine, electronic circuits and systems test to find
code reading process, one can assume that these DTCs possible vehicle problems in the engine system or the
were set by an intermittent malfunction and could be PCM.
helpful in diagnosing the system. The terminal diagnoses as follows:
An intermittent DTC may or may not re-set. If it is • C i r c u i t diagnostic procedures provide
an intermittent failure, a Diagnostic Trouble Code information on how to isolate a problem and
(DTC) chart is not used. Consult the "Diagnostic Aids" repair requirements.
ori the page facing the diagnostic chart corresponding • I f no problem exists, engine performance
to the intermittent DTC. SECTION 2 also covers the problems are diagnosed.
topic of "Intermittents." A physical inspection of the • DTCs stored i n the PCM are read and
applicable sub-system most often will not resolve the diagnosed by the system.
problem. Also needed are a test light, ohmmeter, digital
voltmeter with 10 megohms impedance (J 39200),
tools which are required for system service and the
PCM DIAGNOSIS PROM
Since the PCM can have a failure which may affect A PROM that has failed or was i n s t a l l e d
only one circuit, following the diagnostic procedures in improperly will generally set a DTC 51.
this section can reliably tell when a failure has
occurred in the PCM. Also, a DTC 54 indicates a FUEL CONTROL
failure of the PCM.
If a diagnostic chart indicates that the PCM Fuel delivery is controlled by the control module
connections or PCM is the cause of a problem, and the system.
PCM is replaced, but does not correct the problem, one The diagnosis of fuel control starts with "Engine
of the following may be the reason: Cranks But Will Not Run" CHART A-3. This chart
• There is a problem with the PCM terminal will test the fuel system and if there is a problem, will
connections. - The diagnostic chart will say lead you to checking the fuel lift pump, diagnosing the
PCM connections or PCM. The terminals may injection pump circuit or diagnosing the fuel system.
have to be removed from the connector in order
to check them properly. PCM SENSORS AND INPUT SIGNALS
• The PCM or PROM is not correct for the
application. - The incorrect PCM or PROM A l l of the sensors and input signals can be
may cause a malfunction and may or may not diagnosed by the use of a scan tool. Following is a
set a DTC. short description of how the sensors and signals can be
• The problem is intermittent. - This means that diagnosed by the use of a scan tool. A scan tool can
also be used to compare the values for a normal
running engine with the engine you're diagnosing.
system is being checked. In this case, refer to
Refer to "Typical Scan Tech 1 Engine Data Values.*
manual and make a careful p h y s i c a l
inspection of a l l portions of the system Engine Coolant Temperature (ECT) Sensor
involved.
• Shorted solenoid, relay coil, or harness. - A scan tool displays engine coolant temperature in
Solenoids and relays are turned "ON" and degrees (Celsius & Fahrenheit). After engine is
"OFF" by the PCM, using internal electronic started, the temperature should rise steadily to about
switches called "Drivers." 90°C (194°F) then stabilize when thermostat opens.
A shorted solenoid, relay coil, or harness will not DTC 14 or DTC 15 indicates a failure in Engine
damage the PCM, but will cause the circuit and Coolant Temperature (ECT) sensor circuit.
controlled component to be inoperative. When the The DTC charts also contain a chart to check for
circuit fault is not present or has been repaired, the ECT sensor resistance values relative to temperature.
driver will again operate in a normal manner due to
it's fault protected design. If a fault has been repaired Accelerator Pedal Position (APP) Module
in a circuit controlled by a driver, the original PCM
should be reinstalled and the circuit checked for proper If the PCM has determined that there is a fault in
operation. PCM replacement will not be necessary i f one APP sensor, the PCM will store a current and
the repair circuit or component now operates correctly. history DTC, but, it will not turn "ON" the "Service
J 34636 or BT-8405 testers or equivalent provide a Throttle Soon" lamp. The vehicle and throttle pedal
fast, accurate means of checking for a shorted coil or a will operate normally i f only one of the three APP
short to battery voltage. sensors i f found have a fault. I f the PCM has
determined two APP sensors are faulty, a current and
• The PROM may be faulty. - Although the PROM
history DTC will set and the PCM will turn "ON" the
rarely fails, i t operates as part of the PCM.
"Service Throttle Soon" lamp. At this point, some
Therefore, it could be the cause of the problem.
engine performance will be lost. If three APP sensors
Substitute a known good PROM.
malfunction, a current and history DTC will be stored,
• The replacement PCM may be faulty. - After the
the "Service Throttle Soon" lamp will come "ON," and
PCM is replaced, the system should be rechecked
the PCM will only allow the vehicle to idle. If the PCM
for proper operation. If the diagnostic chart again
has recognized an intermittent fault (a fault not
indicates the PCM is the problem, substitute a
recognized by the normal APP DTC setting criteria), it
known good PCM. Although this is a rare
will then only allow the vehicle to operate under
condition, it could happen.
limited performance and store a DTC 84.
A scan tool reads APP 1 position i n voltage, and EGR Control Pressure/BARO Sensor
Voltage should increase at a steady rate as accelerator A scan tool displays EGR pressure i n volts. Low
position is also read in voltage, and should read about high pressure (low vacuum) reads a high voltage. A
4.5 volts at idle, and should steadily decrease to a failure in the EGR control pressure/BARO sensor
about 1.5 volts as accelerator pedal is moved to WOT. circuit should set a DTC 31 or 33 and using the chart
APP 3 is also read in voltage, and should read about will find the cause of the problem. Any other failure in
4.0 volts at idle, and should steadily decrease to about the EGR system should set a DTC 32, 44 or 45. On
2.0 volts. Its possible idle voltage may vary, because vehicles using only a BARO sensor a failure i n the
the PCM has a "learning" ability which allows i t to sensor circuit should set a DTC 31 or 33. Also refer to
make corrections for minor variations. "EGR Control Pressure/BARO Sensor Output Check"
in this section.
Pump Cam Signal
Loss of pump cam signal reference pulses will set a
DTC 18. I f the pump cam signal is lost while the A scan tool display of mph / km/h should closely
engine is running, the fuel injection system will shift match with the speedometer display. A failure in the
to a time base fuel injection (back up fuel) mode based VSS input circuit should set a DTC 24 or DTC 16.
on crankshaft position sensor signal, and the engine
will continue to run. The engine can be restarted and Fuel Inject Signal
will run in the calculated fuel injection mode as long as
the fault is present. A scan tool will display the injection pulse width
See DTC 18 for further information. feedback in milliseconds. I f the PCM detects an error
in the fuel inject response time, a DTC 35 or DTC 36
Fuel Temperature Sensor will set.
The scan tool displays fuel temperature in degrees Brake Switches

failure in the fuel temperature sensor circuit. A scan tool will display the status of the brake
switches. The cruise control brake switch is normally
Crankshaft Position Sensor open and TCC brake switch normally closed. A
malfunction in the brake switches circuit should set a
A scan tool displays engine speed in RPM. RPM DTC 37,38 or 41.
will still be displayed with a fault in this circuit. If the
signal is lost while the engine is running, the fuel Glow Plug Signal
injection system will shift to a time base fuel injection
mode based on pump cam signal, and the engine will A scan tool will display this signal i n voltage. A
continue to run. The engine can be restarted and will malfunction in this system should set a DTC 29 or
run in the backup fuel mode as long as fault is present. refer to SECTION 7 for diagnosis of the glow plug
See DTC 19 for further information. control system.
Intake Air Temperature (IAT) Sensor Cruise Control
A scan tool displays temperature of the air A scan tool will display cruise control "ON/OFF"
entering the engine and should read close to ambient status. For diagnosis of the cruise control refer to
air temperature when the engine is cold, and rise as "Cruise Control Diagnosis." A malfunction in the
underhood temperature increases. I f the engine has set/coast switch circuit should set a DTC 71. A
not been run for several hours (overnight), the IAT malfunction in the resume/accel switch circuit should
sensor temperature and engine coolant temperature set a DTC 76.
should read close to each other. A failure in the IAT
sensor circuit should set DTC 47 or 48. The DTC chart
also contains a "Diagnostic Aid" to check for sensor
resistance values relative to temperature.
A / C Request Signal
The scan tool should indicate A/C clutch "ON"

when A/C is selected. Refer to "A/C Signal Diagnosis"
for diagnosis of the A/C signal.
Automatic Transmission Sensors and Signals

signals.

• r H- iH 1061 ORN/BLK SERIAL DATA
DIAGNOSTIC
DATA LINK " 451 WHT/BLK REQUEST
CONNECTOR
TO WATER S51 TAN/WHT SYSTEM GROUND
IN FUEL
F E B A
c o SENSOR T 0 F u a
G H '« L M BULKHEAD * HEATER ENGINE

GROUNDS
CONNECTOR
*
TO SIR DERM""
—m- 450 BLK/WHT SYSTEM GROUND
ECMI
IGNITION IGNITION FEED
SWITCH " 439 PNK/BLK
10 AMP
ECMB
10 AMP BULK HEAD
MIL CONNECTOR
TO
IGNITION
SWITCH
4
GAGES
20 AMP
39 PNK/BLK SSI
•SERVICE
ENGINE
419 BRN/WHT
PCM CONN. ID
MIL "SERVICE
ENGINE SOON"
CONTROL
TO "SERVICE SOON"
THROTTLE S O O N * • PA/PB - PINK - 32 PIN
AND CRUISE J PC/PD - PINK - 24 PIN 1-13-94
CONTROL SWITCH i BC/BD - BLUE - 32 PIN PS 17639
CHART A-1
NO MIL
There should always be a steady MIL with the ignition "ON" and engine "OFF." Switched battery voltage is
supplied to the lamp. The PCM will control the lamp and turn i t "ON" by providing a ground path through CKT
419.
for complete circuit. • Gauges fuse open. This will result in no brake
ground circuits.
CHART A-1
NO MIL
© CHECK:
• CONTINUOUS BATTERY FUSIBLE LINK.
- ECM-IGN FUSE.
- GAUGES FUSE.
1
FUSES OK OPEN FUSE
• IGNITION "OFF." LOCATE AND CORRECT SHORT TO

• DISCONNECT PCM CONNECTORS. GROUND THAT HAD AN OPEN FUSE.
• PROBE CKT 440 AND CKT 439 WITH A
TEST LIGHT TO GROUND.
TEST LIGHT "ON" TEST LIGHT "OFF* ONE

I I
PROBE CKT 419 WITH A TEST LIGHT LOCATE AND REPAIR

1
MIL "ON" MIL "OFF"
1 — "1
FAULTY PCM GROUNDS CKT 419 OPEN OR SHORTED
OR TO VOLTAGE FAULTY BULB.
OR
FAULTY PCM.
5-4-92
MS 13407

i i n
1
H — 1061 ORN/BLK SERIAL DATA
DIAGNOSTIC
D A T A LINK 451 W H T / B L K REQUEST
CONNECTOR
(DLC) TO WATER 551 T A N / W H T SYSTEM GROUND
IN F U E L
CTBTA SENSOR T O FUEL
cannnncj BULKHEAD
CONNECTOR
• HEATER
T O SIR D E R M 450 B L K / W H T SYSTEM GROUND
ECMI
IGNITION
439 P N K / B L K IGNITION F E E D
SWITCH
10 AMP
ECMB
B*-«- 440 ORN BATTERY FEED
10 AMP BULK HEAD

MIL CONNECTOR
GAGES
TO MIL "SERVICE
IGNITION -
39 P N K / B L K 419 B R N / W H T ENGINE SOON"
SWITCH 20 AMP "SERVICE CONTROL
ENGINE P C M C O N N . ID
TO "SERVICE SOON"
THROTTLE SOON** P A / P B - P I N K - 32 P I N
AND CRUISE P O P D - P I N K - 2 4 PIN 1-13-94
CONTROL SWITCH iBC/BD - BLUE - 3 2 PIN P S 17639
CHART A-2
NO SCAN DATA OR
MIL (SERVICE ENGINE SOON) "ON" STEADY
419.
With the "diagnostic" terminal grounded, the lamp should flash a DTC 12, followed by any Diagnostic
Trouble Code (DTC) stored in memory.
A steady lamp indicates a short to ground in the lamp control CKT 419 or an open in diagnostic CKT 451.
circled number(s) on the diagnostic chart. 451.
1. I f there is a problem with the PCM that causes a 4. At this point, the MIL wiring is OK. The problem
scan tool not to read serial data, then the PCM is a faulty PROM. I f DTC 12 does not flash, the
should not flash a DTC 12. I f DTC 12 does flash, PCM should be replaced using the original PROM.
check that the scan tool is functioning properly on Replace the PROM only after trying a PCM.
properly, and CKT 1061 is OK, the PEOM, PCM,
or SIR DERM may be at fault for the NO DLC
symptom.
2. If the light goes "OFF" when the PCM connector is
ground.
CHART A-2
NO SCAN DATA OR
MIL (SERVICE ENGINE SOON) ' W STEADY
• IGNITION " O N " . ENGINE "OFF.**
MIL"OM" MIL "OFF"
r — m.m. , .
m mmmmm mmm
• GROUND DIAGNOSTIC TERM. J REFER TO I

DOES MIL FLASH? I CHART A-1 i
, j
NO YES
i
© IGNITION " O F F . "
DISCONNECT PCM CONNECTORS.
IGNITION "ON."
© IF PROBLEM WAS NO SERIAL DATA:
CHECK SERIAL DATA CIRCUIT FOR OPEN
OR
SHORT TO GROUND
OR
DLC. IF OK, IT IS A FAULTY PCM, PROM
OR SIR DERM (REFER TO SECTION 9J).
© MIL "OFF" MIL "ON"
"T
IGNITION " O F F . " REPAIR SHORT TO
DIAGNOSTIC TERMINAL NOT GROUNDED. GROUND IN CKT 419.
RECONNECT PCM CONNECTORS.
BACK PROBE PCM, CKT 451, WITH TEST
LIGHT TO GROUND.
DOES MIL FLASH?
YES
m
© •
•
IF OK REPLACE PCM USING ORIGINAL PROM.
f
CHECK FOR OPEN IN DLC DIAGNOSTIC
TERMINALS. " B " AND CKT 451 TO PCM.
• RECHECK FOR FLASHING MIL. CHECK FOR OPEN IN DLC TERMINAL. "A"
DOES MIL FLASH? TO PCM.
NO YES
i
REPLACE PROM SYSTEM OK
IF PCM IS FAULTY AND MUST BE REPLACED, "TDC OFFSET" MUST BE PROGRAMMED INTO THE NEW PCM. % f 3
REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION. u$ 14043

ENGINE HARNESS PCM

CONNECTOR (16 PIN)

\
SOLENOID
FUEL INJECT CONTROL
1.
984 LT GRN FUEL INJECT CONTROL
MS RBI FUEL INJECT SIGNAL
FUEL OISQ 339 PNK
i
SOLENOID
I
DRIVER
• 950 LT GRN CLOSURE GROUND
ENGINE
339 PNK
J HARNESS
CONNECTOR
7 (8 PIN)
FUEL
sue TO
IGNITION 20 AMP
SOLENOID SWITCH
RED -
r©- FUEL SOLENOID

HARNESS CONNECTOR [^reMCONN.ID^J
J PA/PS FINK 32 PIN I

[ PC/PD PINK 24 PIN I
[BC/BD BLUE 32 PIN I
NS 14320
CHART A-3
This chart assumes that battery condition and engine cranking speed are OK, adequate fuel in the tank, and
Chart Test Description: Number(s) below refer to Diagnostic Aids: I f no trouble is found i n the fuel
circled number(s) on the diagnostic chart. pump circuit and the cause of a "Engine Cranks But
and ignition 12 volts to PCM. No DLC may be due • Basic engine problem.
to a PCM problem and CHART A-2 will diagnose
the PCM. NOTICE: I f crankshaft position sensor and
2. This step will check to see i f there is an inject optical sensor are disconnected or inoperable at the
command coming from the PCM. same time this will cause a "Engine Cranks But
3. This step will check ground circuit. Will Not Run" condition.
CHART A-3
© •
•
IGNITION "ON."
YES NO
IE
INSTALL SCAN TOOL. REFER TO CHART A-1.
1
YES NO
m H
• LOOSEN INJECTION LINE AT INJECTOR. REFER TO CHART A-2.
• CRANK ENGINE.
NO YES
I T T
DISCONNECT OPTICAUFUEL TEMP SENSOR. INJECTION SYSTEM OK, REFER
T
NO YES
© RECONNECT OPTICAUFUEL TEMP SENSOR.

FAULTY INJECTION PUMP.
WITH J 39200 CONNECTED TO GROUND, PROBE

HARNESS TERMINAL " A * .
CRANK ENGINE.
NO
© PROBE TERMINAL " B " AT FUEL SOLENOID

OR
LIGHT CONNECTED TO B • . FAULTY PCM CONNECTION
IS TEST LIGHT "ON"? OR
FAULTY PCM.
YES NO
m PROBE TERMINAL " C " AT FUEL SOLENOID OPEN CKT 950

FAULTY PCM.
YES NO
I
FAULTY INJECTION PUMP. OPEN CKT 339.
IF PCM IS FAULTY AND MUST BE REPLACED, "TDC OFFSET* MUST BE PROGRAMMED INTO THE NEW PCM.
tl-f-93
REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION. NS 15748
BLANK
CHART A-5
FOR MECHANICAL FUEL PUMP DIAGNOSIS, REFER TO SECTION 4 (FUEL SYSTEMS).
4-21-93
PS17S77
TO ECT, IAT AND PCM

CRANKSHAFT
POSITION SENSOR
EGR CONTROL 452 BLK/WHT PD6 SENSOR GROUND

PRESSURE/BARO EGR CONTROL
SENSOR — 433 GRY/BLK - PC5
— 416 GRY PC10 --AAAA 5 VOLT
EGR REFERENCE
VALVE
^ i
1
TO CRANKSHAFT
POSITION SENSOR
z ^1
— J
i
I
PCM CONN. ID
4
i
! PA/PB - PINK - 32 PIN |

J PC/PD - PINK - 24 PIN i TO EGR VENT
i BC/BD - BLUE - 32 PIN i SOLENOID 12-7-93
PS 17645

An EGR control pressure/BARO sensor is used to monitor the amount of vacuum in the EGR circuit. I t senses
reading.
Chart Test Description: Number(s) below refer to 3. Check vacuum hose to sensor for leaking or
\Y] Important
• Be sure to use the same diagnostic test equipment NOTICE: Make sure electrical connector remains
securely fastened.
for all measurements.
1. Checks sensor output voltage to the PCM. This 4. Disconnect sensor from bracket and twist sensor
voltage, without engine running, represents a by hand (only) to check for i n t e r m i t t e n t
barometer reading to the PCM. connection. Output changes greater that .1 volt
• When comparing Tech 1 scan readings to a indicates a bad connector or connection. I f OK,
known good vehicle, it is important to compare replace sensor.
page.
a faulty sensor.

OUTPUT CHECK
© •
•
IF ANY DTC(s) ARE STORED. REFER TO THOSE CHARTS FIRST.
• TECH 1 SCAN TOOL SHOULD DISPLAY A SENSOR VOLTAGE.
SEE FACING PAGE TEST DESCRIPTION. STEP 1.
VOLTAGE READING SHOULD BE WITHIN ± .4 VOLT.
IS IT?
1
YES NO
© •
•
DISCONNECT AND PLUG VACUUM SOURCE TO SENSOR.
REPLACE EGR
CONTROL
• START ENGINE. PRESSURE/BARO
• NOTE SENSOR VOLTAGE. SENSOR.
• APPLY 34 kPa (10" Hg) OF VACUUM AND NOTE VOLTAGE CHANGE.
SHOULD BE GREATER THAN 1.S VOLTS.
IS IT?
YES
© ©
H
NO TROUBLE FOUND. CHECK SENSOR VACUUM CHECK SENSOR CONNECTION.
SOURCE FOR LEAKAGE OR RESTRICTION. IF OK, REPLACE EGR CONTROL
R
m
o 0
c 8 A
N I
JL.039 XXXX J
IB—1 f
HOT-STAMPED
NUMBER
COLOR
KEYED INSERT
LS8963-6E LS9045-6E

10-28-93
TO
-••SERVICE
IGNITION 20A^ THROTTLE
SOON* LAMP
l/P HARNESS
- 39 PNK/BLK (10 PIN)
•OH/OFF*
- 397 GRY REQUEST SIGNAL
- 83 OK GRN RESUME/ACCELERATOR
REOUEST SIGNAL
- 84 DK BLU SET/COAST
REQUEST SIGNAL
l/P HARNESS
PCM CONN. ID
PA/PB PINK 32 PIN
i PC/PD PINK 24 PIN 11-2-93
i BC/BD BLUE 32 PIN
I NS 14322

The cruise on/off, set/coast and resume/accel signals are inputs to the fuel control portion of the PCM. These
inputs allow the PCM to control and hold a requested speed.
If cruise is inoperative, and no DTCs are stored, check for faulty cruise switch, wiring harness for opens or
faulty connections.
The cruise control switch on the clutch panel stuck i n the open position will cause a "No Cruise" complaint.
PCM
HIGH PRESSURE CUTOUT

A/C CONTROL SWITCH
SWITCH
TO - * - f T
IGNITION
SWITCH
#- 59 OK GRN
0 -59DKGRN-4 P B 4
A/C SIGNAL
B 59 DK GRN
A 150 BLK
i ,
A/C COMPRESSOR — I PCM CONN. ID l
CLUTCH I — 4
IPA/PB - PINK - 32 PIN >
JPC/PD - PINK - 24 PIN ,
12-7-93
i BC/BD - BLUE - 32 PIN i
PS 17631
A/C SIGNAL DIAGNOSIS

terminal TPB12" of the PCM to increase and maintain idle speed.
The PCM does not control the A/C compressor clutch. Therefore, i f A/C does not function, refer to the A/C
DIAGNOSIS:
2. If there are no obvious reasons for the excessive backpressure, the catalytic converter is suspected to be
1-9-93
SS3984

The MIL (Service Engine Soon) will be "ON" i f an emission malfunction exists. If the malfunction clears, the
w w
lamp will go OFF and the DTC will be stored in the PCM. Any DTCs stored will be cleared i f no problem
Important
All DTCs with the sign * are transmission related DTCs and have descriptions, diagnostic charts are in
SECTION 10A. Remember, always start with the lowest numerical engine DTC first. When diagnosing
some engine DTCs, other transmission symptoms can occur.
DTC 13 - Engine Shutoff Solenoid DTC 23 - Accelerator Pedal

DTC 14 - Engine Coolant •DTC 24 - Vehicle Speed Sensor 10A (4L60E)

Temperature (ECT) Sensor Circuit Circuit Low (Output Speed Signal)
Tow (High Temperature Indicated)
DTC 15 - Engine Coolant DTC 25 - Accelerator Pedal

Temperature (ECT) Sensor Position 2 Circuit High
Circuit High (Low Temperature
Indicated)
DTC 26 - Accelerator Pedal
DTC 16 - Vehicle Speed Sensor Position 2 Circuit Low
Buffer Fault
DTC 17 - High Resolution Circuit Position 2 Circuit Range Fault
Fault
•DTC 28 - Trans Range Pressure 10A (4L60E)
DTC 18 - Pump Cam Reference Switch Circuit
Pulse Error
DTC 29 - Glow Plug Relay Fault
DTC 19 - Crankshaft Position
Reference Error
DTC- Accelerator Pedal DTC 31-EGR Control
Position 1 Circuit High Pressure/Baro Sensor Circuit Low
(High Vacuum)
Position 1 Circuit Low DTC 32 - EGR Circuit Error
PS 17817

lamp will go "OFF* and the DTC will be stored in the PCM. Any DTCs stored will be cleared i f no problem
[ T | Important
• A l l DTCs with the sign * are transmission related DTCs and have descriptions, diagnostic charts are i n
SECTION 10A. Remember, always start with the lowest numerical engine DTC first. When diagnosing
DTC 33-EGR Control 3 DTC 46 - Malfunction Indicator 3

Pressure/Baro Sensor Circuit High Lamp Circuit Fault
DTC 34 - Iqjection Timing Stepper 3 DTC 47 - Intake Air Temperature 3

Motor Fault Sensor Circuit Low (High Temp
Indicated)
DTC 35 - Injection Pulse Width 3
Error (Response Time Short) DTC 48 - Intake Air Temperature 3
Sensor Circuit High (Low Temp
Indicated)
Error (Response Time Long)
DTC 49 - Service Throttle Soon 3
Lamp Circuit Fault
•DTC 37 - TCC Brake Switch Stuck
w w
10A(4L60E)
ON
DTC 51-PROM Error 3
•DTC 38 - TCC Brake Switch Stuck 10A(4L60E)

«OFF M
*DTC 52 - System Voltage High 10A(4L60E)
Long
DTC 41 - Brake Switch Circuit 3
Fault *DTC 53 - System Voltage High 10A(4L60E)
DTC 42 - Fuel Temperature Circuit 3 DTC 54 - PCM Fuel Circuit Error 3

Low (High Temp Indicated)
DTC 56 - Injection Pump 3
DTC 43 - Fuel Temperature Circuit 3 Calibration Resistor Error
High (Low Temp Indicated)
DTC 57 - PCM 5 Volt Shorted 3
DTC 44 - EGR Pulse Width Error 3
•DTC 58 - Trans Fluid Temp 10A(4L60E)
DTC 45 - EGR Vent Error 3 Circuit Low
•DTC 59 - Trans Fluid Temp 10A (4L60E)

Circuit High
12-14-93
PS 17818

Important
is
• All DTCs with the sign • are transmission related DTCs and have descriptions, diagnostic charts are in
SECTION 10A. Remember, alwavs start with the lowest numerical engine DTC first. When diagnosing
DTC NUMBER AND NAME | SECTION DTC NUMBER AND NAME SECTION
DTC 63 - Accelerator Pedal 3 • DTC 81 - 2-3 Shift Solenoid Circuit 10A(4L60E)

Position 3 Circuit High
DTC 64 - Accelerator Pedal 3 •DTC 82 -1-2 Shift Solenoid Circuit 10A (4L60E)
DTC 65 - Accelerator Pedal 3 DTC 88 - TDC Offset Error 3
Position 3 Circuit Range Fault
* DTC 66 - 3-2 Control Solenoid 10A(4L60E) DTC 91 - Cylinder Balance Fault 3
Circuit #lCyl
•DTC 67 - TCC Solenoid Circuit 10A (4L60E) DTC 92 - Cylinder Balance Fault 3
#2Cyl
• DTC 68 - Trans Component 10A (4L60E) DTC 93 - Cylinder Balance Fault 3
Slipping #3 Cyl
10A(4L60E) DTC 94 - Cylinder Balance Fault 3
• DTC 69 - TCC Stuck "ON" #4 Cyl
3 DTC 95 - Cylinder Balance Fault 3
DTC 71 - Set/Coast Switch Fault #5 Cyl
•DTC 72 - Vehicle Speed Sensor #6 Cyl
Circuit Loss (Output Speed Signal)
•DTC 73 - Pressure Control Solenoid #7 Cyl
Circuit
• DTC 75 - System Voltage Low #8 Cyl
3 DTC 99 - Accelerator Pedal 3
DTC 76 - Resume/Accel Switch Position 2 (5 Volt Reference
Fault Fault)
10A (4L60E)
• DTC 79 - Trans Fluid Overtemp
5-13-93
PS 17819
ENGINE HARNESS PCM

(15 PIN)
ENGINE SHUT-OFF
ENGINE SHUT-OFF SOLENOID SOLENOID CONTROL
— 981 BLU/WHT
— 339PNK
FPMP
TO IGNITION SWITCH
20 AMP
I PCM CONN. ID 1
* -———4
J PA/PS - PINK - 32 PIN ! TO
JPC/PD - PINK - 24 PIN J FUEL DRIVER
PS 17641
DTC 13
CIRCUIT FAULT
tt w
When the ignition switch is in the OFF position, the engine shutoff solenoid is in the *No Fuel" position. By
DTC 13 Will Set W h e n : Ignition voltage on CKT 981 when PCM is requesting engine shutoff solenoid m
ON. n
OR
No ignition voltage on CKT 981 when PCM is requesting engine shutoff solenoid "OFF."
Action T a k e n (PCM will default to): A current and history DTC 13 will set.
refer to circled number(s) on the diagnostic chart. cause a DTC 13. Also a no start condition will exist.
1. Check for open circuit from ignition switch to the The Tech 1 scan tool has the ability to turn the
w w
solenoid. engine shut off solenoid O N and "OFF" This can be
2. Check CKT 981 from solenoid to PCM for open. used as a quick operational check.
DTC 13
CIRCUIT FAULT
© •
•
IGNITION-OFF.-
• IGNITION "ON."
• PROBE ENGINE SHUTOFF HARNESS TERMINAL "B~ WITH
IS TEST L I G H T - O N " ?
1
NO
(T) • PRC
PROBE ENGINE SHUTOFF CHECK FOR OPEN OR SHORT TO
HARNESS TERMINAL "A" WITH GROUND IN CKT 339.
TEST LIGHT CONNECTED TO B + .
IS TEST L I G H T - O N - ?
YES NO
JLZ
OR OR
SHUTOFF SOLENOID.
IF PCM IS FAULTY AND MUST BE REPLACED, *TDC OFFSET* MUST BE PROGRAMMED INTO THE NEW PCM.
REFER TO "ON-VEHICLE SERVICE* IN THIS SECTION.
4-22-93
I
PCM
ENGINE
COOLANT
TEMPERATURE
(ECT) SENSOR
M TO E G R ^
410 YEL
TO T F T
ECT SIGNAL
CONTROL SENSOR
PRESSURE/BARO (A/T ONLY)
SENSOR
INTAKE AIR
TEMPERATURE
0 SENSOR GROUND
(IAT) SENSOR
tie 472 TAN - f PB12 IAT SIGNAL
i PCM CONN. ID i
TO CRANKSHAFT POSITION S E N S O R * - !• —'—: 4
[PA/PB - PINK - 3 2 PIN !
JPC/PD - PINK - 24 PIN J
i BC/BD - BLUE - 3 2 PIN I 12-7-13
PS 1 7 6 7 4
DTC 14
ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT LOW
DTC 14 Will Set W h e n : Engine coolant temperature greater than 151°C (304°F) for 2 seconds.
Action Taken (PCM will default t o ) : The PCM will use 77°C (171°F) as measured engine coolant temp.
1. This step determines i f DTC 14 is a hard failure or After engine is started, the coolant temperature
2. This test will determine i f CKT is shorted to The PCM default value w i l l flash on the data
ground. screen intermittently.
Refer to "Intermittents" in SECTION 2.
sensor. A "skewed" sensor could result i n poor
DTC 14
ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT LOW

TEMPERATURE OF 130X (266°F)OR HIGHER?
NO
T
ENGINE COOLANT TEMPERATURE TO 'DIAGNOSTIC AIDS" ON FACING PAGE.
BELOW -30°C (-22*F).
DOES IT?
YES NO

OR
OR
FAULTY PCM.
DIAGNOSTIC AID
(APPROXIMATE)
X •F OHMS
100 212 177
90 154 241
80 176 332
70 158 467
60 140 667 IF PCM IS FAULTY AND MUST BE REPLACED. "TDC
SO 122 973 OFFSET" MUST BE PROGRAMMED INTO THE NEW PCM.
45 113 1188 REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION.
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
•40 -40 100700
10-29-93

PGM
ENGINE
TEMPERATURE
(ECT) SENSOR TO EGR ^
CONTROL
PRESSURE/BARO
SENSOR

TEMPERATURE
(IAT) SENSOR IAT SIGNAL
i PCM CONN. ID i
TO CRANKSHAFT POSITION SENSOR** % 4
J PA/PB - PINK - 32 PIN f
PC/PD - PINK - 2 4 P I N !
i BC/BD - BLUE - 32 PIN i 12-7-03
PS17S74
DTC 15

Action T a k e n (PCM will default to): The PCM will use 18°C (64°F) as measured engine coolant temp and
increase idle speed.
1. This test determines if DTC 15 is a hard failure or ECT temperature should rise steady to about 85°C
2. This test will determine if CKT 410 is open or for a the data screen.
faulty PCM. The "Temperature to Resistance Value" scaled at
the right may be used to test the engine coolant sensor
"skewed" sensor could result i n poor driveability
complaints.
DTC 15
• DOES TECH 1 SCAN TOOL DISPLAY ECT OF «30*C (-22*F) OR LESS?
I YES NO
• DISCONNECT ECT SENSOR.

mDTC 15 IS INTERMITTENT. IF NO
• TECH 1 SCAN TOOL SHOULD DISPLAY 130°C (266*F) OR MORE. TO "DIAGNOSTIC AIDS" ON FACING PAGE.
DOES IT?
YES
T
© •
•
DOES IT?
1
YES NO
m HI
OPEN ECT SENSOR GROUND CIRCUIT. FAULTY OPEN CKT 410. FAULTY
CONNECTION OR FAULTY PCM. CONNECTION AT PCM. OR
FAULTY PCM.
DIAGNOSTIC AID
(APPROXIMATE)
X °F OHMS
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973 IF PCM IS FAULTY AND MUST BE REPLACED. "TDC OFFSET" MUST
45 113 1188 RE PROGRAMMED INTO THE NEW PCM.
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED. CLEAR DTC(s) AND VERIFY PROPER OPERATION.
822 LT GRNB
/ LK PCM
OUTPA
UNTDSPEED VSS INPUT | C7 H GROUND -•TO BRAKE SWITCH
VEHI
C
SENLE
SOSPEED
R GROUND J C8 p 150BLIC
(VSS) BRK TO IGNITION

IGNITION FEED I C9 h 350 PNKW / HT SWITCH
VMSSOD
BUU F
FER h 698 W HT ^
T O 10 AMP
LE ANTILOCK
C11
VSS INPUT I ^12 TRANSMISSION
i PCM CONN. ID i TRANS. OUTPUT I C13 h 437 BRN OUTPUT SPEED
PC15 SIGNAL
% 4
' PA/PB - PINK - 32 PIN * VSS OUTPUT [C14J- 817 DK GRNW / HT BD8 V EHICLE SPEED
SIGNAL
PCP
/D - PINK -24 PIN J VSS OUTPUT | C15 |- 824 LT BLUB / LK-•T—OSPEEDO
i BCB
/ D - BLUE - 32 PIN i 12-7-93
821 PPLW
/ HT — PS 17678
DTC 16
to the PCM. The 437 circuit relays the transmission output speed which is used to control shift points, line
pressure, TCC, DTC 24 and DTC 72. The 817 circuit relays the vehicle speed which is used to control engine
occur.

• Greater than 20 mph. • CKT 817 open or grounded.
• 1000 to 4400 RPM. • All conditions must be met for 2 seconds.
Action Taken (PCM Will default to): No cruise control or fuel cutoff.
DTC 16 Will Clear When: ft

The fault condition(s) no longer exist, and the ignition switch is cycled OFF w
then "ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: Check connections at VSS buffer
refer to circled number(s) on the diagnostic chart. and PCM. Refer to "4L60E Diagnostic Trouble Codes,"
1. This tests for B + at VSS buffer. SECTION 10 if DTC 24 or DTC 72 is also set.
2. This tests for proper ground path for vehicle speed
sensor signal buffer.
3. This tests for vehicle speed sensor signal buffer
signal to PCM.
4. This tests for a signal from VSS buffer to the PCM.
DTC 16
BUFFER FAULT
INSTALL TECH1.
RECORD, THEN CLEAR DTC($).
RAISE DRIVE WHEELS.
ENGINE OPERATING.
TRANSMISSION IN ANY DRIVE RANGE.
WITH DRIVE WHEELS ROTATING. DOES "VEHICLE SPEED"
YES
HZ
© •
•
TRANSMISSION IN PARK.
•DIAGNOSTIC AIDS."
CONNECTOR TERMINAL "C9" WITH A TEST LIGHT TO
GROUND.
IS TEST LIGHT "ON"?
NO
"1

CONNECTOR TERMINAL "C9" TO TERMINAL "C8"
WITH A TEST LIGHT.
IS TEST LIGHT "ON"?
YES NO

CONNECTOR TERMINAL "C7" TO TERMINAL
VSS BUFFER MODULE.
"C12" WITH J 39200 DVM ON A/C SCALE.
DOES VOLTAGE INCREASE ON J 39200 DVM.
YES NO
H
© • DOES TECH 1 DISPLAY TRANS OUTPUT SPEED

(MPH) INCREASE WITH DRIVE WHEEL SPEED
CHECK CKTs 821 OR 822 FOR OPEN
SHORT TO GROUND OR FAULTY
INCREASE? CONNECTIONS. IF OK. REPLACE VSS.
3L
YES NO
CHECK CKT 817 FOR OPEN. SHORT. OR FAULTY CHECK VSS BUFFER CONNECTIONS.
CONNECTIONS AT VSS SIGNAL BUFFER CONNECTOR IF OK. REPLACE VSS BUFFER.
AND PCM CONNECTOR. IF OK. REPLACE PCM.
IF PCM IS FAULTY AND MUST BE REPLACED. "TDC OFFSET" MUST BE PROGRAMMED INTO THE NEW PCM.
1-S-94
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED. CLEAR DTC(s) AND VERIFY PROPER OPERATION. PS 18974
ENGINE HARNESS
OPTICAL FUEL
TEMPERATURE SENSOR
SVOLT
- J W J E F E R E N C E
- 474 GRY N T - 474 GRY -o n
- 442 PNK
- 943 PPL
JL r - 982 PNK - CAM SIGNAL
H 983 PPL - HIGH RESOLUTION SIGNAL
• 987 WHT J - 987 WHT - SENSOR GROUND
• 1578 YEL r 1678 YEL -
*
ES3 ¥ff
BWLT
987 WHT
REFERENCE
FUEL
PCM CONN. ID TERMPERATURE
SIGNAL
J PA/PB PINK 32 PIN ,
J PC/PD PINK 24 PIN
[BC/BD BLUE 32 PIN J
NS 14321
DTC 17
The optical sensor provides a high resolution signal to the PCM by counting pulses on the sensor disk located
in the injection pump. The high resolution is one of the most important inputs by the PCM for fuel control and
timing.
DTC 17 Will Set W h e n : 8 cam reference pulses without and increase in high resolution counts (internal to
PCM).
DTC 17 Will Clear W h e n The fault condition(s) no longer exist, and the ignition switch is cycled "OFF"
w
then ON."
1. This step w i l l determine i f there is a 5 volt 18 is also stored, there is a possible problem with CKTs
reference. 474 or 987, It is possible DTC 17 may set i f there is air
2. This step checks the ground circuit. in the fuel system, refer to SECTION 4.
3. This step will check to see if the sensor is sending a
signal back to the PCM.
•
DTC 17
HIGH RESOLUTION
CIRCUIT FAULT
• IGNITION " O F F . "

• DISCONNECT OPTICAUFUEL TEMPERATURE SENSOR.
• IGNITION "ON.-
• PROBE TERMINAL "A" ON SENSOR HARNESS
CONNECTOR WITH J 39200 CONNECTED TO GROUND.
IS THERE 5 VOLTS?
NO
JLZ
© • WITH TEST LIGHT CONNECTED
TO B • , PROBE SENSOR
OR
FAULTY PCM.
YES NO
IT-
m
©i RECONNECT SENSOR.
OR
BACKPROBE PCM CONNECTOR TERMINAL "PD9" FAULTY CONNECTIONS
WITH 139200 CONNECTED TO GROUND. OR
CRANK ENGINE. FAULTY PCM.
YES NO
HZ T
OR OR
FAULTY PCM. FAULTY OPTICAUFUEL TEMPERATURE SENSOR
CONNECTION
OR
FAULTY OPTICAUFUEL TEMPERATURE SENSOR.
ENGINE HARNESS
CONNECTOR (IS PIN) PCM
OPTICAL FUEL
TEMPERATURE SENSOR
i 5 VOLT
-J^5?FiRENCl
474 GRY
442 PNK CAM SIGNAL
987 WHT SENSOR GROUND
T w Y f g VOLT
REFERENCE
—FUEL
f PCM CONN. ID 1 TERM PERATURE
SIGNAL
f PA/PB PINK 32 PIN . 1
J PC/PD PINK 24 PIN !

• BC/BD BLUE 32 PIN 11-4-93
!• mm mm mm* mm mm mm mm mm mi
NS 14321
DTC 18
The optical sensor also provides a pump cam signal to the PCM by counting pulses on the sensor disk located
in the injection pump. The pump cam reference signal is one of the most important inputs used by the PCM for
timing and start of injection.
DTC 1S Will Set W h e n : 8 cam reference pulses missed for every crankshaft position pulse.
DTC 18 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled OFF then
tt w
"ON."
refer to circled number(s) on the diagnostic chart. rough idle and poor performance problems will exist.
1. This step determines i f i t is the result of a hard If DTC 17 is stored, there is a possible problem with
failure or intermittent. CKTs 474 or 987.
4. This step checks to see i f the sensor is sending a
signal to the PCM and to check CKT 982 for an
open.
DTC 18
PUMP CAM REFERENCE
PULSE ERROR
© INSTALL SCAN TOOL.

PULSES MISSED?
1
NO
X
© •
•
IGNITION "OFF."
DISCONNECT OPTICAL/FUEL TEMPERATURE
• PROBE SENSOR HARNESS TERMINAL " A " WITH
J 39200 TO GROUND.
IS THERE 5 VOLTS?
3d NO
m
OR
FAULTY CONNECTIONS.
OR
FAULTY PCM.
1
YES NO
I
© •
•
RECONNECT SENSOR.
OR
BACKPROBE PCM TERMINAL "PD1S". FAULTY PCM.
I S T H E R E 6 0 H z ( ± 3 Hz)?
YES NO

OR OR
OR
FAULTY OPTICAUFUEL TEMPERATURE SENSOR.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. ps 16982
TO ECT AND
IAT _ENGINE HARNESS PCM
A CONNECTOR (15 PIN)

/ CRANKSHAFT
643 DK BLU/WHT - PD13 POSITION SIGNAL
452 BLK — PD6 SENSOR GROUND
E 416 GRY PC10 5V REFERENCE
TO TFT TO EGR CONTROL

PCM CONN. ID i SENSOR PRESSURE/BARO
. 4 SENSOR
i PA/PB - PINK - 32 PIN J
J P 0 P D - PINK - 24 PIN !
i BC/BD - BLUE - 32 PIN l
12-7-93
PS 17642
DTC 19
The crankshaft position sensor is a hall effect type sensor that monitors crankshaft position and speed. There
are four teeth 90° apart on the front of the crankshaft sprocket that induce a pulse in the sensor which is
DTC 1S Wi 11 Set W h e n : 8 crankshaft position pulses missed for every cam reference pulse.
DTC 1 9 WiII Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled "OFF then
n w
ON.
refer to circled number(s) on the diagnostic chart. idle and poor performance will exist.
1. This step will determine if DTC 19 is the result of a Check for good connection at crankshaft position
hard failure or an intermittent condition. sensor and at PCM.
DTC 19
CRANKSHAFT POSITION
REFERENCE ERROR
© •
•
3L
NO
X
© •
•
IGNITION "OFF."
IF NO ADDITIONAL DTC($) ARE STORED,
• IGNITION "ON," ENGINE "OFF." REFER TO "DIAGNOSTIC AIDS."
• PROBE SENSOR HARNESS TERMINAL " C * WITH
J 39200 TO GROUND.
IS THERE 5 VOLTS?
It 1
NO
X
OR
OR
FAULTY PCM.
I
J YES
1_
NO
X
© •
•
RECONNECT SENSOR.
OR
IS THERE 4 VOLTS?
YES NO
X
OR OR
OR
PCM
l/P J U M P E R
HARNESS
997 ORN — p - 997 LTBLU/BLK - BD2 SV REFERENCE

APP1 > i u 992 DK BLU
P 9 9 2 LT BLU PC4 APP 1 SIGNAL
SENSOR v^nAr— 9 9 8 BRN — — 998 BRN - PD4 SENSOR GROUND
A
ACCELERATOR
996 GRY - 9 9 6 PPL SV REFERENCE
PEDAL D PB7
POSITION
(APP) SENSOR V^-W 993 WHT - 993 LT BLU APP 2 SIGNAL
C PC3
MODULE
999 YEL — — 9 9 9 PPL PD3 SENSOR GROUND
S
995PNK — 995 YEUBLK SV REFERENCE

E PD11
APP 3 S IAN
9 9 4 PPL — — 994GRN PB10 APP 3 SIGNAL
J K
SENSOR ^* vr— 961 T A N — 961 R E D
PD5
SENSOR GROUND
J
I JLJLJLJLJL l i
I
P C M C O N N . ID
—
! P A / P B - P I N K - 3 2 PIN
J P C / P D - P I N K - 2 4 PIN
i B C / B D - B L U E - 3 2 PIN
APP M O D U L E CONNECTOR
12-7-93
PS 17643
DTC 21
Soon* lamp will light and the PCM will limit power. If three APP sensors have a malfunction present, the
"ON."
1. This step determines i f DTC 21 is the result of a Scan APP 1 sensor while depressing accelerator
3. This will check for an open in ground CKT 998. closed to about 3.7 volts when throttle is held at Wide
in volts. Should read about .45 to .95 volt with throttle 992 is shorted to voltage.
closed and ignition "ON" or at idle. Voltage should Refer to "Intermittent" in SECTION 2.
DTC 21
CIRCUIT HIGH
© IGNITION " O N * ENGINE " O F F . "

#

1
NO
X
© •
•
APP 1 VOLTAGE OP .25V OR STORED, REFER TO "DIAGNOSTIC
©
I •
•
APP MODULE DISCONNECTED.
PROBE APP 1 HARNESS
TERMINAL " A * WITH TEST
1
NO
X
OR
FAULTY PCM.
LIGHT CONNECTED TO B • .
• TEST LIGHT SHOULD LIGHT.
1
TEST LIGHT " O N -
TEST LIGHT "OFF"
I I
OR OR
4-18-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. N S 15525
3-52 DRIVEABILITY AN DEMISSIONS (DIESEL)
PCM
l/P J U M P E R
HARNESS
•
G 997 ORN — - 997 LT BLU/BLK - BD2 SV REFERENCE
1
APP > A k K
— 992 DK BLU -
SENSOR S ^ - W ^ — P 992 LT BLU PC4 APP 1 SIGNAL
A 998 BRN — 998 BRN - PD4 SENSOR GROUND

ACCELERATOR
PEDAL 998 G R Y — 996PPL - SV REFERENCE
D
POSITION APP 2 > AkK
(APP) SENSOR 993 WHT 993 LT BLU APP 2 SIGNAL
C
MODULE
B 999 YEL - — 999 PPL H PD3 SENSOR GROUND
995 PNK - 99SYEL/BLK - PD11 SV REFERENCE
S k i\
E
APP 3 a APP 3 SIGNAL
994 PPL " — 994 GRN -
<-*-Vr—
K
SENSOR SENSOR GROUND
961 T A N - 961 RED -
J
A B C D E i PCM C O N N . ID i
* --,|
K J H G F |PA/PB - P I N K - 32PIN «
PC/PD - P I N K - 24 PIN i
. B C / B D - B L U E - 32 P I N i
12-7-93
PS 1 7 6 4 3
DTC 22
will set but i t will not turn "ON" the "Service Throttle Soon" lamp. The throttle will operate normally as long as
there is only one sensor malfunctioning. I f two different APP sensors have a malfunction, the "Service Throttle
"ON."
DTC Chart Test Description: Number(s) below closed and ignition "ON" or at idle. Voltage should
refer to circled number(s) on the diagnostic chart. increase at a steady rate as throttle is moved toward
1. This step determines i f DTC 22 is the result of a Wide Open Throttle (WOT).
hard failure or an intermittent condition. Also, 90% pedal travel is acceptable for correct
2. This step checks the PCM and wiring. APP operation.
3. This step will determine i f there is a faulty Scan APP 1 sensor while depressing accelerator
connection or sensor. pedal with engine stopped and ignition "ON." Display
4. This step will check the ground circuit. should vary from about .74 volt when throttle is closed
Diagnostic Aids: A scan tool reads APP 1 position Throttle (WOT) position.
in volts. Should read about .45 to .95 volt with throttle A DTC 22 will result if circuit is open.
DTC 22
CIRCUIT LOW
© THROTTLE CLOSED.
OF .25V OR L E S S ?
YES NO
© •
•
SCAN TOOL SHOULD DISPLAY APP 1 VOLTAGE REFER TO "DIAGNOSTIC AIDS."
GREATER THAN 4.0V.
DOES IT?
NO YES
© PROBE CKT 992 WITH A TEST LIGHT

CONNECTED TO B +.
© • POOR CONNECTION OR FAULTY
APP SENSOR.
GREATER THAN 4.0V.
DOES IT?
NO
YES

CKT 997 OPEN OR SHORTED TO GROUND OR
OR FAULTY PCM CONNECTION
FAULTY CONNECTION OR
OR FAULTY PCM.
FAULTY PCM.
-
IF PCM IS FAULTY AND MUST BE REPLACED. "TDC O F F S E T MUST BE PROGRAMMED INTO THE NEW PCM.
PCM
W JUMPER
HARNESS
G
\ 997 LT BLU/BLK - SV REFERENCE
997 ORN — BD2
APP1 > — 992 DK BLU
A k K
F 992 LT BLU PC4 APP 1 SIGNAL
SENSOR s-^Vr— 998 BRN — 998 BRN - PD4 SENSOR GROUND
A
ACCELERATOR
PEDAL 996 GRY " — 996 PPL - 5V REFERENCE
D
POSITION APP 2 > A k K
(APP) C 993 WHT - 993 LT BLU - APP 2 SIGNAL

MODULE SENSOR ^ H A T —
999 YEL — — 999 PPL - PD3 SENSORGROUND
B
995 PNK — 995 YEUBLK - PD11 SV REFERENCE
E
APP 3 > A k K APP 3 SIGNAL
994 PPL — — 994 GRN -
SENSOR ^ n / T — K
9St TAN — 961 RED - SENSOR GROUND
J
A B C D E i PCM CONN. ID i
K J H G F I 4
« PA/P8 - PINK • 32 PIN |
\?O?0 - PINK - 24 PIN !
APP MODULE CONNECTOR

12-7-93
PS 17643
DTC 23
DTC 23 Will Set W h e n : PCM has recognized a ""skewed" (mis-scaled) sensor. The PCM compares all three
APP 3.
will set but it will not turn "ON" the "Service Throttle Soon" lamp. Throttle will operate normally as long as
w w
there is only one malfunction present. If there are two APP malfunctions present, the PCM will turn O N the
w
lamp will be ON" and only allow the engine to operate at idle.
w
"ON.
DTC Chart Test Description: Number(s) below closed and ignition "ON* or at Idle. Voltage should
refer to circled number(s) on the diagnostic chart. increase at a steady rate as throttle is moved toward
1. This step determines i f there is a good 5 volt Wide Open Throttle (WOT).
reference. Also, 90% pedal travel is acceptable for correct
2. This* step will check for an open in the ground APP operation.
circuit. Scan APP 1 sensor while depressing accelerator
tt w
pedal with engine stopped and ignition ON. Display
Diagnostic Aids: A scan tool reads APP 1 position should vary from about .74 volt when throttle was
in volts. Should read about .45 to .95 volt with throttle closed to about 3.7 volts when throttle is held at Wide
DTC 23
CIRCUIT RANGE FAULT
© •
•
IGNITION "ON," ENGINE " O F F *
• WITH J 39200 CONNECT TO GROUND. PROBE
HARNESS TERMINALS "G"» "D" AND " E * .
IS THERE 5.0 VOLTS ( t .2) ON EACH QRCUIT?
1
NO

B • , PROBE HARNESS TERMINALS
CKT($) 997,99S OR 995 OPEN
OR
" A " , " B " AND " J " . SHORTED TO GROUND
1
YES NO
JLZ X
OR 998.999,961
APP MODULE. OR
OR
FAULTY PCM.
IF PCM IS FAULTY AND MUST BE REPLACED. 'TDC OFFSET" MUST BE PROGRAMMED INTO THE NEW PCM.
REFER TO 'ON-VEHICLE SERVICE" IN THIS SECTION.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION JI"\T*|F,
NS 15527
PCM
l/P JUMPER
HARNESS
•
u t f 7 ORN — - 997 LT BLU/BLK BD2 5V REFERENCE
P P
A 1 > AkK - 992 DK BLU •
992 LT BLU PC4 APP 1 SIGNAL
SENSOR V * ^ — F
ACCELERATOR
PEDAL 996 GRY — 996 PPL 5V REFERENCE
D PB7
POSITION
(APP) SENSOR ^ " W 1
C 993 WHT - 993 LT BLU APP 2 SIGNAL
PC3
MODULE
999 YEL — — 999 PPL PD3 SENSOR GROUND
B
995 PNK — 995 YEUBLK SV REFERENCE
E PD11
A P P 3
> AkK 994 GRN APP 3 SIGNAL
994 PPL —
SENSOR S"*"V\T K
961 TAN — 961 RED SENSOR GROUND
J
i PCM CONN. ID i
I JL JL JL JL I „ 4
! PA/PB - PINK - 32 PIN J
JPC/PD - PINK - 24 PIN J

12-7-93
PS 17643
DTC 25
"ON."
1. This step determines if DTC 25 is a hard failure or Refer to SECTION 2 for "Intermittents."
2. This will check for an open in ground CKT 999. pedal with engine stopped and ignition "ON." Display
Diagnostic Aids: A Tech l scan tool reads APP 2 Open Throttle (WOT) position.
toward WOT.
DTC 25
© •
•
IGNITION "ON." ENGINE " O F F . "
1
NO
X
© •
•
PROBE APP 2 HARNESS
TERMINAL * B " WITH TEST LIGHT STORED, REFER TO "DIAGNOSTIC
CONNECTED TO B • . AIDS" ON FACING PAGE.
IS TEST LIGHT "ON"?
JL
NO
X
CKT 999 OPEN
OR
FAULTY PCM.
1
YES NO
X
OR OR
OR
FAULTY PCM.
PCM
l/P JUMPER
HARNESS
G
I 997 LT BLU/BLK
997 ORN — BD2 SV R E F E R E N C E
APP1 > A k K
— 992 DK BLU
F 992 LT BLU PC4 APP 1 SIGNAL
SENSOR S ^ V V ^ —
ACCELERATOR
996 GRY — 996 PPL - SV REFERENCE
PEDAL D PB7
POSITION APP 2 > A K K
(APP) C 993 WHT 993 LT BLU - APP 2 SIGNAL

pa
MODULE SENSOR ^-Vr—
B
999 YEL - 999 PPL - PQ3 SENSOR GROUND
995PNK - 9 9 5 YEUBLK - 5V REFERENCE

E PD11
A W
*3 > A A K 994 PPL - — 994 GRN - APP 3 SIGNAL
SENSOR <^-W K PB10
961 T A N - 961 RED SENSOR G R O U N D

PD5
J
A B C D E f P C M C O N N . ID I
K J H G F
L 4
• P A / P B - P I N K - 3 2 PIN •
J P C / P D - P I N K - 2 4 PIN J
i B C / B D - B L U E - 3 2 PIN i
12-7-93
PS 1 7 6 4 3
DTC 26
DTC 26 Will Set W h e n : Voltage is less than .25 volt for 2.seconds on APP 1 sensor.
Action Taken (PCM will default to): The input from the sensor is ignored. A current and history DTC
"ON."
DTC Chart Test Description: Number(s) below An open or short to ground in CKT 996 or 993 will
refer to circled number(s) on the diagnostic chart. result in a DTC 26.
1. This step determines i f DTC 26 is the result of a Refer to SECTION 2 for "Intermittents."
hard failure or an intermittent condition. Scan APP 2 sensor while depressing accelerator
2. This step checks the PCM and wiring. pedal with engine stopped and ignition "ON." Display
3. This will check the PCM and CKT 993. should vary from about 4.5 volts when throttle was
Diagnostic Aids: A Tech l scan tool reads APP 2 Open Throttle (WOT) position.
toward WOT.
DTC 26
©[ DOES SCAN TOOL DISPLAY APP 2 LESS THAN .25 VOLTS?
1
NO
J L
© •
•
IS THERE 5 VOLTS ( 1 2 V)?
NO
J L

PROBE HARNESS TERMINAL " C " .
OR
IS THERE 5 VOLTS ( ± J V ) ? FAULTY PCM CONNECTION
OR
FAULTY PCM.
1
YES NO
X
OR OR
OR
FAULTY PCM.
IF PCM IS FAULTY AND MUST BE REPLACED, ' T D C OFFSET" MUST BE PROGRAMMED INTO THE NEW PCM.
REFER TO *ON-VEHICLE SERVICE* IN THIS SECTION.
PCM
l/P JUMPER
HARNESS
•
997 ORN — 997 LT BLU/BLK - BD2 5V R E F E R E N C E
APP1 992 DK BLU -
SENSOR 992 LT BLU PC4 APP 1 SIGNAL
998 BRN — 998 BRN - PD4 SENSOR GROUND

ACCELERATOR
PEDAL 996 GRY - 996 PPL - SV REFERENCE
PB7
POSITION APP 2
(APP) SENSOR 993 WHT - 993 LT BLU APP 2 SIGNAL
pa"
MODULE
999 YEL — — 999 PPL - PD3 SENSOR GROUND
995PNIC — 995YEL/BLK - PD11 SV REFERENCE

APP 3 APP 3 SIGNAL
SENSOR 994 PPL — 994 GRN - PB10
961TAN — 961 RED - SENSOR GROUND

PD5
|. ... 4
K J H G F ! PA/PB - PINK - 32 PIN |
JPOPD - PINK - 24 PIN J
APP M O D U L E C O N N E C T O R
12-7-93
PS 17643
DTC 27
APP 2 and a 10% difference to APP 3.
f,
will set but i t will not turn ON" the "Service Throttle Soon" lamp. Throttle will operate normally as long as
there is only one malfunction present. If there are two APP malfunctions present, the PCM will then turn "ON"
the "Service Throttle Soon" lamp and limit power. If a third APP malfunction is present, the "Service Throttle
Soon" lamp will be "ON" and will only allow the engine to operate at idle.
DTC 27 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled "OFF then M
"ON.*
DTC Chart Test Description: Number(s) below should decrease at a steady rate as throttle is moved
refer to circled number(s) on the diagnostic chart. toward WOT.
1. This step determines i f there is a good 5 volt Also, 90% pedal travel is acceptable for correct
reference. APP operation.
2. This step will check for an open in the ground Refer to SECTION 2 for "Intermittents."
circuits. Scan APP 2 sensor while depressing accelerator
position in volts and should read about 4.5 volts with closed to about 1.5 volts when throttle is held at Wide
DTC 27
CIRCUIT RANGE FAULT

o DISCONNECT APP MODULE.
WITH J 39200 CONNECT TO GROUND, PROBE
HARNESS TERMINALS " G " . " D " AND " E " .
IS THERE S.0 VOLTS ( t .2) ON EACH CIRCUIT?
1 WITH TEST LIGHT CONNECTED TO

1
NO
CKT(s) 997,996 OR 995 OPEN

B 4 - . PROBE HARNESS TERMINALS OR
YES NO
T JL
OR 998.999,961
APP MODULE. OR
OR
FAULTY PCM.
REFER TO 'ON-VEHICLE SERVICE" IN THIS SECTION.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED. CLEAR DTC(s) AND VERIFY PROPER OPERATION. NS 1SS27
BULKHEAD TO FUEL HEATER

CONNECTOR PCM
^ - T O WATER IN
FUEL SENSOR
TO IGNITION GAGES
SWITCH TO GENERATOR
20 AMP ANDEGR
JUNCTION 1
CONTROL
39 PNK/BLK— SOLENOIDS , —
BLOCK
50SYEL— GLOW PLUG RELAY
B+ < » * CONTROL
150 BLK TO
WINDSHIELD
r WASHER
PUMP MOTOR
LEFT
GLOW
PLUGS
503 ORN
503 ORN
507 DK BLU GLOW PLUG SIGNAL
509 ORN/BLK
i PCM CONN. ID
I.—.
! PA/PB - PINK - 32 PIN RIGHT -=5r
GLOW —
PC/PD - PINK - 24 PIN PLUGS
i BC/BD - BLUE - 32 PIN
12-7-93
PS 17644
DTC 29
engine operation. The PCM controls the glow plugs by sending a B + signal.
OR
• Glow plugs "OFF" and "glow plug volts" is greater that .8 volt.
OR
Action Taken (PCM will default to): Hard start.
DTC Chart Test Description: Number(s) below 4. This step will check relay ground.
refer to circled number(s) on the diagnostic chart. 5. This step will determine if CKT 505 is open.
1. This step will determine i f DTC 29 is a hard 6. This step will check relay and wiring.
a
failure. Diagnostic Aids: I f glow plug relay was stuck in

2. The Tech 1 scan tool may not display system the "ON" position, check for proper operation of glow
voltage. The important thing is that the PCM is plugs, refer to SECTION 7. When glow plugs are
cycling voltage "ON" and "OFF" indicating that commanded "ON" by the Tech 1, an internal PCM
the PCM is OK. timer protects the glow plugs from damage by cycling
3. This step will check relay feed circuit. them "ON" for 3 seconds and the "OFF" for 12 seconds.
DTC 29
GLOW PLUG RELAY
CIRCUIT FAULT
© •
•
• DOES "GLOW PLUG VOLTS" DISPLAY B +
NO YES
© •
•
OTHER DTCs ARE STORED.
VOLTAGE CYCLING "ON" AND "OFF"? REFER TO "DIAGNOSTIC AIDS."
YES NO
© •
•
OR
PCM.
• WITH TEST LIGHT CONNECTED TO GROUND. PROBE
GLOW PLUG RELAY HARNESS TERMINAL " A " .
IS TEST LIGHT "ON"?
•E
YES NO
© • CONNECT TEST LIGHT BETWEEN GLOW PLUG HARNESS TERMINALS " A " AND " C "
IS TEST LIGHT "ON"?
OPEN CKT 39.
•E
YES NO
—r~
© •
•
WITH TEST LIGHT CONNECTED TO GROUND. PROBE HARNESS TERMINAL " B "
OPEN CKT 1 SO.

IS TEST LIGHT "ON"?
YES NO
"" • "
© •
•
WITH TEST LIGHT CONNECTED TO GROUND. PROBE GLOW PLUG SIDE OF RELAY.
OPEN CKT 505
OR
PCM.
3L
YES NO

OR OR
OR OR
12-2-93
TO ECT. IAT AND PCM

CRANKSHAFT
POSITION SENSOR
A
EGR CONTROL — 452 BLK/WHT PD6 SENSOR GROUND

SENSOR PCS
PC 10 - ^ V W — 5 VOLT
EGR REFERENCE
VALVE
TO CRANKSHAFT
POSITION SENSOR
Z3 ' PA/PB - PINK - 32 PIN

| PC/PD - PINK - 24 PIN
i BOBD - BLUE 32 PIN TO EGR VENT
SOLENOID 12-7-S3
PS 17645
DTC 31
(HIGH VACUUM)
A MAP sensor is used to monitor the amount of vacuum i n the EGR circuit. I t senses the actual vacuum i n
the EGR vacuum line and sends a signal back to the PCM. This signal is used to control EGR duty cycle
calculated by the PCM.
DTC 31 Will Set W h e n : EGR pressure is less than 15 kPa for 2 seconds.
Action Taken (PCM will default to): The PCM will shut down the EGR system.
DTC 31 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled "OFF* the
"ON."
refer to circled number(s) on the diagnostic chart. engine stopped, the EGR pressure is equal to
an intermittent condition. high. The information is used by the PCM as an
important thing is that the PCM recognized the result i n a DTC 31.
DTC 31
(HIGH VACUUM)
* IF DTC 57 IS ALSO STORED. REFER TO THAT CHART FIRST.
DOES TECH 1 DISPLAY EGR PRESSURE VOLTAGE BELOW 1.0 VOLT?
1
YES NO
H
© •
•
IGNITION "OFF."
DTC 31 IS INTERMITTENT. IF NO ADDITIONAL
DTCs WERE STORED, REFER TO "DIAGNOSTIC
• JUMPER HARNESS TERMINALS " B " TO " C " . AIDS."
• IGNITION "ON."
• EGR PRESSURE VOLTAGE SHOULD READ OVER
4.0 VOLTS.
DOES ITT
I NO YES
I E
© IGNITION "OFF."
REMOVE JUMPER WIRE.
FAULTY CONNECTION
OR
PROBE TERMINAL " B " WITH A TEST SENSOR.
IGNITION "ON."
TECH 1 SHOULD READ EGR
PRESSURE OVER 4 VOLTS.
DOES IT?
!L
YES NO
ZE
CKT 416 OPEN CKT 433 OPEN
OR OR
OR
OR
FAULTY PCM.
11-15-S3
PCM
TO ECT, IAT AND CRANKSHAFT
POSITION SENSORS
TO
VACUUM PD6 SENSORGROUND
PUMP EGR CONTROL 452 BLK
PRESSURE/BARO PCS MAP SIGNAL
432 LT GRN
SENSOR
416 GRY PC10 5V REFERENCE
§71 WHT EGR VENT

CONTROL
435 GRY EGR CONTROL

, PA/PB - PINK - 32 PIN
i PC/PD - PINK - 24PIN
I BC/BD . BLUE - 32 PIN
12-7-93
i. ... PS 17646
DTC 32
EGR CIRCUIT ERROR
corrections i n the duty cycle accordingly. If there is a difference in the PCM command and what is at the EGR
valved sensed by the EGR control pressure/BARO sensor, the PCM makes minor adjustments to correct.
DTC 32 Will Set When:

• No DTC 31 or 33 stored.
• 50 kPa difference between desired EGR and EGR pressure for 25.5 seconds.
w
ON."
1. This step determines i f DTC 32 is a hard failure or lines and components connected to the hoses for leaks
an intermittent. or sharp bends. Check vacuum source to EGR
2. This step checks vacuum at EGR vent solenoid. solenoid. Also check for small leak in EGR valve.
3. This step checks the EGR valve.
DTC 32
EGR CIRCUIT ERROR
9| IMPORTANT:
THE PCM WILL SHUT DOWN THE EGR SYSTEM IN 15 SECONDS. TO PROPERLY DIAGNOSIS
EGR SYSTEM, IGNITION SHOULD BE CYCLED " O N " AND "OFF" BEFORE EACH PROCEDURE.
© •
•
INSTALL VACUUM GAGE IN PLACE OF EGR VALVE.
START ENGINE.
• AT IDLE, OBSERVE VACUUM
IS IT?
1
YES NO
3 Z T
©
• DISCONNECT EGR VENT SOLENOID
CHECK VACUUM SOURCE
ELECTRICAL CONNECTOR.
AT SOLENOID ASSEMBLY.
• OBSERVE VACUUM GAGE AT IDLE.
• THERE SHOULD BE NO VACUUM.
ABOUT 50 kPa BELOW 50 kPa

VACUUM PRESENT NO VACUUM (15-) VACUUM. {15") VACUUM.
REPLACE EGR
VENT © •
•
KEY " O F F . "
INSTALL VACUUM PUMP
ON EGR VALVE.
CHECK FOR
PLUGGED
CHECK FOR PLUGGED
OR LEAKY VACUUM
HOSE TO THE VACUUM
SOLENOID. OR LEAKY VACUUM
• PUMP UP TO 50 kPa (15") VACUUM HOSES. PUMP. IF OK, CHECK
AND OBSERVE EGR VALVE FOR IF OK, REFER TO VACUUM PUMP OUTPUT
MOVEMENT. •DIAGNOSTIC AIDS" AND REPAIR.
ON FACING PAGE.
NO EGR EGR VALVE

MOVEMENT. MOVES.
1 1
REPLACE EGR NO TROUBLE FOUND;
VALVE. SEE DIAGNOSTIC AIDS.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. mUM?
TO ECT, IAT AND PCM

CRANKSHAFT
POSITION SENSOR
EGR CONTROL A I— 452 BLK/WHT PD6 SENSOR GROUND

SENSOR 433 GRY/BLK - PCS
PC10 - V W
J S
5 VOLT
EGR REFERENCE
VALVE
TO CRANKSHAFT
POSITION SENSOR
Z=5
] PA/PB - PINK - 3 2 PIN
| PC/PD - PINK - 2 4 PIN
i BC/BD - BLUE - 32 PIN TO EGR VENT
SOLENOID 12-7-93
PS 17645
DTC 33
(LOW VACUUM)
A EGR control pressure/BARO sensor is used to monitor the amount of vacuum i n the EGR circuit. It senses
the actual vacuum in the EGR vacuum line and sends a signal back to the PCM. This signal is used to control
EGR duty cycle calculated by the PCM.

• EGR vent "OFF."
• Desired EGR is less than or equal to 60 kpa.
• EGR pressure is greater than 101 kpa.
Action Taken (PCM will default to): PCM will shut "OFF" EGR system.
"ON."
PCM recognizes the change, the PCM and CKT 433 is shorted to voltage or to CKT 416.
engine stopped, the manifold pressure is equal to securly fastened.
high. This information is used by the PCM as an • Refer to "EGR Control Pressure/BARO Sensor
DTC 33
(LOW VACUUM)
© •
•
INSTALL SCAN TOOL.
ENGINE IDLING.
• DOES SCAN TOOL DISPLAY EGR PRESSURE
NO
© •
•
IGNITION "OFF."
DOES IT?
YES NO
JEZ HZ
PROBE SENSOR HARNESS TERMINAL CKT 433 SHORTED TO VOLTAGE
OR
FAULTY PCM.
YES NO
JEZ
PLUGGED OR LEAKING SENSOR VACUUM HOSE OPEN CKT 452.
OR
FAULTY BARO SENSOR.
4-21-93
ENGINE HARNESS
CONNECTOR (15 PIN)
PCM
564 TAN/BLK B 564 TAN/BLK PA9 ITS COIL 1 LOW
INJECTION I
TIMING 50$ RED/BLK D 565 RED/BLK PAS ITS COIL 1 HIGH
STEPPER I
(ITS) 566 ORN/BLK E 566 ORN/BLK PA10 ITS COIL 2 LOW
MOTOR I
567 YEUBLK C 567 Y E U B L K PA11 ITS COIL 2 HIGH
[ PCM CONN. ID ]

PC/PO PINK 24 PIN
[BC/BD BLUE 32 PIN J
NS 14055
DTC 34

• Engine operating at steady RPM.
• A 5° difference between measured and desired injection timing for 20.8 seconds.
refer to circled number(s) on the diagnostic chart. performance condition might exist. Also measure
1. This step determines i f DTC 34 is a hard failure or injection timing will freeze at the point of the fault.
an intermittent.
and 565.
and 567.
sending a pulsing voltage. This will indicate that
DTC 34
© •
•
• SCAN INJECTION TIMING AT IDLE AND AT 1500 RPM.
TOES SCAN TOOL DISPLAY A 5° DIFFERENCE BETWEEN
MEASURED INJECTION TIMING AND DESIRED INJECTION
TIMING AT IDLE OR AT 1500 RPM?
1
YES NO
m
© •
•
IGNITION "OFF."
DISCONNECT PCM.
• MEASURE RESISTANCE BETWEEN PCM HARNESS TERMINAL REFER TO "DIAGNOSTIC AIDS."
"PA8" AND "PA9".
TOES RESISTANCE MEASURE BETWEEN 10 AND 60 OHMS?
1
YES NO
3Z m
"PA11"AND"PA10".
CHECK FOR OPEN IN CKT 565/564
OR
TOES RESISTANCE MEASURE BETWEEN 10 AND 60 OHMS? FAULTY STEPPER MOTOR.
YES NO
T
© •
•
RECONNECT PCM.
DISCONNECT INJECTION TIMING STEPPER MOTOR.
OR
• START AND IDLE ENGINE. FAULTY STEPPER MOTOR.
• USING TECH 1, COMMAND "TDC TIME S E T " "ON."
• WITH J 39200 CONNECTED TO GROUND CHECK FOR A
PULSING VOLTAGE ON TERMINALS " A " , " B " , " C " . "D"
DOES VOLTAGE PULSE ON ALL CIRCUITS?
1
YES NO
FAULTY INJECTION PUMP. CHECK FOR A GROUNDED

CIRCUIT
OR
FAULTY CONNECTION
OR
FAULTY PCM.
TO ENGINE PCM
SHUT-OFF
i -i
M BC14 FUEL INJECT CONTROL
U£- §84 LT GRN -4f T BD13 FUEL INJECT CONTROL
—X 985 RED }• ~ f 985 RED
PC2 FUEL INJECT SIGNAL
FUEL L 4 - 3 3 9 P N K - I - }
SOLENOID
DRIVER
- O — T & M CLOSURE GROUND
950 GRY/BLK
ENGINE
HARNESS 339 PNK
CONNECTOR
(8 PIN)
FPMP
TO-
IGNITION 20 AMP
SWITCH
BULKHEAD
r 1 CONNECTOR
FUEL i PCM CONN. ID i
SOLENOID * 4
I PA/PB - PINK - 32 PIN |
! PC/PD - PINK - 24 PIN !
i BC/BD - BLUE - 32 PIN t 12-7-93
PS 17547
DTC 35
output to the fuel solenoid that controls injection. I t also returns an injection pulse width signal back to the PCM
seconds

• Engine coolant temperature greater that 20°C (68°F).
• Injection pulse width less that 1.2 milliseconds.
Action Taken (PCM will default to): Fixed injection pulse width value of 1.95 milliseconds.
*ON."
DTC 35
© ENGINE AT OPERATING TEMPERATURE.

DOES SCAN TOOL DISPLAY I N J E C T I O N
P U L S E WIDTH OF 1.95 MS?
YES NO
i
• D O E S INJECTION PULSE WIDTH F L U C T U A T E ? REFER TO 'DIAGNOSTIC AIDS" ON
FACING PAGE.
YES NO
I i
OR OR
OR
FAULTY PCM.
REFER TO " O N - V E H I C L E SERVICE" IN THIS SECTION.
12-2-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND V E R I F Y PROPER OPERATION. NS15532
TO ENGINE PCM
SHUT-OFF
BC14 FUEL INJECT CONTROL

984 LT GRN 4 BD13 FUEL INJECT CONTROL
985 RED 985 RED - PC2 FUEL INJECT SIGNAL
FUEL 339 PNK
SOLENOID
DRIVER
— 950 GRY/BLK CLOSUREGROUND
ENGINE
HARNESS 339 PNK
CONNECTOR
(8 PIN)
TO-*
IGNITION 20 AMP
SWITCH
BULKHEAD
r n CONNECTOR
FUEL i PCM CONN. ID 1
SOLENOID ^ - -I
•PA/PB - PINK - 3 2 P I N •
JPC/PD - PINK - 2 4 PIN J
1 BC/BD - BLUE - 32 PIN 1
12-7-93
PS 17647
DTC 36
to inform it when the fuel solenoid has actually seated. This injection pulse width signal is measured in micro
seconds.

Action Taken (PCM Will default to): Fixed injection pulse width value of 1.95 milliseconds.
DTC 36 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled OFF" ft
then ÔN."
DTC Chart Test Description: Number(s) below Diagnostic Aids: The injection pulse width w i l l
refer to circled number(s) on the diagnostic chart. fluctuate when throttle is depressed.
1. This step determines i f DTC 36 is a hard failure or A weak (mechanical failure) fuel solenoid will
2, This step sill determine if the solenoid is at fault,
DTC 36
© •
•
ENGINE IDLING.
NO
i
• DOES INJECTION PULSE WIDTH FLUCTUATE? REFER TO "DIAGNOSTIC AIDS* ON
FACING PAGE.
1
YES NO
i
OR OR
OR
FAULTY PCM.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. P ^ l 6758
STOP-HZ PCM
• TO TURN
SIGNAL SWITCH
20 AMP
l/P JUMPER
HARNESS
STOP -140 ORN
LAMP N.O.N* -820 Y E L — CRUISE CONTROL
SWITCH BRAKE SWITCH SIGNAL
-350PNK/WHT
N.C
-420 PPL TCC BRAKE SWITCH SIGNAL
BULKHEAD
CONNECTOR
TO ANTILOCK
BRK
TO
IGNITION
SWITCH 10 AMP
- ^ T O ANTILOCK
TO V S S - * -
BUFFER
MODULE
1 PCM CONN. ID
I —
J PA/PB - PINK - 32 PIN
! PC/PD - PINK - 24 PIN
I BC/BD - BLUE - 32 PIN
12-7-93
PS 17648
DTC 4.1
The TCC normally closed brake switch supplies a B 4- signal on CKT 420 to the PCM. The signal voltage is
opened when the brakes are applied.
The stop lamp/cruise control normally open brake switch supplies a B + signal on CKT 820 to the PCM when

OR
• TCC and cruise control brake switches not toggling "open" and "closed," during 6 brake applications on
same ignition cycle.
Action Taken (PCM Will default to): An incorrect brake signal can affect TCC, fourth gear operation, in
hot mode and cruise control.
DTC 41 Will Clear When: The fault condition(s) no longer exist.

?t
refer to circled number(s) on the diagnostic chart. • Refer to PCM Intermittent Diagnostic
switch.
being applied.
DTC 41
• INSTALL SCAN TOOL.
• APPLY BRAKES.
DOES SCAN TOOL DISPLAY C/C BRAKE SWITCH "CLOSED"
NO YES
X
• DOES SCAN TOOL DISPLAY TCC BRAKE SWITCH "OPEN"
© •
•

PROBE HARNESS TERMINAL " A " .
NO NO YES
I X JL
© JUMPER HARNESS
TERMINALS " A " AND
OPEN IN CKT 140 CHECK FUSE.
I
" B " TOGETHER.
SCAN TOOL SHOULD
DISPLAY C/C BRAKE
© •
•
STORED, REFER TO
FACING PAGE.
• WITH TEST LIGHT CONNECTED
SWITCH "CLOSED."
DOES IT?
TERMINALS".
IS TEST LIGHT "ON"?
1
NO YES NO
X X X
OPEN CKT 820 FAULTY (T) • jut*
JUMPER HARNESS OPEN IN CKT 439
OR CONNECTION AT TERMINALS " C * AND
FAULTY PCM CONNECTION STOP LAMP " D " TOGETHER.
OR SWITCH SCAN TOOL SHOULD
FAULTY PCM OR DISPLAY TCC BRAKE
FAULTY STOP SWITCH "CLOSED."
LAMP SWITCH. DOES IT?
NO YES
I X
OPEN CKT 420 FAULTY CONNECTION
OR AT BRAKE SWITCH
OR BRAKE SWITCH
FAULTY PCM
REFER TO "ON-VEHICLE SERVICE* IN THIS SECTION.
4-21-93
E N G I N E HARNESS
OPTICAL FUEL
TEMPERATURE SENSOR
5 VOLT
p ^ J E P
- 474 GRY 474 GRY 4
- 442 PNK - 982 PNK I CAM SIGNAL
• 943 PPL 983 PPL HIGH RESOLUTION SIGNAL
987 WHT 987 WHT SENSOR GROUND
1578 YEL {- 1578 YEL
v
987 WHT **5VOLT

REFERENCE
-FUEL
|" PCM CONN. ID 1 TERMPERATURE
SIGNAL
J PC/PD PINK 24 PIN
[ B C / B D BLUE 3 2 PIN J
NS 14321
DTC 42
Action T a k e n (PCM Will default to): Poor idle quality during hot conditions.
1. This step determines if DTC 42 is a hard failure or started, the fuel temperature should rise steadily.
2. This test will determine if CKT 1578 is shorted to 987 will result in a DTC 43.
ground. The "Temperature To Resistance Value" scale at
DTC 42

1
YES NO
i
© DISCONNECT SENSOR.
FUEL TEMPERATURE BELOW -26°C (-15°F). TO "DIAGNOSTIC AIDS" ON FACING PAGE.
DOES IT?
YES NO
T
FAULTY OPTICAUFUEL TEMPERATURE SENSOR. CKT 1578 SHORTED TO GROUND
OR
OR
FAULTY PCM.
DIAGNOSTIC AID IF PCM IS FAULTY AND MUST BE REPLACED, "TDC

OFFSET* MUST BE PROGRAMMED INTO THE NEW
FUEL TEMPERATURE SENSOR PCM. REFER TO "ON-VEHICLE SERVICE" IN THIS
SECTION.
(APPROXIMATE)
°C °F OHMS
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
•10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
11-15-93
ENGINE HARNESS
CONNECTOR (15 PIN)
PCM
OPTICAL FUEL
TEMPERATURE SENSOR
I 5 VOLT
^JPIEFERENCE
CAM SIGNAL

SENSOR GROUND
y v
* 5 VVOLT
OI
REFERENCE
-FUEL
| PCM CONN. ID | TERMPERATURE
SIGNAL
f PA/PB PINK 32 PIN "|
PC/PD PINK 24 PIN
NS 14321
DTC 43

• Fuel temperature less than - 14°C (6°F).
Action Taken (PCM Will default to): Poor idle quality during hot conditions.
2. This test simulates a DTC 42. I f the PCM 987 will result in a DTC 43.
recognizes the low signal voltage (high temp), the The Temperature To Resistance Value" scale at
PCM and wiring are OK, the right may be used to test the fuel sensor at various
3. This test will determine i f CKT 1578 is open. temperature levels to evaluate the possibility of a
There should be 5 volts at sensor connector i f "skewed" (mis-scaled) sensor.
measured with J 39200-DVM. This will determine
if there is a wiring problem or a faulty PCM.
DTC 43
• DOES TECH 1 SCAN TOOL DISPLAY FUEL TEMP OF -14°C (6°F) OR LESS?
YES NO
© •
•
DISCONNECT SENSOR.
JUMPER HARNESS TERMINALS " E " AND " F " TOGETHER.
ADDITIONAL DTCs WERE STORED. REFER
• TECH 1 SCAN TOOL SHOULD DISPLAY 107°C (244°F) OR MORE. TO 'DIAGNOSTIC AIDS" ON FACING PAGE.
DOES IT?
YES
© JUMPER CKT 1578 TO GROUND.

FAULTY CONNECTION
OR OPTICAL/FUEL
DOES IT? TEMPERATURE SENSOR.
YES NO
m
OPEN SENSOR GROUND CIRCUIT, FAULTY OPEN CKT 1578, FAULTY
FAULTY PCM.
DIAGNOSTIC AID
(APPROXIMATE)
°c °F OHMS
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
5-7-93
PCM
POSITION SENSORS
TO
VACUUM
PUMP EGR CONTROL
PRESSURE/BARO
SENSOR
EGR CONTROL
12-7-93
PS 17S46
DTC 44
During normal operation, the PCM compares its EGR duty cycle signal with the EGR control pressure/BARO
signal and makes corrections in the duty cycle accordingly. I f there is a difference in the PCM command and
what is at the EGR valve sensed by the EGR control pressure/BARO, the PCM makes minor adjustments to
correct.
DTC 44 Will Set W h e n : Ignition voltage on CKT 435 when PCM is requesting EGR solenoid "ON."
OR
No ignition voltage on CKT 435 when PCM is requesting EGR solenoid "OFF."
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: An open in CKTs 439 or 435 will
refer to circled number(s) on the diagnostic chart. cause a DTC 44 to set.
an intermittent.
2. This step checks to see if PCM and wiring are OK.
3. This step checks voltage at the EGR solenoid.
DTC 44
© •
•
1
• COMMAND EGR SOLENOID "ON" AND "OFF.
SOLENOID COMMAND?
YES
T
© •
•
DISCONNECT EGR SOLENOID.
CONNECT TEST UGHT BETWEEN
• IGNITION " O N / ENGINE "OFF."
NO YES

FAULTY CONNECTIONS
OR
NO YES
X J L
OR
FAULTY CONNECTIONS
OR
FAULTY PCM.
PCM
POSITION SENSORS
TO
VACUUM PD6
m m 452 BLK SENSORGROUND
EGR CONTROL
PRESSURE/BARO 432 LT GRN PCS MAP SIGNAL
SENSOR
41S GRY PC10 5V REFERENCE
EGR
SOLENOID
A 971 WHT EGR VENT

CONTROL
1 B
J_ PCM CONN. ID j
i PA/PB - PINK - 32 PIN j 435 GRY EGR CONTROL
i PC/PD - PINK - 24P1N i
i BC/BD . BLUE - 32PIN i
u . . . . . I 12-7-93
PS 17646
DTC 45
EGR VENT ERROR
When the PCM recognizes the operating range for no EGR, the PCM energizes the EGR vent solenoid which
allows rapid venting of EGR vacuum. This solenoid is normally open.
DTC 45 Will Set W h e n : Ignition voltage on CKT 971 when PCM is requesting EGR vent "ON."
OR
No ignition voltage on CKT 971 when PCM is requesting EGR vent "OFF."
Action Taken (PCM Will default to): The PCM will shut "OFF" EGR system.
"ON."
refer to circled number(s) on the diagnostic chart. cause DTC 45.
2. This step checks the PCM and wiring.
3. This step checks power and control circuit.
DTC 45
EGR VENT ERROR
© •
•
• COMMAND EGR VENT "ON" AND "OFF."
VENT COMMAND?
NO YES
I
© •
•
DISCONNECT EGR VENT.
HARNESS CONNECTOR TERMINALS.
REFER TO "DIAGNOSTIC AIDS."
IS TEST LIGHT "ON"?
NO YES
JLZ
© • PROBE HARNESS TERMINAL " A " WITH
FAULTY CONNECTIONS
OR
IS TEST LIGHT "ON"?
NO YES
I E I
OR
FAULTY CONNECTIONS
OR
FAULTY PCM.
12-1-93
BULK HEAD PCM

MIL CONNECTOR
39 PNK/BLK M
"SERVICE
ENGINE
419 BRN/WHT
MIL "SERVICE
ENGINE SOON'
CONTROL
1
SOON**
i/P JUMPER
HARNESS
GAGES
TO • 39 PNK/BLK 960 ORN "SERVICE
1
IGNITION 20AMP •SERVICE THROTTLE S O O N
SWITCH THROTTLE LAMP CONTROL
SOON** LAMP PCM CONN. ID t
% --4
TO | PA/PB - PINK - 32 PIN !
CRUISE CONTROL -24 PIN J
SWITCH j PC/PD - PINK 32 PIN
i BC/BD - BLUE 12-7-93
k— —— — — — ——— — — —— — J PS 17679
DTC 46
ff
MIL "SERVICE ENGINE SOON CIRCUIT FAULT
There should always be a MIL "Service Engine Soon" when the ignition is "ON" and the engine stopped. The
PCM will control the MIL and turn i t "ON" by providing a ground path.
DTC 46 Will Set W h e n : Ignition voltage on CKT 419 when PCM is requesting MIL "ON."
OR
No ignition voltage on CKT 419 when PCM is requesting MIL "OFF."
Action Taken (PCM will default to): No MIL.
command the MIL.
DTC 46
© •
•
INSTALL TICH 1 SCAN TOOL.
IGNITION "ON,* ENGINE "OFF.
MIL "ON."
DOES MIL COME "ON"?
X
YES
© IGNITION "OFF."
IGNITION "ON." FACING PAGE.
CONNECT TEST LIGHT TO PCM
HARNESS TERMINAL "BC5" TO
GROUND.
DOES MIL COME "ON"?
CHECK:
- FUSE.
- FAULTY BULB.
- OPEN CKT 419.
12-16-93

f PCM
ENGINE
TEMPERATURE
(ECT) SENSOR TO EGR ^
CONTROL
PRESSURE/BARO
SENSOR

TEMPERATURE
i PCM CONN. ID i
TO CRANKSHAFT POSITION S E N S O R S U • 4
J PA/PB - PINK - 32 PIN j
JPC/PD - PINK - 2 4 PIN I
i BC/BD - BLUE - 32 PIN i 12-7-93
PS 17674
DTC 47

• Engine coolant less than 38°C(100°F).
Action Taken (PCM W i l l default to): Poor performance during cold weather operation.

1. This step determines i f DTC 47 is a hard failure or Tech 1 scan tool displays intake air temperature in
an intermittent condition. degree centigrade. A faulty connection or an open in
2. This test will determine i f CKT 472 is shorted to CKTs 452 and 472 will result in a DTC 47.
ground. Refer to "Intermittents" in SECTION 2.
sensor. A "skewed" sensor could result i n poor
DTC 47
* IF DTC 57 IS ALSO STORED. REFER TO THAT CHART FIRST.
© DOES TECH 1 SCAN TOOL DISPLAY IAT OF 96°C (205°F) OR HIGHER?
1
YES NO
X H
LESS THAN -26°C (-15°F). AIDS" ON FACING PAGE.
DOES IT?
YES NO
JEZ IE
OR
DIAGNOSTIC AID OR FAULTY PCM.

(APPROXIMATE)
°C °F OHMS
100 212 177

90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. Ns"l4cSo

PCM
ENGINE
COOLANT
TEMPERATURE
rBr 410 YEL ECT SIGNAL
(ECT) SENSOR TO E G R * *
TO TFT
CONTROL SENSOR
PRESSURE/BARO (A/TONLY)
SENSOR

j - \ f o y y - i
TEMPERATURE
(IAT) SENSOR 472 TAN IAT SIGNAL
'ME
PCM CONN. ID
TO CRANKSHAFT POSITION S E N S O R S
! PA/PB - PINK - 32 PIN
j PC/PD - PINK - 24 PIN
i BC/BD - BLUE - 32 PIN 12-7-93
PS17S74
DTC 48
The intake air temperature sensor is a thermistor that controls signal voltage to the PCM. When the air is,
DTC 48 Will Set W h e n : Intake air temperature less than -38°C (-39°F) for 2 minutes.
Action Taken (PCM will default to); Possible poor performance during cold weather operation.
1. This step determines i f DTC 48 is a hard failure or Tech 1 scan tool displays intake air temperature in
an intermittent condition. degrees centigrade. A faulty connection or an open in
2. This test will determine if circuit 472 is shorted to CKTs 472 and 452 will result in a DTC 14.
3. This step will determine i f there is a wiring The 'Temperature to Resistance Value" scale at
problem or a faulty PCM. the right may be used to test the engine coolant sensor
complaints.
DTC 48
© • DOES TECH 1 SCAN TOOL DISPLAY IAT -38°C (-39?F) OR COLDER?
YES NO
H Z ZE
© •
•
DISCONNECT SENSOR.
TOGETHER. STORED. REFER TO "DIAGNOSTIC
• TECH 1 SCAN TOOL SHOULD AIDS" ON FACING PAGE.
130°C(266°F).
DOES IT?
YES NO
m
© •
•
130°C(266*F).
DOES IT?
DIAGNOSTIC AID

31 X
°C °F OHMS
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
IF PCM IS FAULTY AND MUST 8E REPLACED, "TDC OFFSET" MUST BE PROGRAMMED INTO THE NEW PCM.
4-23-93
BULKHEAD PCM
MIL CONNECTOR
39 PNK/BLK M
"SERVICE
419 BRN/WHT
MIL "SERVICE
ENGINE SOON"
CONTROL
ENGINE
SOON"
l/P JUMPER
HARNESS
GAGES
TO • 39 PNK/BLK 960 ORN "SERVICE
IGNITION 20AMP "SERVICE THROTTLE S O O N '
SWITCH THROTTLE LAMP CONTROL
SOON" LAMP PCM CONN. ID
1 — . ...— 4
TO J PA/PB - PINK - 32 PIN \
CRUISE CONTROL | PGPD - PINK - 2 4 PIN J
SWITCH iBC/BD - B L U E - 3 2 P I N i
L . . . . . . . . . . . . . . mm mm 4
12-7-93
PS 17679
DTC 49
tf
There should be a "Service Throttle Soon" lamp when the ignition is "ON" and the engine OFF" for 2
seconds. The PCM will control the "Service Throttle Soon" and turn i t "ON" by providing a ground path.
DTC 49 Will Set W h e n : Ignition voltage on CKT 960 when PCM is requesting "Service Throttle Soon" lamp
"ON."
OR
No ignition voltage on CKT 960 when PCM is requesting "Service Throttle Soon" lamp "OFF."
Action T a k e n (PCM Will default to): DTC 49 will not turn "ON" the MIL, but will set a current and history
DTC.
DTC 49
SERVICE THROTTLE SOON" LAMP CIRCUIT FAULT
© •
•
INSTALL SCAN TOOL.
IGNITION "ON", ENGINE " O F F " .
DOES "SERVICE THROTTLE S O O N -
COME ON?
©
1
•
•
•
IGNITION "OFF."
DISCONNECT24 PIN (PINK) PCM CONNECTOR.
IGNITION "ON."
YES
m
REFER TO "DIAGNOSTIC AIDS."
PROBE PCM HARNESS TERMINAL "PA5".
CHECK:
- FUSE.
FAULTY BULB.
- OPEN CIRCUIT.
- CKT 9S0 SHORTED TO VOLTAGE.
OPEN IGNITION FEED TO BULB.
11-1-93
DTC 51
PROM ERROR
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. NSMTM
DTC 54
* CHECK TO SEE IF A DTC 17 IS ALSO STORED, IF THERE IS REFER TO THAT
CHART FIRST, IF NOT. REPLACE PCM.
10-27-93
PS 20090
TO ENGINE
SHUT-OFF
PCM
FUEL INJECT C O N T R O L
FUEL INJECT C O N T R O L
FUEL INJECT SIGNAL

FUEL
SOLENOID
DRIVER
CLOSURE GROUND
BULKHEAD
R „ „ . — . CONNECTOR
FUEL i PCM C O N N . ID i
SOLENOID ^ — • • • — -4
! P A / P B - PINK - 3 2 PIN '
| P C / P D - PINK - 2 4 PIN J
i B C / B D - B L U E - 3 2 PIN i
12-7-93
PS17S47
DTC 56
INJECTION PUMP CALIBRATION RESISTOR ERROR
DTC 56 Will Set When: PCM has lost its memory and is unable to read a resistor value on CKT 960 on the
next ignition cycle. Possible poor performance problem.
"ON."
refer to circled number(s) on the diagnostic chart. driver. Clear DTC, and cycle ignition. If DTC clears,
1. This step will determine i f DTC 56 is a hard treat condition as an intermittent.
failure.
DTC 56
RESISTOR ERROR
© ARE THERE ANY OTHER ENGINE D T C s STORED?
YES NO

CONNECTION
OR
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. _ f "J:|f *
P5 io75o
ENGINE HARNESS PCM

C O N N E C T O R (15 P I N )
OPTICAL F U E L
TEMPERATURE SENSOR
. 1 . SVOLT
A 474 QRY • 474 QRY - PD10 W REFERENCE
B 442 P N K ' 982 PNK H PD15 | C A M S I G N A L
C 943 P P L • 883 PPL — PD9 HIGH R E S O L U T I O N SIGNAL

§87 W H T • 987 W H T - P014 SENSOR GROUND
F YEL'
F
1578
887 W H T
f-H-ln • 1578 Y E L — PB11
^ 5 VOLT
REFERENCE
I V— «.J
FUEL
TEMPERATURE
TFT TO BOOST T O E C T , IAT A N D SIGNAL
(A/TONLY) (TURBO ONLY) POSITION S E N S O R
ii
SENSOR GROUND
EGR CONTROL
EGR CONTROL
PRESSURE/BARO
SENSOR
W 5 VOLT
REFERENCE
T O CRANKSHAFT
POSITION S E N S O R
P A / P B PINK 3 2 PIN
TO BOOST
• P C / P D PINK 2 4 PIN . TO E G R VENT
SENSOR
1 1
B C / B D B L U E 3 2 PIN SOLENOID
(TURBO ONLY)
PS 20236
DTC 57
PCM 5 VOLT SHORTED
Action Taken (PCM will default to): Backup fuel, no EGR and no turbo boost.
et
ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: During the time the failure is
refer to circled number(s) on the diagnostic chart. present, the setting of additional DTCs that share a 5
1. Checks to confirm that a DTC is still present. volt reference may also set.
2. Checks to determine i f there is a 5 volt reference
from the PCM.
3. Checks to determine i f there is a short-to-ground
in CKT 416 or CKT 474, or a short-to-ground in
the PCM.
DTC 57
PCM 5 VOLT SHORTED
0 •
•
INSTALL SCAN TOOL.
IGNITION • O N . " ENGINE "OFF."
• RECORD AND CLEAR DTCs.
• CRANK ENGINE FOR 15 SECONDS OR START UP.
DOES DTC 57 RESET?
YES NO
© •
•
DISCONNECT EGR CONTROL PRESSURE/BARO SENSOR.
REFER TO "DIAGNOSTIC AIDS.'
NO
© •
•
DISCONNECT PCM 32 PIN PINK CONNECTOR ONLY.
REPLACE EGR CONTROL
• WITH TEST LIGHT CONNECTED TO B * , PROBE PCM
TERMINALS "PC10" AND "PD10".
IS TEST LIGHT "ON," IN EITHER CIRCUIT?
NO YES

IN CKT 416 OR 474.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. JJ
PCM
l/P JUMPER
HARNESS
•
G 997 ORN — 997 LT BLU/BLK - BD2 5V REFERENCE
APP1 > A/kK — 992 DK BLU APP 1 SIGNAL
F 992 LT BLU PC4
SENSOR s^vr— 998 BRN — 998 BRN PD4 SENSOR GROUND
A
ACCELERATOR
PEDAL 996 GRY — 996 PPL H 5V REFERENCE
D PB7
POSITION APP 2 > A A N
(APP) 993 WHT - 993 LT BLU - APP 2 SIGNAL

MODULE SENSOR ^MAr— C
999 YEL — — 999 PPL -
PO"
SENSOR GROUND
B PD3
995 PNK — 995 YEUBLK— 5V REFERENCE

E PD11
APP3
S AA K 994 PPL — — 994 G R N - PB10
APP 3 SIGNAL
SENSOR — K
961 TAN - — 961 RED -
SENSOR GROUND
J PD5
i — „ ~ 4
K J H 13 F | PA/PB - PINK - 32 PIN |
| PC/PD - PINK - 24 PIN j

12-7-93
PS 17643
DTC 63
"ON."
1. This step will determine i f DTC 63 is the result of a closed and ignition "ON" or at idle. Voltage should
3. This will check for an open in ground CKT 994. Also, 90% pedal travel is acceptable for correct
APP operation.
DTC 63
CIRCUIT HIGH
(7) • IGNITION "ON." ENGINE "OFF."

• DOES SCAN TOOL DISPLAY APP 3
YES NO
IE m
© •
•
WITH TEST LIGHT CONNECTED TO B 4-. TO "DIAGNOSTIC AIDS" ON FACING PAGE.
IS TEST LIGHT "ON"?
3L
YES NO
m
CKT 961 OPEN
OR
FAULTY PCM.
3L
YES NO
T T
FAULTY APP CONNECTION OPEN CKT 994 OR SHORTED
OR OR
OR
FAULTY PCM.
4-23-93
m 1
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. 5537
PCM
l/P JUMPER
HARNESS
•
IS 997 ORN — • 997 LT BLU/BLK - | BD2 5V REFERENCE
APP 1 > AkK - 992 DK BLU
F 992 L T BLU PC4 APP 1 SIGNAL
SENSOR S^Vr— 998 B R N —• 998 BRN PD4 SENSOR GROUND
A
ACCELERATOR
PEDAL 996 GRY - 996 PPL 5V REFERENCE
D
POSITION APP 2 > AkK
(APP) C 993 WHT - 993 LT BLU APP 2 SIGNAL
MODULE SENSOR ^*^fr— 999 Y E L — — 999 PPL SENSOR GROUND
B PD3
995 P N K '*— 995 YEUBLK 5V REFERENCE

PD11
S
E
APP 3 AkK
994 GRN APP 3 SIGNAL
994 P P L —
SENSOR K
961 TAN - 961 RED SENSORGROUND
J
A B C D E i PCM CONN. ID I
I- . „ — -— . -4
K J H G F ' PA/PB - PINK - 32 PIN |
I PC/PD - PINK - 24 PIN j
l BC/BD - BLUE - 32 PIN i

12-7-93
P S 17643
DTC 64
"ON."
1. This step will determine i f DTC 64 is the result of a Scan APP 3 sensor while depressing accelerator
3. This will check the PCM and CKT 994. closed to about 2.0 volts when throttle is held at Wide
in volts. Should read about 4.0 volts with throttle 994 is shorted to ground.
closed and ignition "ON" or at idle. Voltage should Refer to "Intermittents " in SECTION 2.
DTC 64
CIRCUIT LOW
DOES SCAN TOOL DISPLAY APP 3 LESS THAN .25 VOLTS?
1
YES NO
JL
© •
•
WERE STORED REFER TO •DIAGNOSTIC AIDS'*
IS THERE 5 VOLTS (JL-2V)?
NO

PROBE HARNESS TERMINAL " K " .
OR
IS THERE 5 VOLTS ( t .2 V)? FAULTY PCM CONNECTION
OR
FAULTY PCM.
1
YES NO
X
OR OR
OR
FAULTY PCM.
4-23-93 .
P S 1 7 5 0 8
PCM
l/P JUMPER
HARNESS
G 997 ORN — 997 LT BLU/BLK BD2 5V REFERENCE

APP1 — 992 DK BLU -
SENSOR F 992 LT BLU pa APP 1 SIGNAL
998 BRN — 998 BRN - PD4 SENSOR GROUND

A
ACCELERATOR
PEDAL 996 GRY — 996 PPL 5V REFERENCE
D
POSITION APP 2
(APP) SENSOR C 993 WHT 993 LT BLU APP 2 SIGNAL
MODULE
999 YEL - — 999 PPL PD3 SENSOR GROUND
B
995 PNK - — - 995 YEUBLK 5V REFERENCE
E PD11
APP 3 APP 3 SIGNAL
SENSOR 994 PPL - 994GRN
K
961 TAN 961 RED SENSOR GROUND
J
A B C D E i PCM CONN. ID
K J H G F
i — — . — -
! PA/PB - PINK - 3 2 PIN
| PC/PD - PINK - 2 4 PIN
i BC/BD - BLUE - 3 2 PIN

12-7-93
PS 17643
DTC 65
will set but i t will not turn "ON" a "Service Throttle Soon" lamp. Throttle will operate normally as long as there
is only one malfunction present. If there are two APP malfunctions present the PCM will then turn "ON" the
"ON."
1. This step determines i f there is a good 5 volt Scan APP 3 sensor while depressing accelerator
2. This step will check the ground circuit. should vary from about 4.0 volts when throttle was
Diagnostic Aids: A scan tool reads APP 3 position Open Throttle (WOT) position.
in volts. Should read about 4.0 volts with throttle
DTC 65
CIRCUIT RANGE FAULT
© •
•
IGNITION "ON," ENGINE " O F F . "
HARNESS TERMINALS " G " , "0" AND " E " .
1
NO
z i z _ X

B • , PROBE HARNESS TERMINALS
CKT(s) 997, 996 OR 995 OPEN
OR
"A", " B " AND * J " . SHORTED TO GROUND
1
YES NO
JLZ
OR 998,999,961
APP MODULE. OR
OR
FAULTY PCM.
IF PCM IS FAULTY AND MUST BE REPLACED, ' T D C OFFSET" MUST BE PROGRAMMED INTO THE NEW PCM.
4-16-93
3-1 Oft DRIVEABILITY AND EMISSIONS (DIESEL)
TO GAGES
PCM
IGNITIONS- -^Nji 1
SWITCH 20 AMP J
39 PNK/BLK
CRUISE
A CRUISE "ON/OFF-
CONTROL
SWITCH 1^1 397 GRY - — 397 GRY H BD3 REQUEST SIGNAL
w W 1
RESUME/
... 84 DK BLU 83 DK GRN H 8 P 1 1
ACCELERATE
REQUEST SIGNAL
83 DK GRN • 84 DK BLU H B D 1 5 SET/COAST
REQUEST SIGNAL
i PCM CONN. ID i
^ . . „ . 4
J PA/PB - PINK - 32 PIN J
PC/PD - PINK - 24 PIN J
l BC/BD - BLUE - 32 PIN i 12-7-93
PS1767S
DTC 71
PCM when set/coast is depressed.

affected.
"ON."
1. This step determines if the cruise control switch is
OK.
fault.
DTC 71
© •
•
NOTE TEST LIGHT.
3
I 1
© WITH PROBE STILL CONNECTED, ENGAGE AND RELEASE

SET/COAST SWITCH.
OR
DOES TEST LIGHT COME "ON" AND GO "OFF" WHEN FAULTY CRUISE SWITCH.
1
NO YES
JL
OR
FAULTY PCM.
NS 15540
TO GAGES
PCM
IGNITION < •X^-
SWITCH 20 AMP
39 PNK/BLK
CRUISE
CONTROL CRUISE "ON/OFF"
SWITCH 397 GRY - — 397 GRY - 4 8 P 3 REQUEST SIGNAL
RESUME/
84 DK BLU 83DKGRN H B P 1 1
ACCELERATE
REQUEST SIGNAL
83 DK GRN • 84 DK BLU H B D 1 5 SET/COAST
REQUEST SIGNAL
i PCM CONN. ID i
l . . . . 4
• PA/PB - PINK - 32 PIN |
PC/PD - PINK - 24 PIN J
i BC/BD - BLUE - 32 PIN i 12-7-93
PS 17675
DTC 76
PCM.

• Cruise control ÔN."
W
• Ignition voltage on terminal BD1V for more than 25.5 seconds.
Action T a k e n (PCM Will default to): The PCM will disallow all cruise inputs. TCC shift schedules may be
affected.
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: Check for a resume/accel switch
refer to circled number(s) on the diagnostic chart. stuck in the engage position, or CKT 83 shorted to
1. This step determines i f CKT 83 is shorted to voltage.
voltage.
fault.
DTC 76
© •
•
IGNITION ' O N / * ENGINE "OFF."
HARNESS WITH A TEST LIGHT CONNECTED TO
GROUND.
NOTE TEST LIGHT.
TEST LIGHT-OFF" TEST LIGHT "ON*

I
© • WITH PROBE STILL CONNECTED, ENGAGE AND

OR
DOES TEST LIGHT COME "ON" AND GO "OFF" FAULTY CRUISE SWITCH.
WHEN RESUME/ACCEL SWITCH IS RELEASED?
NO YES
= c n z
OR
FAULTY PCM.
NS 15858
PCM
l/P JUMPER
HARNESS
•
G 997 ORN — 997 LT BLU/BLK BD2 5V REFERENCE
APP 1 — 992 DK BLU -
SENSOR F 992 LT BLU PC4 APP 1 SIGNAL
A 998 BRN — 998 BRN - PD4 SENSORGROUND

ACCELERATOR
PEDAL 996 GRY — 996 PPL - 5V REFERENCE
D PB7
POSITION APP 2
(APP) SENSOR C 993 WHT - 993 LT BLU APP 2 SIGNAL
PC3
MODULE
999 YEL — — 999 PPL - PD3 SENSORGROUND
B
995 PNK — 995YEL/BLK " f r a i l 5V REFERENCE
E
APP 3 APP 3 SIGNAL
SENSOR 994 PPL — 994 GRN PB10
K
961 TAN — 961 RED H PD5 SENSORGROUND
J
l 4
K J H G F I PA/PB - PINK - 3 2 PIN "
J pc/PD - PINK - 24 PIN J
l BC/BD - BLUE - 32 PIN i

12-7-93
PS 17643
DTC 84
faults stored.
Action Taken (PCM Will default to): When DTC 84 is set, a current and history DTC will set, but will not
"ON."
refer to circled number(s) on the diagnostic chart. APP module, PCM and I/P connector.
DTC 84
CIRCUIT FAULT
CHECK COMPLETE APP HARNESS POR INTERMITTENT SHORTS OR OPENS.

IF OK, REPLACE APP MODULE.
IF DTC RESETS. REPLACE PCM.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. P s 16757
DTC 88
TDC OFFSET ERROR
DTC 88
TDC OFFSET ERROR
• THIS DTC WILL SET IF TDC OFFSET IS GREATER THAN * 2M°, OR THE PCM HAS LOST MEMORY (TDC
3-17-93
DTC 91

CYLINDER # 7 .

DELIVERY FAILURES. (LOW COMPRESSION. FAULTY
NOZZLE, FUEL LEAK. RESTRICTED HIGH PRESSURE LINE, ETC..)
DTC 92

CYLINDER # 2 .

DTC 93

CYLINDER # 6 .

11-3-93
PS 1S7SS
DTC 94

CYLINDER # 5 .

DTC 95

CYLINDER # 4 .

NOZZLE, FUEL LEAK, RESTRICTED HIGH PRESSURE LINE, E T C . . )
DTC 96

CYLINDER # 3 .
* CHECK : FOR BASIC ENGINE MECHANICAL OR CYLINDER FUEL

DTC 97

DELIVERY PROBLEM WITH CYLINDER #1.

FUEL LEAK, RESTRICTED HIGH PRESSURE LINE, ETC.).
DTC 98

DELIVERY PROBLEM WITH CYLINDER #8.

FUEL LEAK, RESTRICTED HIGH PRESSURE LINE, ETC.).
11-4-93
PS 20092
PCM
l/P JUMPER
HARNESS
G 997 ORN — - 997 LT BLU/BLK - BD2 5V REFERENCE

APP1 > A k K
- 992 DK BLU -
SENSOR F 992 LTBLU PC4 APP 1 SIGNAL
A 998 BRN — - — 998 BRN PD4 SENSOR GROUND

ACCELERATOR
PEDAL 996 GRY — — 996 PPL - f 5V REFERENCE
D
POSITION APP 2 > A AN
(APP) SENSOR C 993 WHT - 993LTBLU - APP 2 SIGNAL
MODULE
999 YEL — — 999 PPL - PD3 SENSOR GROUND
B
995PNK — 995 YEUBLK - 5V REFERENCE
E P D 1 1
APP 3 > AkK

APP 3 SIGNAL
SENSOR 994 PPL — 994 GRN - PB10
K
961 TAN — 961 RED SENSOR GROUND
J PD5
A B C D E i PCM CONN. ID 1
K J H G F . 4
J PC/PD - PINK - 24 PIN J
i BC/BD - BLUE - 32PIN i

12-7-93
PS 17643
DTC 99
Action Taken (PCM Will default to): I f DTC 99 is present, the PCM will turn -ON" the "Service Throttle
"ON."
DTC Chart Test Description: Number(s) below A short to ground in CKT 996 will result in a DTC
refer to circled number(s) on the diagnostic chart. 99.
1. This step will determine i f there is a good 5 volt Refer to SECTION 2 for "Intermittents."
reference. Scan APP 2 signal while depressing accelerator
position in volts. It should read about 4.5 volts with closed, to about 1.5 volts when throttle is held at Wide
DTC 99
© •
•
• WITH J 39200 CONNECTED TO GROUND,
PROBE APP HARNESS TERMINAL " D " .
YES NO
r r
CKT 99S SHORTED TO GROUND DTC 99 IS INTERMITTENT. IF NO OTHER
4-23-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. PS 1711 f
l/P JUMPER HARNESS

PCM
• r-i
1061 ORN/BLK - J P C 1 4 SERIAL DATA
DIAGNOSTIC
• 451 WHT/BLK H P A 1 2
REQUEST
DATA LINK
CONNECTOR
p*q' n i r—-
5S1 TAN/WHT SYSTEM GROUND
| g J F JE |D | C | | JQJ
B A
TO WATER
IN FUEL TO FUEL
BULKHEAD S E N S R
i ° HESTER ENGINE
CONNECTOR GROUNDS
TO SIR DERM SYSTEM GROUND

450 BLK/WHT
ECMI
IGNITION
SWITCH *
10 AMP
ECMB
B+ < 440 ORN BATTERY FEED
10 AMP
l/P JUMPER
HARNESS
•
G 997 ORN — 997 LT BLU/BLK 5V REFERENCE
APP1 992 DK BLU .
F 992 LTBLU APP 1 SIGNAL
SENSOR
998 BRN — 998 BRN SENSOR GROUND
A
ACCELERATOR
PEDAL 9 9 i GRY - 996 PPL 5V REFERENCE
D
POSITION APP 2
(APP) SENSOR C 993 WHT - 993 LTBLU APP 2 SIGNAL
MODULE
999 YEL — — 999 PPL PD3 SENSOR GROUND
B
995 PNK — 995 YEUBLK PD11 5V REFERENCE
E
APP 3
SENSOR 994 PPL ' 994 GRN APP 3 SIGNAL
K
J 961 TAN 961 RED SENSOR GROUND
ENGINE HARNESS
CONNECTOR (15 PIN)
474 GRY 474 GRY — PP10 SV REFERENCE

982 PNK/WHT 982 PNK/WHT H PD15 CAM SIGNAL
943 PPL 983 PPL PD9 HI RES. SIGNAL
OPTICAL/
FUEL TEMP' 987 WHT 987 LT GRN/WHT PD14 SENSOR GROUND
SENSOR
1578 YEL 1578 YEL PB11 FUEL TEMP SIGNAL
987 WHT
12-8-93
Figure 3-9-PCM Wiring Diagram 6.5L Diesel (1of6)


PCM
ENGINE
COOLANT
TEMPERATURE
(ECT) SENSOR
A
——Ef ECT SIGNAL
INTAKE
AIR
TEMPERATURE
CRANKSHAFT
POSITION SIGNAL
SENSORGROUND
5V REFERENCE
TO TFT * * T O EGR CONTROL

SENSOR PRESSURE/BARO
SENSOR
ENGINE
HARNESS
CONNECTOR
(15 PIN)
•
i 1
INJECTION 564 TAN/BLK f - 564 TAN/BLK - PA9 ITS COIL 1 LOW
TIMING 565 RED/BLK 565 RED/BLK - PA8 ITS COIL 1 HIGH
STEPPER
(ITS) 566 ORN/BLK 566 ORN/BLK - PA10 ITS COIL 2 LOW
MOTOR
567 YEUBLK 567 YEUBLK - PA 11 ITS COIL 2 HIGH
ENGINE ENGINE SHUT-OFF

SHUT-OFF SOLENOID CONTROL
SOLENOID
FUEL INJECT CONTROL
FUEL INJECT CONTROL

FUEL INJECT SIGNAL
FUEL
SOLENOID
DRIVER
CLOSURE GROUND
ENGINE
HARNESS 339 PNK
CONNECTOR
(8 PIN)
7BLK FPMP
TO^-
IGNITION 20 AMP
SWITCH
BULKHEAD
CONNECTOR
SOLENOID W w /
1-6-94

BULKHEAD - T O FUEL HEATER

CONNECTOR PCM
^ - T O WATER IN
FUEL SENSOR
T O IGNITION GAGES
SWITCH TO GENERATOR
JUNCTION
20 AMP • c AND EGR
CONTROL
— 3 9 PNK/BLK SOLENOIDS
BLOCK
505 YEL GLOW PLUG RELAY
B+ < # * • f CONTROL
150 BLK -*-TO
WINDSHIELD
X WASHER
PUMP MOTOR
LEFT
GLOW
PLUGS
503 ORN
503 ORN
507 DK BLU" GLOW PLUG SIGNAL
509 ORN/BLK
RIGHT
GLOW
PLUGS
^ TO TURN
SIGNAL SWITCH
STOP
LAMP CRUISE CONTROL
SWITCH BRAKE SWITCH SIGNAL
TCC BRAKE SWITCH SIGNAL
TO ANTILOCK
IGNITION
SWITCH
TO ANTILOCK
TO V S S - *
BUFFER
MODULE
* FUSIBLE LINK

822 LT GRN/BLK PCM
- • T O BRAKE SWITCH
OUTPUT SPEED VSS INPUT C7 GROUND
AND
VEHICLE SPEED GROUND C8 150 BLK :
SENSOR BRK
(VSS) IGNITION FEED C9 - 350 PNK/WHT "TO IGNITION
10 AMP SWITCH
C10 696 WHT —•TO
VSS BUFFER ANTILOCK
MODULE C11
VSS INPUT C12 TRANSMISSION

SIGNAL
VSS OUTPUT C14 817 DK GRN/WHT BD8 VEHICLE SPEED
SIGNAL
VSS OUTPUT C15 824 LT BLU/BLK — - • T O SPEEDO
821 PPL/WHT
HIGH PRESSURE
A/C CONTROL CUT-OUT SWITCH
SWITCH
TO 66 LT GRN 59 DK GRN A/C SIGNAL
IGNITION
SWITCH - 0 -
150 BLK
A/C COMPRESSOR
CLUTCH
BULKHEAD
MIL CONNECTOR
¥
MIL "SERVICE
I— 39 PNK/BLK 419 BRN/WHT - | BCS ENGINE SOON* 1
-SERVICE CONTROL
ENGINE
SOON"
l/P JUMPER
HARNESS
GAGES
"SERVICE
TO 39 PNK/BLK 960 ORN THROTTLE SOON 1
IGNITION 20AMP "SERVICE LAMP CONTROL

SWITCH THROTTLE
SOON" LAMP
39 PNK/BLK
CRUISE
CONTROL CRUISE "ON/OFF"
1 ^ 8 0 3
SWITCH W W 1 397 GRY - — 397 GRY H REQUEST SIGNAL
RESUME/
i --- 84 DK BLU — 83 DK GRN "A 8011
ACCELERATE
REQUEST SIGNAL
H-#^1 — f J S J - 83 DK GRN - 84 DK BLU H BD15 SET/COAST
REQUEST SIGNAL
12-8-93
Figure 3-12-PCM Wiring Diagram 6.5L Diesel (4of 6)

TO ECT, IAT AND PCM

CRANKSHAFT
POSITION SENSOR
A
EGRCONTROL 452 BLK PD6 SENSOR GROUND

433 GRY/BLK PCS
41 i GRY PC10 5V REFERENCE
EGR
VALVE
TO CRANKSHAFT
POSITION SENSOR
Z 3
971 LTBLU EGR VENT SOLENOID

CONTROL
39 PNK/BLK -i
• TO FUEL HEATER
TO GENERATOR
GAGES
IGNITION^ TO GLOW PLUG RELAY
39 PNK/BLK
SWITCH
20 AMP
TO LOW
• COOLANT
SENSOR
TO WATER IN
FUEL SENSOR
TO
VACUUM
PUMP
39 PNK/BLK
EGR
SOLENOID 435 GRY EGR SOLENOID
CONTROL
12-8-93
REFER TO PCM CONNECTOR TERMINAL AND END VIEW FOR PCM CONNECTOR COLOR NS 16255
Figure 3-13 -PCM Wiring Diagram 6.5L Diesel (5 of 6)

PCM
4 WHEEL DRIVE
LOW SWITCH
N.O.
TORQUE
CONVERTER
CLUTCH
(TCC)
SOLENOID
3-2
CONTROL
SOLENOID
1-2 SHIFT
SOLENOID CONTROL
2-3 SHIFT
SOLENOID CONTROL
TRANSMISSION
RANGE
PRESSURE
SWITCH
TO EGR CONTROL
PRESSURE/BARO
SENSOR

11-30-93
Figure3-14-PCM Wiring Diagram 6.5L Diesel (6of 6)


from a known good vehicle. The voltages you get may vary due to Tow battery charge or other reasons,
but t h e y snould be very close.
The "B * ** symbol indicates a nominal system voltage of 12-14 volts.
• Engine at operating temperature • Engine idling {for "Engine Operating** column)
NORMAL VOLTAGE
"ON" OPERATING
A1 IGNITION FEED 439 PNK/BLK B+ B + - NO START
A2 3-2 CONTROL SOLENOID CONTROL 897 WHT B+ B + 66 3 r d

GEAR ONLY
A3 NOT USED - - - - - -
A4 EGR VENT SOLENOID CONTROL 971 LTBLU B# B + 31,45 NO EGR
A5 "SERVICE THROTTLE SOON" LAMP 960 YEL (4) (4) 49 NO SERVICE

CONTROL THROTTLE SOON
LAMP
A6 NOT USED - - - - - -
A7 CRUISE CONTROL BRAKE SWITCH 820 YEL 0 0 37,38,41 NO TCC
SIGNAL
A8 ITS COIL 1 HIGH 565 RED/BLK .9V B + 34 POOR

PERFORMANCE
A9 ITS COIL 1 LOW 564 TAN/BLK B+ .9V 34 POOR

PERFORMANCE
A10 ITS COIL 2 LOW 566 ORN/BLK B+ .9V 34 POOR

PERFORMANCE
A11 ITS COIL 2 HIGH 567 YEL/BLK .9V B + 34 POOR

PERFORMANCE
A12 DIAGNOSTIC REQUEST 451 WHT/BLK 5V 5V NONE -
CD VARIES.
BACK VIEW
(3) GROUNDED CIRCUIT. CONNECTOR
/ A l \ / B l \
m LESS THAN .5 VOLT (500 mV).
1 RR
• l l
VEHICLE: G VAN •pljol

ENGINE: 6.5L DIESEL VIN P (L49) 24 PIN A-B
TRANSMISSION: 4L60E CONNECTOR
(PINK)
12-7-93
NS 16257


NORMAL VOLTAGE
PIN PIN CKT WIRE DTC(S) POSSIBLE
-ON" OPERATING
B1 NOT USED - - - - - - -
B2 NOT USED - - - - - -
83 NOT USED - - - - - • -
B4 A/C SIGNAL 59 DKGRN 0*A 0*A NONE A/C STATUS
B5 NOT USED - - - - - -
B6 NOT USED - - - - - -
B7 APP 2 SENSOR 5V REFERENCE 996 PPL 5V 4.3V 25,26,27,84. POOR PERFORMANCE
99
B8 GLOW PLUG SIGNAL 507 DK BLU B+ B+ 29 HARD START
B9 NOT USED - - - - - -
B10 APP 3 SENSOR SIGNAL 994 DKGRN 4.0V 4.0V 64,65*84 POOR PERFORMANCE
B11 FUEL TEMP SIGNAL 1578 YEL (2) 1.5V 42,43 POOR PERFORMANCE
COLD TEMPS
B12 IAT SIGNAL 472 TAN (2) 1.6V 47,48 POOR PERFORMANCE
(D VARIES. BACK VIEW

(2) VARIES WITH TEMPERATURE. OF
CONNECTOR
(3) OPEN CIRCUIT.
W GROUNDED CIRCUIT.
m LESS THAN 1 VOLT.
* LESS THAN .5 VOLT (500 fflV).
(111
B + WITH A/C "ON."
• MM
VEHICLE: G VAN • p q p j
ENGINE: 6.5L DIESEL VIN P (L49)
24 PIN A-B
TRANSMISSION: 4L60E CONNECTOR
(PINK)
12-7-93
NS 16258


NORMAL VOLTAGE DTC(S)
PIN PIN CKT WIRE POSSIBLE
AFFECTE
FUNCTION # COLOR KEY ENGINE
D
SYMPTOMS
-ON" OPERATING
C1 SYSTEM GROUND 450 SLK/WHT 0* 0* NONE
a FUEL INJECT SIGNAL 985 RED 5.6V 4.0V NONE NONE
a APP SENSOR 2 SIGNAL 993 LTBLU 4.3V 4.3V 26,27,84 POOR PERFORMANCE
C4 APP SENSOR 1 SIGNAL 992 DK BLU .5V .5V 22,23,84 POOR PERFORMANCE
cs EGR CONTROL PRESS/BARO SIGNAL 433 GRY/BLK 4.8V 4.8V 31 NO EGR
C6 PRESSURE CONTROL SOLENOID (HIGH) 1228 RED/BLK 0* 6.3V 73 HARSH SHIFT
a NOT USED — — _ — _
C8 ECT SIGNAL 410 YEL 3.4V (3) 3.0V (3) 14,15 EARLY TCC
C9 TRANSMISSION FLUID TEMPERATURE 1227 BLK/YEL 3.5V 2.8V 58,59,79 EARLY TCC
(TFT) SIGNAL
C10 CRANKSHAFT POSITION AND EGR 416 GRY 5V 5V 19.31 BACK UP FUEL, NO EGR
CONTROL PRESSURE/BARO SENSOR 5V
REFERENCE
CM PRESSURE CONTROL SOLENOID LOW 1229 LTBLU/ 0* 1.5V 73 HARSH SHIFT

WHT
C12 NOT USED — _ — — —. —
C13 GLOW PLUG RELAY CONTROL 505 YEL B+ 0 29 NO GLOW PLUGS,

HARD START
C14 SERIAL DATA 1061 ORN/BLK 5V 5V NONE NO SCAN TOOL DATA
C15 TRANSMISSION OUTPUT SPEED SIGNAL 437 BRN 0* 0* 24,72 2ND GEAR ONLY
C16 NOT USED — — — — — —
BACK VIEW
OF
CONNECTOR
(1) VARIES FROM 0 TO BATTERY VOLTAGE, DEPENDING ON POSITION OF DRIVE WHEELS.

(2) VARIES.
(4) OPEN CIRCUIT.
LESS THAN .5 VOLT (500 mV).
VEHICLE: G VAN
ENGINE: 6.5L DIESEL V I N P ( L 4 9 )
TRANSMISSION: 4L60E 32 PIN C D
CONNECTOR (PINK)
12-7-93
NS 16259

from a known good vehicle. The voltages you get may vary due to fow battery charge or other reasons,
NORMAL VOLTAGE
-ON- OPERATING
D1 SYSTEM GROUND 551 TAN/WHT 0* 0* NONE —
D2 CLOSURE GROUND 950 GRY/BLK 0 0 NO START
03 APP 2 SENSOR GROUND 999 PPL 0 0 26,27,84 POOR

PERFORMANCE
04 APP 1 SENSOR GROUND 998 BRN 0 0 22,23,84 POOR

PERFORMANCE
D5 APP 3 SENSOR GROUND 961 RED 0 0 64,65,84 POOR

PERFORMANCE
D6 ECT, IAT, CRANKSHAFT POSITION, TFT, AND EGR 452 BLK 0* 0* 14,47,19, FAST IDLE
CONTROL PRESSURE SENSOR GROUND 58 BACKUP FUEL
D7 NOT USED — — — —
D8 NOT USED ... — _ _ _ —
D9 HIGH RESOLUTION SIGNAL 983 PPL 5V 2.5V 17 BACKUP FUEL
D10 OPTICAL SENSOR SV REFERENCE 474 GRY 5V 5V 17,18 BACKUP FUEL
D11 APP 3 SENSOR SV REFERENCE 995 YEL/BLK 5V 5V 64,65,84 POOR

PERFORMANCE
D12 NOT USED _ — — —.
D13 CRANKSHAFT POSITION SIGNAL 643 YEL 5V 4.3V 19 BACKUP FUEL
014 OPTICAL SENSOR/FUEL TEMP SENSOR GROUND 987 GRN/WHT 0* o* 17,18 BACKUP FUEL
D15 OPTICAL SENSOR CAM SIGNAL 982 PNK/WHT .2V .5V 18 BACKUPFUEL
016 NOT USED — — — —
BACK VIEW
OF
(1) VARIES FROM 0 TO BATTERY VOLTAGE, DEPENDING ON POSITION OF DRIVE WHEELS. CONNECTOR
(2) VARIES.
(3) OPEN CIRCUIT.
VEHICLE; G VAN
ENGINE: 6.5L DIESEL VIN P (L49)
TRANSMISSION: 4L60E
32 PIN C-D
CONNECTOR (PINK) 12-7-93
NS 16260


• Engine at operating temperature • Engine idling (for "Engine Operating* column)
LT BLUE 32 PIN BC/BD CONNECTOR
NORMAL VOLTAGE
-ON* OPERATING
C1 BATTERY FEED 440 ORN B+ B+ NONE NO START
a NOT USED - - - - - -
a NOT USED - - - - - ' -
a NOT USED - - - - - -
cs MIL "SERVICE ENGINE SOON" CONTROL 41S BRN/WHT (4) (4) NONE NO MIL
C6 TCC SOLENOID CONTROL 422 TAN/BLK B+ B+ 67,69 POOR FUEL

ECONOMY
C7 1-2 SHIFT SOLENOID CONTROL 1222 LTGRN B+ .4V 82 r<f

NO 3 / 4 ^ GEAR
C8 RANGE SIGNAL "A" 1224 PNK B+ B+ 24,28,72 -

C9 RANGE SIGNAL 1225 DK BLU 0 0 24,28,72 -
CIO RANGE SIGNAL 1226 RED B+ B+ 24,28,72 -
C11 NOT USED - - - - - -

C12 NOT USED - - - - - -
C13 2-3 SHIFT SOLENOID CONTROL 1223 YEL/BLK B+ .4V 81 -
C14 FUEL INJECT CONTROL 984 LTGRN 0 1.9 V NONE NO START
C15 EGR SOLENOID CONTROL 435 GRY B+ 9.5V 32,44 NO EGR
C16 ENGINE SHUT-OFF SOLENOID CONTROL 981 DK BLU/ m (4) 13 NO START

WHT
(1) VARIES. BACK VIEW

OF
(2) READS BATTERY VOLTAGE IN GEAR. CONNECTOR
(3) OPEN CIRCUIT.
(4) GROUNDED CIRCUIT. VEHICLE: G VAN
(5) OPEN/GROUNDED CIRCUIT. ENGINE: 6.5L DIESEL V I N P ( L 4 9 )
TRANSMISSION: 4L60E
32 PIN C-D
CONNECTOR
(LT BLUE) -7-93
12
NS16261


from a known good vehicle. The voltages you get may vary due to tow battery charge or other reasons,
a
The "B * symbol indicates a nominal system voltage of 12-14 volts.
• Test terminal notgroun ded • Scan tool not installed
LT BLUE 32 PIN BC/BD CONNECTOR
NORMAL VOLTAGE
PIN PIN CKT WIRE DTC(S) POSSIBLE
-ON" OPERATING
01 NOT USED - - - - - -
02 A P P 1 S E N S O R 5V R E F E R E N C E 997 WHT/BLK 5V 5V 21,22,23. POOR
84 PERFORMANCE
03 CRUISE "ON/OFF" REQUEST SIGNAL 397 GRY 0 0 NONE TCC
04 NOT USED - - - - - -
05 TCC BRAKE SWITCH SIGNAL 420 PPL B + B + 37.38,41 NO TCC
06 NOT USED - - - - - -
07 NOT USED - - - - - -
08 VSS S I G N A L 817 DK 0 0 16 N O CRUISE
GRN/WHT CONTROL
09 NOT USED - - - - -
010 NOT USED - - - - - -
011 RESUME/ACCEL R E Q U E S T SIGNAL 83 DKGRN 0 0 NONE -
012 NOT USED - - - - - -
013 F U E L INJECT C O N T R O L 984 LTGRN 0 1.9 V NONE -
014 NOT USED - - - - - -
015 SET/COAST R E Q U E S T SIGNAL 84 DK BLU 0 0 71 N O CRUISE
016 NOT USED - - - - - -

(D VARIES. BACK VIEW
VARIES WITH TEMPERATURE. OF
(2)
(3) O P E N CIRCUIT. y1^ . q VAN
(4) 1\ / D l \
G R O U N D E D CIRCUIT. ENGINE: 6.5L DIESEL VIN P (L49)
(5)
(6)
* L E S S T H A N .5 V O L T (500 mV).
TRANSMISSION: 4L60E ^
ST
• ••
32 P I N C D
CONNECTOR 12-7-93
(LT B L U E ) N S 16262

BLANK
ON-VEHICLE SERVICE
WIRE HARNESS If this happens, to the wrong terminal pair, i t is
spliced, i n t o a harness, use w i r e w i t h high contains an assortment of flexible connectors, used to
the system, i t is important that the best possible bond fuse and to adapt fuse holder, with a meter, for
Molded on connectors r e q u i r e complete to locate by sight, because oxidation, or terminal
new connector assembly into the harness. wiggling a connector on a sensor, or i n the wiring
CONNECTORS A N D TERMINALS also, be caused by oxidized or loose connections.
terminals in them. I t is possible to short between connectors look similar, but are serviced differently.
opposite terminals.

DRAIN WIRE
OUTERJACKET
MYLAR

REMOVE MYLAR.
SPLICE AND SOLDER
3. SPLICE TWO WIRE TOGETHER USING SPLICE

3. UNTWIST CONDUCTORS. STRIP INSULATION AS
NECESSARY.
DRAIN WIRE
T 3
4. SPLICE WIRES USING SPLICE CUPS AND ROSIN CORE
6. TAPE OVER WHOLE BUNDLE TO SECURE AS BEFORE. 4S 0570-6E

Micro-Pack To remove a terminal:

1. Slide the seal back on the wire.
Refer to Figure 3-22 and repair procedure for 2. Insert tool (3) BT-8518, or J 35689, or
replacement of a Micro-Pack terminal. equivalent, as shown i n insert "A* and to
connector.
(2).
Weather-Pack

oxidation and deposits on the terminals. T h i s
voltage and current levels found i n the electronic
system.
2 TERMINAL 4 TOOL J 33095/BT8234-A Repair of a Weather-Pack terminal is shown i n
7S3548-6E
Metri-Pack I f removal is attempted with an ordinary pick,
because, to install a terminal on a wire, the wire is seated and all of the sealing rings i n place, when
terminal pulled back into the connector to seat i t in They are used to improve the connector reliability by
place. retaining the terminals, i f the small terminal lock
Weather-Pack connector and terminal packages.
1. METRI-PACK SERIES 3. TOOL J 35689 OR BT-8446

150 FEMALE TERMINAL 4. CONNECTOR BODY
2. LOCKING TANG 5. SEAL
2-5-90
*7S3213-6E

OPEN SECONDARY LOCK HINGE ON CONNECTOR. Compact Three

FEMALE MALE
CONNECTOR CONNECTOR The Compact Three connector, which looks similar
SECONDARY- This type of connector, most likely, is used at the air
LOCK HINGE control solenoid. Use the standard method, when
2. REMOVE TERMINAL USING TOOL. repairing a terminal. Do not use the Weather-Pack
PUSH TO terminal tool J 28742, or BT-8234-A, as these w i l l
RELEASE
TOOLJ28742/BT8234-A
POWERTRAIN CONTROL MODULE (PCM)
CUT WIRE IMMEDIATELY BEHIND CABLE SEAL.

WIRE
SEAL
4. REPLACE TERMINAL replaced, the PROM and PCM should be checked first
A. SLIP NEW SEAL ONTO WIRE. to see i f they are the correct parts. If they are, remove
B. STRIP 5mm (.2") OF INSULATION FROM WIRE.
C CRIMP TERMINAL OVER WIRE AND SEAL. the PROM from the faulty PCM and install i t i n the
new service PCM. THE SERVICE PCM W I L L NOT
SEAL installed improperly or has malfunctioned. When
PUSH TERMINAL AND CONNECTOR AND
bent pins or pin not fully seated in the socket. I f i t is
ENGAGE LOCKING TANGS. installed correctly and DTC 51 is still displayed,
CLOSE SECONDARY LOCK HINGE.
7S3542-6E
replace the PROM.
Figure 3-24 - Weather-Pack Terminal Repair [ 1 1 Important

PCM, a DTC 88 will be stored. I t is important to
f
program TDC Offset" into the service PCM. Refer
to 'TDC Offset Program Procedure."
[T] Important
PCM (controller), i t is important to transfer the
service PCM label. Please Do Not record on PCM
PCM parts throughout the service life of the
vehicle.
[T| Important
• To prevent internal PCM damage, the ignition
must be " O F F " when d i s c o n n e c t i n g or
cable, PCM pigtail, PCM fuse, jumper cables, etc.).
The ignition should be "OFF" for at least 30
seconds before disconnecting power to the PCM.

pHh| Install or Connect

[T] Important
• Gently press down on PROM.

4. Connectors to PCM.
Functional Check
1. Turn ignition "ON."

is installed properly, and the PCM is
Figure 3-25 B. I f DTC 51 occurs, or i f the MIL (Service Engine
Soon) is "ON" constantly with no DTC(s), the
0 Remove or Disconnect
1. Negative batteiy cable.
PROM is not fully seated or is defective.
• If not fully seated, press firmly on the ends
3. PCM mounting hardware. • I f i t is necessary to remove the PROM,
4. PCM from passenger compartment. follow the previous removal instructions.
[T] Important This procedure allows the PCM memory to be

used when removing i t from the defective PCM been completed.
because it will be reused in the new PCM. Set up:
* • Battery is fully charged.
N O T I C E : To prevent possible electrostatic • Engine operating at idle.
circuit from carrier. • Select "OUTPUT TESTS" and "INJ. PUMP."
• Activate "TDC LEARN."
• Verify "TDC OFFSET" in data list.
g£| Inspect • DTC 88 will be stored if procedure has not been
done correctly.
• For alignment notches of the PROM and carefully
set i t aside. NOTICE: I f the PCM fails to program the TDC
j+njjj Remove or Disconnect software version.
service number to make sure i t is the same as the replace the PCM. Refer to "PCM Replacement.
defective PCM.
2. Access cover.
1 FRONT COVER
NS 15745 NS15749
Sensor
Engine Coolant Temperature (ECT) Sensor Remove or Disconnect
Figure 3-27
sensor. Damage to sensor w i l l affect proper 3. Sensor bolt.
4~» Remove or Disconnect Inspect

3. Electrical connector releasing locking tab. before installing.
4. Sensor.
£t+J Install or Connect
H Install or Connect 1. Sensor in engine.
1. Sensor in engine. 2. Sensor bolt, tighten to 25 N-m (17 lb. ft.).
2. Electrical connector. 3. Sensor electrical connector.
3. Refill coolant system. 4. Negative battery cable.
[T] Important
Accelerator Pedal Position (APP) Module • The procedure, called the "TDC Offset Program
Refer to SECTION 4 for replacement. scan tool. This procedure must be done when a
Optical/Fuel Temperature Sensor "TDC Offset Program Procedure."

7S3263-6E
Intake Air Temperature (IAT) Sensor PLENUM PANEL
Figure 3-29 SENSOR PS 17309
B Remove or Disconnect
Figure 3-30 - EGR Control Pressure/BARO Sensor

3. IAT sensor.
Install or Connect
1. IAT sensor.

Figure 3-30

replacement i f diagnosis shows sensor to be faulty.
pH*] Remove or Disconnect

1 PARKING BRAKE
B Install or Connect
1. Bolts (3.5 N-m 27 lb. in.) or snap sensor on
2
3
VELCRO
VSS BUFFER MODULE

bracket. PS 17912
Figure 3-31 - VSS Buffer Module
4. Negative battery cable. VSS Buffer Module
Figure 3-3f
The VSS buffer module is mounted i n the
Refer to SECTION 10 for on-vehicle service of the instrument panel. Refer to SECTION 8C of the
transmission mounted VSS. appropriate service manual for on-vehicle service.
Brake Switches PARTS INFORMATION

Refer to SECTION 5 of the appropriate service PART NAME GROUP
manual for on-vehicle service of the brake (stoplamp)
switches. Module, Eng. Cont. 3.670
- . _ A l . .
e PROM,ECM . . . . . . . . . . . . . . . . . . 3.670
Cruise Control Switches & n s o r > E n g i n e C o o l a n t T e m p # 3 6 8 2
The cruise control switches are part of the multi-

function turn signal lever. Refer to SECTION 3F of
BLANK
P3
DRIVEABILITY
AND
EMISSIONS
(DD2SEL)
SECTION 3
SECTION 3
CONTENTS
General Description 3- 3 PCM Diagnosis 3-17
Powertrain Control Module (PCM) . 33 PROM 3-17
PCM Learning Ability . . . . . . . . . . . . 33 Fuel Control 3-17
Electrostatic Discharge Damage . . . . . . 34 PCM Sensors and Input Signals 3-17
PCM Function 4 Engine Coolant Temperature (ECT)
MEMORY . 4 Sensor • 3-17
ROM . . . 4 Accelerator Pedal Position (APP)
RAM . . . 4 Module • • • • 3-17
PROM . . 5 Pump Cam Signal • 3-18
PCM Sensors and Input Signals 35 Fuel Temperature Sensor . . . . . . . . . 3-18
Engine Coolant Temperature (ECT) Crankshaft Position Sensor 3-18
Sensor . . . . . . . . . . . . . . . 3-5 Intake Air Temperature (IAT) Sensor . . 3-18
Accelerator Pedal Position (APP) BARO Sensor • 3-18
Module 3-5
3 Boost Sensor . . . . . . . . . . . . . . . . . 3-18
Optical Sensor 3-5
3 Vehicle Speed Sensor (VSS) 3-18
High Resolution Signal 3-6
3 Fuel Inject Signal • 3-18
Pump Cam Signal 36 Brake Switches 3-18
Fuel Temperature Sensor 36 Glow Plug Signal 3-18
Crankshaft Position Sensor . . . . . . . . . 36 Cruise Control •••• 3-19
Intake Air Temperature (IAT) Sensor 3-i6 A/C Signal 3-19
BARO Sensor 36 Automatic Transmission Information
Boost Sensor . 37 Sensors and Signals 3-19
Vehicle Speed Sensor (VSS) . . . . . . . . . 37 Chart A-1
Vehicle Speed Signal (VSS) Buffer No MIL (Service Engine Soon) . . . . . . 3-20
Module 3-7
3 Chart A-2
Fuel Inject Signal 3-7 No Scan Data or Will Not Flash MIL
Brake Switch Signals . . . . . . . . . . . . . 3-7 or MIL (Service Engine Soon)
Glow Plug Signal . . . . 3-8 "ON" Steady 3-22
Cruise Control Signal 3-8 Chart A-3
A/C Request Signal . .. . . . . .. .. .. . . . .. .. .. .. 33-8 Engine Cranks But Will Not Run 3- 24
Automatic Transmission Sensors Chart A-5
and Signals ••••••••• 38 Fuel Pump Relay Circuit Diagnosis ... 3-26
Diagnosis 39 EGR Control Pressure/BARO Sensor
Diagnostic Information 39 Output Check • 3-28
Malfunction Indicator Lamp (MIL) Cruise Control Signal Diagnosis 3-30
"Service Engine Soon" 39 A/C Signal Diagnosis . . . . . . . . . . . . . . 3-31
"Service Throttle Soon" Lamp 39 Restricted Exhaust System Check 3-32
On-Board Diagnostic (OBD) System Check 3- 9 Diagnostic Trouble Code (DTC)
On-Board Diagnostic (OBD) System Check Identification 3-33
(With Tech 1 Scan Tool) 310 DTC 13- Engine Shutoff
Typical Tech 1 Engine Data Values . . . . . . 312 Solenoid Circuit Fault
3-36
Engine Tech 1 Data Definitions 313 DTC 14- Engine Coolant Temperature (ECT)
Tech 1 Scan Tool 315 Circuit Low (High Temperature
PCM Information Modes • 3 15 Indicated)
3-38
Normal (Open) Mode . . . . . . . . . . . . 3 15 DTC 15 - Engine Coolant Temperature (ECT)
Diagnostic Mode • 3 15 Circuit High (Low Temperature
Reading Diagnostic Trouble Codes 15 Indicated)
3-40
DTC 12 3- 15 DTC 16 - Vehicle Speed Signal
Clearing Diagnostic Trouble Codes . . . . 3- 16 Buffer Fault 3-42
Intermittents • 3- 16 DTC 17- High Resolution Circuit Fault 3-44
Scan Tool Use with Intermittents . . . 3 16 DTC 18-Cam Reference Pulse Error .... 3-46
T100- GM CAMS 3 16

Error .. 3-48 Circuit Range Fault 3-102
DTC 21 - Accelerator Pedal Position (APP) 1 DTC 71 - SetCoast Switch Fault . . . . . . . 3-104
Circuit High 3-50 DTC 76 - Resume/Accel Switch Fault . . . . 3-106
DTC 22 - Accelerator Pedal Position (APP) 1 DTC78-WastegateSolenoid Fault 3-108
Circuit Low . . . . . . . . . . . . . . . . . . 3-52 DTC 84 - Accelerator Pedal Position (APP)
DTC 23 - Accelerator Pedal Position (APP) 1 Circuit Fault 3-110
Circuit Range Fault 3-54 DTC88-TDCOffset Error 3-112
DTC 25 - Accelerator Pedal Position (APP) 2 DTC 91-Cylinder Balance Fault . . . . . . . 3-113
Circuit High 3-56 DTC 92 - Cylinder Balance Fault . . . . . . . 3-113
DTC 26 - Accelerator Pedal Position (APP) 2 DTC 93 - Cylinder Balance Fault . 3-113
Circuit Low 3-58 DTC94-Cylinder Balance Fault . 3-114
DTC 27 - Accelerator Pedal Position (APP) 2 DTC 95 - Cylinder Balance Fault . . . . . . . 3-114
Circuit Range Fault 3-60 DTC96-Cylinder Balance Fault . . . . . . . 3-114
DTC 29 - Glow Plug Relay Circuit Fault • • . 3-62 DTC 97 - Cylinder Balance Fault 3-115
DTC 31 - BARO Sensor Circuit Low . . . . . 3-64 DTC 98 - Cylinder Balance Fault 3-115
DTC 33 - BARO Sensor Circuit High . . . . 3-66 DTC 99 - Accelerator Pedal Position (APP) 2
DTC 34 - Injection Timing Stepper (ITS) 5 Volt Reference Fault 3-116
Motor Circuit Fault 3-68 PCM Wiring Diagram (1 of 6) 3-118
DTC 35 - Injection Pulse Width Error PCM Connector Terminal End View
(Response Time Short) 3-70 (1of6) 3-124
DTC 36 - Injection Pulse Width Error On-Vehicle Service 3-131
(Response Ti me Long) 3-72 Wire Harness 3-131
DTC 41 - Brake Switch Circuit Fault .... 3-74 Connectors and Terminals . . . . . . . . . . 3-131
DTC 42 - Fuel Temperature Circuit Low Micro-Pack 3-132
(High Temperature Indicated) . . . . . . 3-76 MetriPack 3-132
DTC 43 - Fuel Temperature Circuit High Weather-Pack . . . . . . . . . . . . . . . . 3-132
(Low Temperature Indicated) 3-78 Com pact Three 3-133
DTC 46 - MIL "Service Engine Soon" Powertrain Control Module (PCM) 3-133
Circuit Fault . . . . . . . . . . . . . . . . . 3-80 PCM or PROM Replacement . . . . . . . . . 3-134
DTC 47 - Intake Air Temperature (IAT) If PCM Is Being Replaced 3-134
Circuit Low (High Temperature Functional Check 3-134
Indicated) . . . . . . . . . . . . . . . . . 3-82 TDC Offset Program Procedure . . . . . . . 3-134
DTC 48 - Intake Air Temperature (IAT) PCM Sensors and Input Switches . . . . . . 3-135
Circuit High (LowTemperature Engine Coolant Temperature (ECT)
Indicated) 3-84 Sensor • • • • • • • • • • • • • • 3-135
DTC 49 - "Service Throttle Soon" Accelerator Pedal Position (APP)
Lamp Circuit Fault . . . . . . . . . . . . . 3-86 Module 3-135
DTC 51 - PROM Error (Faulty or Optical/Fuel Temperature Sensor . . . . 3-135
Incorrect PROM) . . . . . . . . . . . . . . 3-88 Crankshaft Position Sensor . . . . . . . . 3-135
DTC 54 - PCM Fuel Circuit Error 3-89 Intake Air Temperature (IAT) Sensor . . 3-136
DTC 56 - Injection Pump Calibration BARO Sensor 3-136
Resistor Error 3-90 Boost Sensor 3-136
DTC 57 - PCM 5 Volt Shorted . . . . . . . . 3-92 Wastegate Solenoid . . . . . . . . . . . . 3-137
DTC 61 - Turbo Boost Sensor Vehicle Speed Sensor (VSS) 3-137
Circuit High . . . . . . . . . . . . . . . . . 3-94 VSS Buffer Module 3-137
DTC 62 - Turbo Boost Sensor Brake Switches . . . . . . . . . . . . . . . 3-137
Circuit Low 3-96 Cruise Control Switches 3-137
DTC 63 - Accelerator Pedal Position (APP) 3 Parts Information 3-137
Circuit High 3-98
DTC 64 - Accelerator Pedal Position (APP) 3
Circuit Low 3-100
GENERAL DESCRIPTION
The control module system has a computer, MIL (Service Engine Soon), and store one or more
Powertrain Control Module (PCM) to control fuel DTCs which identify the problem areas to aid the
delivery, timing, and some emission control systems. technician in making repairs. See diagnosis section
The control module system, monitors a number of for more information.
engine and vehicle functions (Figure 3-1) and controls The PCM is designed to process the various input
the following operations: information (Figure 3-1) and then sends the necessary
• Fuel control. electrical responses to control fuel delivery, timing and
• Fuel injection timing. other emission control systems. The input information
• Exhaust gas recirculation. has an interrelation to more than one output,
• Transmission shift and shift quality functions. therefore, i f the one input failed i t could affect more
Specific transmission control diagnostics are than one system's operation.
covered in SECTION 10 of this service manual.
PCM Learning Ability
Figure 3-2 The PCM has a "learning" ability which allows i t
to make corrections for minor variations in the fuel
The diesel Powertrain Control Module (PCM) is system to improve driveability. I f the battery is
located i n the passenger compartment and is the disconnected to clear DTCs, or for repair, the
control center of the control module system. The PCM "learning" process has to begin all over again.
used on the electronic fuel injected 6.5L diesel is A change may be noted i n the vehicle's
referred to as PCME. performance. To "teach" the vehicle, make sure the
The PCM constantly looks at the information from engine is at operating temperature, and drive at part
various sensors, and controls the systems that affect t h r o t t l e , w i t h moderate acceleration and i d l e
vehicle performance. The PCM performs the conditions, until normal performance returns.
diagnostic function of the system. I t can recognize
operational problems, alert the driver through the
OPERATING CONDITIONS SENSED
A/C Status • Exhaust Gas Recirculation (EGR) Operation

Vehicle Speed (VSS) • Injection Timing
Engine Coolant Temperature (ECT) • Fuel Control
Crankshaft Position - Idle Speed and Quality
Engine Speed (RPM) • Diagnostics
Injection Pump Timing - Malfunction Indicator Lamp (MIL)
- Pump Cam Reference Signal POWERTRAIN - "Service Throttle Soon** Lamp
Boost Pressure CONTROL
- Data Output
System Voltage MODULE
• Turbo Boost
(PCM)
Accelerator Pedal Position (APP) • Transmission Functions
EGR Control Pressure - Electronic Automatic Transmission
Barometric Pressure (BARO) • Glow Plug System
Intake Air Temperature (IAT) • Cruise Control
Brake Switch
Transmission Functions
Fuel Temperature
Cruise Control Request
3-11-93
*AII systems not used on all engines. PS 17155



discharge. I t is possible for less than 100 volts of static
components. By comparison, i t takes as much as 4,000 Figure 3-2 - Powertrain Control Module
volts for a person to even feel the zap of a static
discharge. PCM FUNCTION
There are several ways for a person to become
statically charged. The most common methods of The PCM supplies a buffered 5 or 12 volts to power
charging are by friction and by induction. An example various sensors or switches. This is done through
of charging by friction is a person sliding across a car resistances in the PCM which are so high i n value that
seat, in which a charge of as much as 25,000 volts can a test light will not light when connected to the circuit.
build up. Charging by induction occurs when a person In some cases, even an ordinary shop voltmeter will
with well insulated shoes stands near a highly charged not give an accurate reading because its resistance is
object and momentarily touches ground. Charges of too low. Therefore, the use of a 10 megohm input
the same polarity are drained off, leaving the person impedance digital voltmeter is necessary to assure
highly charged with the opposite polarity. Static accurate voltage readings.
charges of either type can cause damage, therefore, i t The input/output devices i n the PCM include
is important to use care when handling and testing analog to digital converters, signal buffers, counters,
electronic components. and special drivers. The PCM controls output circuits
such as the inject solenoids, etc. by controlling the
N O T I C E : To prevent possible Electrostatic ground circuit through transistors or a device called a
Discharge damage: driver in the PCM.
• Do Not touch the PCM connector pins or
soldered components on the PCM circuit board. MEMORY
• When handling a PROM, Do Not touch the
component leads, and Do Not remove integrated There are three types of memory storage within
circuit from carrier. the PCM: ROM, RAM and PROM.
• Be sure to follow the guidelines listed below if
servicing any of these electronic components. ROM
1. Do not open the replacement part package
until i t is time to install the part. Read Only Memory (ROM) is a permanent memory
2. Avoid touching electrical terminals of the part. that is physically soldered to the circuit boards within
3. Before removing the part from its package, the PCM. The ROM contains the overall control
ground the package to a known good ground on algorithms. Once the ROM is programmed, i t cannot
the vehicle. be changed. The ROM memory is non-volatile, and
4. Always touch a known good ground before does not need power to be retained.
handling the part. This step should be
repeated before installing the part i f the part RAM
has been handled while sliding across the seat,
while sitting down from a standing position, or Random Access M e m o r y ( R A M ) is the
while walking a distance. microprocessor "scratchpad/* The processor can write
into, or read from this memory as needed.
This memory is volatile and needs a constant supply of Engine Coolant Temperature (ECT) Sensor
voltage to be retained. I f the voltage is lost, the Figure 3-3
memory is lost.
The Engine Coolant Temperature (ECT) sensor is
PROM a thermistor (a resistor which changes value based on
Figure 3-4 temperature) mounted in the engine coolant stream.
Programmable Read Only Memory (PROM) is the (100,000 ohms at -40°C/-40°F) while high temperature
portion of the PCM that contains the different engine causes low resistance (70 ohms at 130°C/266°F).
calibration information that is specific to year, model The PCM supplies a 5 volt signal to the Engine
and emissions. Coolant Temperature (ECT) sensor through a resistor
The PROM also contains specific calibration in the PCM and measures the voltage. The voltage
information used to allow fuel delivery i f other parts of will be high when the engine is cold, and low when the
the PCM are damaged. The PROM is a non-volatile engine is hot. By measuring the voltage, the PCM
memory that is read only by the PCM. knows the engine coolant temperature. Engine
While one PCM part number can be used by many coolant temperature affects fuel control and the glow
vehicle lines, a PROM is very specific and must be plug system.
used for the right vehicle. For this reason, i t is very
important to check the latest parts book and service
bulletin information for the correct part number when
replacing a PROM.
A PCM used for service comes without a PROM.
The PROM should be retained with the vehicle
PCM must be carefully removed and installed in the
w
new PCM refer to On-Vehicle Service."
1 HARNESS CONNECTOR
PCM SENSORS AND INPUT SIGNALS
2 LOCKING TAB
In addition to the PCM, the control module system 3

SENSOR SS1640-6E
has some or all of the following information sensors:
Figure 3-3 - Engine Coolant Temperature (ECT)
• Engine Coolant Temperature (ECT) sensor.
Sensor
• Accelerator Pedal Position (APP) module.
• Optical sensor. Accelerator Pedal Position (APP) Module
• Fuel temperature sensor. Figure 3-4
• Intake Air Temperature (IAT) sensor. The APP module contains three potentiometers (a
• Barometric Pressure (BARO) sensor. device for measuring an unknown voltage or potential
• Boost sensor. difference by comparison to a standard voltage). Each
• Vehicle Speed Sensor (VSS). of the APP sensors send a varying voltage to the PCM.
And some or all of the following input signals: By monitoring the output voltage from the
• Fuel inject signal. Accelerator Pedal Position (APP) module, the PCM
• Brake switch signals. can determine fuel delivery based on the accelerator
• Glow plug signal. pedal position (driver demand).
• Cruise control signals.
• A/C signal. Optical Sensor
The optical sensor sends what is called a High
Resolution Signal and a Pump Cam signal to the PCM.
_ PS 16763 PS17S1S
Figure 3-5 - Optical/Fuel Temperature Sensor

Figure 3-4 - Accelerator Pedal Position (APP) Module
High Resolution Signal
Figure 3-6
The PCM uses this signal to determine injection
timing and for fuel control and is one of the most The Intake A i r Temperature (IAT) sensor is a
important inputs to the PCM. thermistor (a resistor which changes value based on
temperature) mounted in the intake manifold.
Pump Cam Signal • Low temperature produces a high resistance
The Pump Cam signal reference pulses are used by causes low resistance (70 ohms at 130°C/266°F).
the PCM to calculate injection timing and is one of the The control module supplies a 5 volt signal to the
most important inputs to the PCM. sensor through a resistor in the control module and
measures the voltage. The voltage will be high when
Fuel Temperature Sensor the intake air is cold, and low when the air is hot. By
Figure 3-5 measuring the voltage, the control module knows the
intake air temperature.
The fuel temperature sensor is part of the The IAT signal is used by the control module to
optical/fuel temperature sensor. The PCM uses the control fuel.
fuel temperature signal for fuel control.
BARO Sensor
Crankshaft Position Sensor Figure 3-7
The crankshaft position sensor provides a signal This sensor is used to measure barometric pressure
which the PCM uses as reference to calculate RPM and (BARO) under certain conditions, which allows the
crankshaft position. PCM to automatically adjust for different altitudes.

7S3263-6E

1 SENSOR
6S2648-6E

Vehicle Speed Signal (VSS) Buffer Module
The VSS buffer module is an electronic device.
The VSS buffer module process inputs from the vehicle
speed sensor and outputs various signals. The VSS
buffer module outputs a 4004 pulse per mile signal.
This signal is used by the PCM to determine vehicle
cruise control and fuel cutoff. The VSS buffer module
1 SENSOR is matched to the vehicle based on transmission, final
drive ratio and tire size. The VSS buffer module is
6S 2648-6E located behind the instrument panel.
Figure 3-7 - BARO Sensor
Fuel Inject Signal
Boost Sensor
Figure 3-8 The fuel injector driver receives an inject
The boost sensor measures the changes in the regulated output to the fuel solenoid that controls
intake manifold pressure. The boost sensor converts injection. It also returns an injection pulse width
engine load and speed changes, then converts the signal back to the PCM to inform i t when the fuel
change in readings to voltage output. solenoid has actually seated.
The PCM sends a 5 volt reference signal to the
boost sensor. As the manifold pressure changes, the Brake Switch Signals
electrical resistance of the boost sensor also changes.
By monitoring the sensor output voltage, the PCM The TCC normally closed brake switch supplies a
detects the boost pressure. A high pressure (high B + signal into the PCM. The signal voltage is opened
voltage) requires more fuel. A lower pressure (low when the brakes are applied. This signal is used to
voltage) required less fuel. control TCC.
The control module uses the boost pressure signal The cruise control normally open brake switch
to control fuel delivery. supplies a B + signal to the PCM when the brake is
applied. These signals are used by the PCM to control
Vehicle Speed Sensor (VSS) transmission and cruise control functions. The brake
switches are part of the stoplamp switch.
The VSS is attached to the output shaft housing.
This device contains a permanent magnet surrounded
by a coil of wire producing a magnetic field which is
interrupted by rotor teeth pressed on an output shaft.
As the rotor interrupts the magnetic field an AC
voltage is generated in the circuit.
G l o w Plug Signal A/C Request Signal
The glow plug system is used to assist in providing This signal indicated that the A/C compressor
the heat required to begin combustion during engine clutch is engaged. The PCM uses this signal to adjust
starting at cold ambient temperatures. The glow plugs the idle speed.
are heated before and during cranking, as well as
initial engine operation. The PCM monitors the glow Automatic Transmission Sensors a n d Signals
plug relay output.
Refer to SECTION 10 of this service manual for a
Cruise Control Signal description of automatic transmission sensors and
signals.
The cruise control switches are part of the
mulitfunction turn signal lever. These switches
enable the driver to control the cruise on/off, set/coast
and resume/accel signals. These signals are inputs to
the fuel control portion of the PCM and allow the PCM
to maintain a desired vehicle speed under normal
driving conditions.
DIAGNOSTIC INFORMATION As a bulb and system check, the light will come
"ON" with the key "ON" for 2 seconds. When the
The diagnostic "tree" charts and functional checks engine is started, the light will turn "OFF." I f the
in this manual are designed to locate a faulty circuit or light remains "ON," the self-diagnostic system has
component through logic based on the process of detected a problem. If the problem goes away, the light
elimination. will go out in most cases after 10 seconds, but a DTC
The charts are prepared with the requirements will remain stored in the PCM.
that the vehicle functioned correctly at the time of When the light remains "ON" while the engine is
assembly and that there are no multiple failures. running, or when a malfunction is suspected, an "On-
The PCM performs a continual self-diagnosis on Board Diagnostic (OBD) System Check" must be
certain control functions. This diagnostic capability is performed. This check w i l l expose malfunctions
complemented by the diagnostic procedures contained which may not be detected i f other diagnostics are
i n t h i s manual. The PCM's language for performed prematurely.
communicating the source of a malfunction is a system • It displays DTCs stored by the PCM which help
of Diagnostic Trouble Codes (DTCs). The DTCs are the technician diagnose system problems.
two digit numbers that can range from 12 to 99. When As a bulb and system check, the light will come
a malfunction is detected by the PCM, a DTC is set "ON" with the key "ON" and the engine not running.
and the Malfunction Indicator Lamp ( M I L ) is When the engine is started, the light will turn "OFF."
illuminated. If the light remains "ON," the self-diagnostic system
has detected a problem. I f the problem goes away, the
Malfunction Indicator Lamp (MIL) "Service light will go out i n most cases after 10 seconds, but a
Engine Soon" DTC will remain stored in the PCM.
When the light remains "ON" while the engine is
This light is on the instrument panel and has the running, or when a malfunction is suspected an "On-
following functions: Board Diagnostic (OBD) System Check" must be
• I t informs the driver that a problem has performed. This check will expose malfunctions which
occurred and that the vehicle should be taken may not be detected if other diagnostics are performed
in for service as soon as reasonably possible. prematurely.
"Service Throttle S o o n " Lamp ON-BOARD DIAGNOSTIC (OBD) S Y S T E M

CHECK
This light is on the instrument panel and has the
following functions: After the visual/physical underhood inspection,
• I t informs the driver that a problem has the on-board diagnostic system check, is the starting
occurred i n the Accelerator Pedal Position point for all diagnostic procedures or finding the
(APP) circuit, and the vehicle should be taken cause of an emission test failure.
in for service as soon as reasonably possible.
• If APP DTCs are stored by the PCM, the MIL
will display these. The "Service Throttle Soon"
lamp will not display DTCs.
TO OIL PRESSURE SWITCH • PCM

& FUEL PUMP RELAY
BATTERY +
ECM-BAT
JUNCTION
440 ORN BC1 BATTERY FEED
BLOCK
TERMINAL 10 AMP
IGNITION
SWITCH E CM-CRN K
439 PNK/BLK PA1 IGNITION FEED
- c
10A
CONTROL
419 BRN/WHT BO
MALFUNCTION INDICATOR
LAMP (MIL)
451 WHT/BLK PA12 DIAGNOSTIC TEST

DIAGNOSTIC
1061 ORN/BLK PC14 SERIAL DATA

, . . ,
, PCM CONN. ID J
PA/PB - PINK - 32 PIN \
DATA LINK CONNECTOR i PC/PD - PINK - 24 PIN i 12-9-93
(OLQ i BC/BD - BLUE - 32 PIN i PS 17516
i • i

by a control module system malfunction. It must be the starting point for any driveability complaint diagnosis.
chart and using it properly will reduce diagnostic time and prevent the unnecessary replacement of good parts.
Chart Test Description: Number(s) below refer to 6. Although the PCM is powered up, a "Cranks But
circled number(s) on the diagnostic chart. Will Not Run" symptom could exist because of a
1. When the ignition switch is cycled to "ON," the PCM or system problem.
MIL should turn "ON" briefly, then "OFF" briefly, 7. Comparison of actual control system data with the
then remain "ON" steady. This sequence will Typical Tech 1 Data Values is a quick check to
determine that the vehicle diagnostics are determine if any parameter is not within limits. A
operational. base engine problem (i.e., advanced cam timing
2. This step will isolate i f the customer complaint is may substantially alter sensor values).
a MIL or driveability problem.
3. Although the control module is powered up, a
symptom could exist because of a system fault.
4. Use Tech 1 to aid diagnosis, therefore, serial data
must be available. I f a PROM (MEM-CAL) error is
present, the PCM may have been able to flash DTC
12/51, but not enable serial data.
5. This step will isolate if the customer complaint is a
MIL or driveability problem with no MIL. Refer to
"Diagnostic Trouble Code Identification" i n this
section for a list of valid DTCs. An invalid DTC
may be the result of a faulty scan tool, PROM or
PCM.

CHECK

I
©[ STEADY LIGHT
I
2 Jl NOUGHT
J .
FLASHING UGHT
•
© • WITH TECH 1 SCAN TOOL PERFORM

ON-BOARD DIAGNOSTIC SYSTEM CHECK
| REFER TO J
i CHART A-1. i
CHECK FOR GROUNDED
DIAGNOSTIC TEST CKT 451.
OR
TERMINAL " B " TO "A**.
• DOES MIL FLASH?
YES NO
©I DOES TECH 1 DISPLAY SCAN DATA? ! REFER TO CHART A-2. !
1
YES NO
zxz
J REFER TO CHART A-2. j
©[ ARE ANY DTCs DISPLAYED?
YES NO
ZJEZ
© ( DOES ENGINE START?
© REFER TO "TYPICAL TECH 1 DATA VALUES" AND
COMPARE SCAN DATA.
3L
YES NO
• REFER TO APPLICABLE DTC CHART. i REFER TO CHART A-3.

11-1-93
PS 17310
functioning properly and no DTC(s) displayed, the "Typical Tech 1 Engine Data Values" may be used for
Only the parameters listed below are used in this manual for diagnosing. I f a scan tool displays other
Systems." If all varies are within the range illustrated, refer to "Symptoms," section.

Idle / Lower Radiator Hose Hot / Closed Throttle / Park or Neutral / Accessories Off
o o
ENG COOL TEMP. C°/F° 85 C-105°C(185 F-221°F)
BARO kPa/Volts 70 - 100/3.5-4.5 (varies with altitude)
WASTEGATE SOL DC Percentage 60-100% (may vary)
BOOST PRESSURE kPa/Volts 99-160 kPa/1.0-2.5 volts
o o o
FUEL TEMPERATURE C7F° 21 C-43 C(70 F-110°F)
THROTTLE ANGLE Percentage 0%
SYSTEM VOLTAGE Volts 12.0-14.5
ENG SHUT OFF On/Off On
CRANK REF MISSED Counts 0
CAM REF MISSED Counts 0
Drive 4, Drive 3,
Drive 2, Low,
Park/Neut Park/Neut
TIME FROM START Hrs/Mins/Sec Varies
4-22-93
PS 17587

"Transmission." This information will assist in emission or driveability problems. The displays can be viewed
while the vehicle is being driven. Always perform the "On-Board Diagnostic (OBD) System Check" first. The
"OBD System Check" will confirm proper system operation.
ENGINE DATA
input (low resolution circuit). It should remain close to throttle demanded by the driver. Should read about
desired idle under various engine loads with engine .35-J5 volts at idle to above 4.0 volts at Wide Open
DESIRED IDLE - Range 0-3187 RPM - The idle speed ACCELERATOR PEDAL POSITION (APP 2) - Range 0-5
ENG COOL TEMP - Range -40°C to 151°C, -40*F to 304°F ACCELERATOR PEDAL POSITION (APP 3) - Range 0-5
mounted i n the coolant pump and sends engine throttle demanded by the driver. Should read about
the sensor warms (internal resistance decreases), the missed. At idle it should read 0.
voltage signal w i l l decrease and the PCM w i l l
INTAKE AIR TEMP - Range -40°C to 151°C -40°F to position. The scan tool will display the number of cam
304°F - The PCM converts the resistance of the intake pulses missed. At idle it should read 0.
Temperature (IAT) is used by the PCM to adjust fuel BOOST PRESSURE - Range 10-200 kPa/0-5.0 Volts - The
delivery and spark timing according to incoming air amount of turbo boost pressure in the intake manifold.
density. This is measured in kPa and volts. True boost
pressure is determined by subtracting BARO from the
BARO - Range 10-105 kPa/0.00-5.00 Volts - The BARO actual reading.
reading displayed is determined from the MAP sensor
at ignition "ON," engine "OFF," and WOT conditions. FUEL TEMP - Range -40°C to 151°C -40°F to 304°F -
The BARO reading displayed represents barometric There is a thermistor located in the high resolution
pressure and is used to compensate for altitude sensor that determines fuel temperature. When the
differences. sensor is cold (internal resistance high) the PCM
monitors a high signal voltage which it interprets as
THROTTLE ANGLE - Range 0 -100% - Computed by the low fuel temperature. As the sensor warms (internal
PCM from APP module voltage (throttle position) and resistance low) the voltage signal will decrease and the
should display 0% at idle and 100% at wide open PCM will interpret the low voltage as warm fuel.
at idle. FUEL RATE - Range 0-80 mm - This reading is
fuel the PCM is requesting.
glow plug relay. The PCM will cycle the voltage ONtt ,>
solenoid. When engine load is increased, injector pulse
w
and OFF." Cycling timing will increase when engine width will fluctuate.
A/C REQUEST - Tech 1 displays " Y E S ' V N O " -
GLOW PLUG VOLTS - Range 0-25.5 Volts - This is used Represents if the A/C request from the control head is
by the PCM to determine i f there is voltage coming out being received by the PCM.
of the relay and going towards the glow plugs. During
normal operation the volts reading will be lower than PARK/NEUTRAL POS - Tech 1 displays - " P - N " - or -"R-
glow plug relay voltage because of the high resistance DL" - "P-N"- displayed indicates that the gear select
in the glow plugs. lever is in park or neutral.
DESIRED INJECTION TIMING - Range 0-25.5 Degrees- CRUISE CONTROL - Tech 1 Displays " O F F ' T O N " - This
The amount of injection timing requested by the PCM. will indicate when the cruise control has been enabled.
This signal is used by the PCM to adjust TCC
MEASURED INJECTION TIMING - Range 0-25.0 Degrees engagement scheduling, and to operate PCM cruise
- Current actual injection timing. fuel.
TDC OFFSET - Range ±2.02 Degrees - The PCM has 1 - 2 SHIFT SOL - Tech 1 displays "ON"/"OFF" - When
the ability to determine the amount of offset needed to the transmission in in first or fourth gear, the Tech 1
bring the engine to top dead center. This is used by the should display "ON." When the transmission is i n
PCM to determine proper injection timing and fuel second or third gear, the Tech 1 should indicate "OFF."
delivery. This value may be displayed as a positive or
negative number. 2 - 3 SHIFT SOL - Tech 1 displays "ON"/"OFF" - When
, f n
4WD LOW SWITCH - Indicator to PCM when driver the Tech 1 should Indicate O N . When the
selects 4WD low. transmission is in third or fourth gear, the Tech 1
99
parameter. I t is computed by timing pulses coming C/C BRAKE SWITCH - Tech 1 d i s p l a y s "OPEN /
TCC BRAKE SWITCH - Tech 1 displays " C L O S E D " /
ID is used when i t is necessary to replace the PROM. disengagement switch.
PROMs. PROM ID should not be confused with "Part TIME FROM START - Range 0 : 0 0 : 0 0 - 1 8 : 1 2 : 1 5
Number." HR/MIN/SEC - A measure of how long the engine has
been operating. When the ignition is cycled to " O F F "
1-5-94
PS 17588
TECH 1 SCAN TOOL PCM INFORMATION MODES
essential tool. Although, the term scan tool will
continue to be used for simplicity's sake, we On engines that can be monitored i n the "Open*
terminal V (Figure 3-9). This data is transmitted at
high frequency which requires a scan tool for When the diagnostic terminal is grounded with the
enter what is called the diagnostic mode. I n this mode
the PCM will:
OR
Display any stored DTC by flashing the MIL. Each
TERMINAL IDENTIFICATION DTC will be flashed three times.
[ A ] GROUND
B EBCM DIAGNOSTIC
TERMINAL (ANTILOCK)
[7] E A N D C DATA (RADIO)

PCM DIAGNOSTIC
TERMINAL
The means of communicating with the control
F U E L P U M P PRIME P C M SERIAL Figure 3-9) located under the instrument panel and is
DATA 3-9-93
8S3967-6E
sometimes covered by a plastic cover labeled
"DIAGNOSTIC CONNECTOR." The DLC is used in
Figure 3-9 - Data Link Connector (DLC)
the assembly plant to receive engine information to
With an understanding of the data which the scan determine proper operation before i t leaves the plant.
the scan tool can be very useful i n obtaining be displayed either through the Tech 1 scan tool, a
problem is i n a particular circuit. Diagnostic tree grounded. The DLC terminal " B " (diagnostic
scan tool when i t is applicable. connecting i t to terminal "A" (internal control module
The key to using the scan tool successfully for pause, flash-flash, long pause, flash, pause, flash-flash,
diagnosis lies in the technician's ability to understand long pause, flash, pause, flash-flash." DTC 12
the system being diagnosed, as w e l l as an indicates that the control module diagnostic system is
understanding of the scan tool's limitations. operating properly.
If the DTC 12 is not indicated and a fault is present Scan Tool Use With Intermittents
within the diagnostic system itself, and should be
addressed by consulting the appropriate diagnostic In some scan tool applications, the data update
chart in this section. rate makes the tool less effective than a voltmeter,
The malfunction indicator lamp will indicate a such as when trying to detect an intermittent problem
Diagnostic Trouble Code (DTC) three times i f a DTC is which lasts for a very short time. However, the scan
present, or i t will simply continue to output DTC 12. I f tool allows manipulation of wiring harnesses or
more than one diagnostic trouble code has been stored components under the hood with the engine not
in the control module memory, the DTC(s) will be running, while observing the scan tool readout.
displayed from the lowest to the highest with each The scan tool can be plugged in and observed while
DTC being displayed three times. driving the vehicle under the condition when the MIL
w
"Service Engine Soon" light turns "ON momentarily
Clearing Diagnostic Trouble Codes or when the engine driveability is momentarily poor.
I f the problem seems to be related to certain
To clear the DTC(s) from the memory of the control parameters that can be checked on the scan tool, they
module, either to determine i f the malfunction will should be checked while driving the vehicle. I f there
occur again or because repair has been completed, the does not seem to be any correlation between the
Tech 1 scan tool should be used to clear the DTC(s). I f problem and any specific circuit, the scan tool can be
a scan tool is not available, the following must be checked on each position, watching for a period of time
performed when all repairs have been completed. This to see i f there is any change in the readings that
will allow all DTC(s) to be cleared. indicates intermittent operation.
1. Ignition "OFF." The scan tool is also an easy way to compare the
2. Ground diagnostic terminal "A" to "B" of DLC. operating parameters of a poorly operating engine
3. Ignition "ON." with those of a known good one. For example, a sensor
4. Fully apply brake pedal. may shift In value but not set a DTC. Comparing the
5. Fully apply accelerator pedal. sensor's readings with those of a known good vehicle
6. Check MIL (Service Engine Soon) for DTC 12. may uncover the problem.
7. Release brake pedal. The scan tool has the ability to save time i n
8. Release accelerator pedal. diagnosis and prevent the replacement of good parts.
9. Check MIL (Service Engine Soon) for DTC 12. The key to using the scan tool successfully for
10. Remove jumper from DLC connector. diagnosis lies in the technician's ability to understand
11. Turn ignition "OFF." the system he is trying to diagnose as well as an
understanding of the scan tool operation and
NOTICE: To prevent control module damage, the limitations. The technician should read the tool
key must be "OFF" when disconnecting or manufacturer's operating manual to become familiar
reconnecting module power. with the tool's operation.
Intermittents T100- G M C A M S
A corresponding DTC will be stored in the memory The T100-GM CAMS (Computerized Automotive
of the PCM as a history DTC until DTCs have been Maintenance System) is a computerized technician's
cleared. When unexpected DTCs appear during the terminal unit. When connected to a vehicle, performs
code reading process, one can assume that these DTCs engine, electronic circuits and systems test to find
were set by an intermittent malfunction and could be possible vehicle problems in the engine system or the
helpful in diagnosing the system. PCM.
An intermittent DTC may or may not re-set. If it is The terminal diagnoses as follows:
an intermittent failure, a Diagnostic Trouble Code • C i r c u i t diagnostic procedures provide
(DTC) chart is not used. Consult the "Diagnostic Aids" information on how to isolate a problem and
on the page facing the diagnostic chart corresponding repair requirements.
to the intermittent DTC. SECTION 2 also covers the • I f no problem exists, engine performance
topic of "Intermittents." A physical inspection of the problems are diagnosed.
applicable sub-system most often will not resolve the • DTCs stored i n the PCM are read and
problem. diagnosed by the system.
Also needed are a test light, ohmmeter, digital good PCM. Although this is a rare condition, it could
voltmeter with 10 megohms impedance (J 39200), happen.
tools which are required for system service and the PROM
A PROM that has failed or was installed
PCM DIAGNOSIS improperly will generally set a DTC 51.
Since the PCM can have a failure which may affect FUEL CONTROL
only one circuit, following the diagnostic procedures in
this section can reliably tell when a failure has Fuel delivery is controlled by the control module
occurred in the PCM. Also, a DTC 54 indicates a system.
failure of the PCM. The diagnosis of fuel control starts with "Engine
If a diagnostic chart indicates that the PCM Cranks But Will Not Run" CHART A-3. This chart
connections or PCM is the cause of a problem, and the will test the fuel system and if there is a problem, will
PCM is replaced, but does not correct the problem, one lead you to checking the fuel lift pump, diagnosing the
of the following may be the reason: injection pump circuit or diagnosing the fuel system.
• There is a problem with the PCM terminal
connections. - The diagnostic chart will say PCM SENSORS AND INPUT SIGNALS
PCM connections or PCM. The terminals may
have to be removed from the connector in order All of the sensors and input signals can be
to check them properly. diagnosed by the use of a scan tool. Following is a
short description of how the sensors and signals can be
• The PCM or PROM is not correct for the
diagnosed by the use of a scan tool. A scan tool can
application. - The incorrect PCM or PROM
also be used to compare the values for a normal
may cause a malfunction and may or may not
running engine with the engine you're diagnosing.
set a DTC.
Refer to "Typical Scan Tech 1 Engine Data Values."
• The problem is intermittent. - This means that
system is being checked. In this case, refer to Engine Coolant Temperature (ECT) Sensor
manual and make a careful physical A scan tool displays engine coolant temperature in
inspection of all portions of the system degrees (Celsius and Fahrenheit). After engine is
involved. started, the temperature should rise steadily to about
90°C (194°F) then stabilize when thermostat opens.
• Shorted solenoid, relay coil, or harness. -
Solenoids and relays are turned "ON" and DTC 14 or DTC 15 indicates a failure in Engine
"OFF" by the PCM, using internal electronic Coolant Temperature (ECT) sensor circuit.
switches called "Drivers." The DTC charts also contain a chart to check for
A shorted solenoid, relay coil, or harness will not ECT sensor resistance values relative to temperature.
damage the PCM, but will cause the circuit and
Accelerator Pedal Position (APP) Module
controlled component to be inoperative. When the
circuit fault is not present or has been repaired, the
driver will again operate in a normal manner due to If the PCM has determined that there is a fault in
it's fault protected design. If a fault has been repaired one APP sensor, the PCM will store a current and
in a circuit controlled by a driver, the original PCM history DTC, but, it will not turn on the "Service
should be reinstalled and the circuit checked for proper Throttle Soon" lamp. The vehicle and throttle pedal
operation. PCM replacement will not be necessary if will operate normally if only one of the three APP
the repair circuit or component now operates correctly. sensors is at fault. If the PCM has determined two
APP sensors are faulty, a current and history DTC will
J 34636 or BT-8405 testers or equivalent provide a
set and the PCM will turn on the "Service Throttle
fast, accurate means of checking for a shorted coil or a
Soon" lamp. At this point, some engine performance
short to battery voltage.
will be lost. If three APP sensors malfunction, a
• The PROM may be faulty. - Although the PROM
current and history DTC will be stored, the "Service
rarely fails, it operates as part of the PCM. Therefore,
Throttle Soon" lamp will come "ON," and the PCM will
it could be the cause of the problem. Substitute a
only allow the vehicle to idle. If the PCM has
known good PROM.
recognized an intermittent fault (a fault not
• The replacement PCM mav be faulty. - After the
recognized by the normal APP DTC setting criteria), it
PCM is replaced, the system should be rechecked for
will then only allow the vehicle to operate under
proper operation. If the diagnostic chart again
limited performance and store a DTC 84.
indicates the PCM is the problem, substitute a known
A scan tool reads APP 1 position in voltage, and BARO Sensor

Voltage should increase at a steady rate as accelerator A scan tool displays EGR pressure i n volts. Low
position is also read i n voltage, and should read about high pressure (low vacuum) reads a high voltage. On
4.5 volts at idle, and should steadily decrease to a vehicles using only a BARO sensor a failure i n the
about 1.5 volts as accelerator pedal is moved to WOT. sensor circuit should set a DTC 31 or 33. Also refer to
APP 3 is also read i n voltage, and should read about "EGR Control Pressure/BARO Sensor Output Check"
4.0 volts at idle, and should steadily decrease to about in this section.
2.0 volts. Its possible idle voltage may vary, because
the PCM has a "learning" ability which allows i t to Boost Sensor
make corrections for minor variations.
At idle, the scan tool will display boost pressure
Pump C a m Signal about the same reading as barometric pressure. When
at a full load, with WOT the boost pressure w i l l
Loss of Pump Cam signal reference pulses will set indicate high pressure or voltage. When at a decel
a DTC 18. I f the Pump Cam signal is lost while the with throttle closed, the boost sensor will display low
engine is running, the fuel injection system will shift pressure or voltage. The boost pressure reading is the
to a time base fuel injection (backup fuel) mode based opposite of what you would measure on a vacuum
on crankshaft position sensor signal, and the engine gage. When manifold pressure is high, vacuum is low.
will continue to run. The engine can be restarted and A failure in the boost sensor circuit should set a DTC
will run in the calculated fuel injection mode as long as 61 or 62.
the fault is present.
See DTC 18 for further information. Vehicle Speed Sensor (VSS)
Fuel Temperature Sensor A scan tool display of mph / km/h should closely
match with the speedometer display. A failure in the
The scan tool displays fuel temperature in degrees VSS input circuit should set a DTC 24 or DTC 16.
failure in the fuel temperature sensor circuit. Fuel Inject Signal
Crankshaft Position Sensor A scan tool will display the injection pulse width
feedback in milliseconds. I f the PCM detects an error
A scan tool displays engine speed in RPM. RPM in the fuel inject response time, a DTC 35 or DTC 36
will still be displayed with a fault in this circuit. If the will set.
signal is lost while the engine is running, the fuel
injection system will shift to a time base fuel Injection Brake Switches
(backup fuel) mode based pump cam signal, and the
engine w i l l continue to run. The engine can be A scan tool will display the status of the brake
restarted and will run in the backup fuel mode as long switches. The cruise control brake switch Is normally
as fault is present. See DTC 19 for further open and TCC brake switch normally closed. A
information. malfunction in the brake switches circuit should set a
DTC 37,38 or 41.
G l o w Plug Signal
A scan tool displays temperature of the air
entering the engine and should read close to ambient A scan tool will display this signal in voltage. A
air temperature when the engine is cold, and rise as malfunction in this system should set a DTC 29 or
underhood temperature increases. I f the engine has refer to SECTION 7 for diagnosis of the glow plug
not been run for several hours (overnight), the IAT control system.
sensor temperature and engine coolant temperature
should read close to each other. A failure in the IAT
sensor circuit should set DTC 47 or 48. The DTC chart
also contains a "Diagnostic Aid" to check for sensor
resistance values relative to temperature.
Cruise Control A/C Signal
A scan tool will display cruise control "ON/OFF" The scan tool should indicate A/C clutch "ON"
status. For diagnosis of the cruise control refer to 9
when A/C is selected. Refer to "A/C Signal Diagnosis'
"Cruise Control Diagnosis." A malfunction in the for diagnosis of the A/C signal.
set/coast switch circuit should set a DTC 71. A
malfunction in the resume/accel switch circuit should Automatic Transmission Information Sensors
set a DTC 76. and Signals

signals.
TO OIL PRESSURE SWITCH PCM

& FUEL PUMP RELAY
BATTERY • E CM-BAT
JUNCTION
BLOCK •\^~ 440 ORN
- c
BC1 BATTERY FEED
TERMINAL 10 AMP
IGNITION
SWITCH E CM-CRN K
439 PNK/BLK 1 PA1 IGNITION FEED
- c
10A
ALT MIL CONTROL

419 BRN/WHT 1 BC5
20A MALFUNCTION INDICATOR
LAMP (MIL)
451 WHT/BLK DIAGNOSTIC TEST

DIAGNOSTIC
1061 ORN/BLK PC14 SERIAL DATA

- c
i
m PCM CONN. ID
PA/PB - PINK 32 PIN
-J
PC/PD - PINK 24 PIN

DATA LINK CONNECTOR BC/BD . BLUE 32 PIN 12-9-93
(DLC) L. — ... PS 17516
CHART A-1
NO MIL
There should always be a steady MIL with the ignition "ON" and engine "OFF" Switched battery voltage is
supplied to the lamp. The PCM will control the lamp and turn it "ON" by providing a ground path through CKT
419.
for complete circuit. • ALT fuse open. This will result in no brake
ground circuits.
CHART A-1
NO MIL
© CHECK:
- CONTINUOUS BATTERY FUSIBLE LINK.
- ECM-IGN FUSE.
- GAUGES FUSE.
FUSES OK OPEN FUSE
1 I
IGNITION "OFF." LOCATE AND CORRECT SHORT TO
DISCONNECT PCM CONNECTORS. GROUND THAT HAD AN OPEN FUSE.
PROBE CKT 440 AND CKT 4 3 9 WITH A
TEST LIGHT TO GROUND.
TEST LIGHT "ON" TEST LIGHT " O F F " ONE

PROBE CKT 4 1 9 WITH A TEST LIGHT LOCATE AND REPAIR

1
MIL "ON" MIL "OFF"
~l
© FAULTY PCM GROUNDS
OR
CKT 4 1 9 OPEN OR SHORTED
TO VOLTAGE FAULTY BULB.
OR
FAULTY PCM.
5-4-92
M S 13407
TO OIL PRESSURE SWITCH PCM

& FUEL PUMP RELAY
BATTERY + ECM-BAT
JUNCTION
• x ^ - 440 ORN BC1 BATTERY FEED
BLOCK
TERMINAL 10 AMP
IGNITION
SWITCH ECM-CRNK
10A
ALT MIL CONTROL

- A ^ 419 BRN/WHT
20A MALFUNCTION INDICATOR
LAMP (MIL)
451 WHT/BLK DIAGNOSTIC TEST

DIAGNOSTIC
B IA 1 1061 ORN/BLK SERIAL DATA
M J PCM CONN. ID J
i PA/PB - PINK - 32 PIN \
i PC/PD . PINK - 24PIN i
DATA LINK CONNECTOR i BC/BD - BLUE - 32 PIN i 12-9-93
(DLC) !_„... ._«.„, „.-._! PS 17516
CHART A-2
NO SCAN DATA OR
MIL (SERVICE ENGINE SOON) " O N " STEADY
419.
With the "diagnostic" terminal grounded, the lamp should flash a DTC 12 or any Diagnostic Trouble Code
(DTC) stored i n memory.
A steady lamp indicates a short to ground i n the lamp control CKT 419 or an open in diagnostic CKT 451.
circled number(s) on the diagnostic chart. 451.
1. I f there is a problem with the PCM that causes a 4. At this point, the MIL wiring is OK. The problem
scan tool not to read serial data, then the PCM will is a faulty PROM. I f MIL does not flash, the PCM
not flash the MIL. I f the MIL does flash, check should be replaced using the original PROM.
that the scan tool is functioning properly on Replace the PROM only after trying a PCM.
properly, and CKT 1061 is OK, the PROM or PCM
may be at fault for the NO DLC symptom.
2. I f the light goes "OFF" when the PCM connector is
ground.
CHART A-2
NO SCAN DATA OR WILL
NOT FLASH MIL OR MIL
"ON" STEADY
• IGNITION "ON." ENGINE "OFF.'

IS THE MIL "ON"?
1
YES NO
H
• GROUND DIAGNOSTIC TERMINAL. • REFER TO CHART A-1. 1
DOES MIL FLASH?
© IGNITION "OFF."
DISCONNECT PCM CONNECTORS.
© IF PROBLEM WAS NO SERIAL DATA:
CHECK SERIAL DATA CKT 1061 FOR OPEN
IGNITION "ON" AND NOTE MIL (SERVICE OR
ENGINE SOON). SHORT TO GROUND
OR
D L C IF OK, IT IS A FAULTY PCM
OR
PROM.
1
I MIL' OFF" MIL " O N -
1fc T
© • IGNITION "OFF."
• RECONNECT PCM.
REPAIR SHORT TO
GROUND IN CKT 419.
• IGNITION "ON," ENGINE STOPPED.
• DIAGNOSTIC TERMINAL NOT GROUNDED.
• BACKPROBE PCM. CKT 451, WITH TEST LIGHT TO GROUND.
DOES MIL FLASH?
1
YES
I E
© •
•
IF OK, REPLACE PCM USING ORIGINAL PROM.
• CHECK FOR OPEN IN DLC DIAGNOSTIC
TERMINALS " B " AND CKT 4 5 1 TO PCM.
• RECHECK FOR FLASHING MIL. • IF OK, CHECK FOR OPEN IN DLC TERMINAL
DOES MIL FLASH? " A " TO PCM AND PCM GROUND, CKT 450.
X
NO YES
X m
REPLACE PROM. SYSTEM OK.
5-5-93
PS 17831
ENGINE HARNESS
CONNECTOR (1 SPIN)
TO ENGINE PCM
SHUTOFF 339 PNK
SOLENOID
984 LTGRN FUEL INJECT CONTROL
[T~!
984LTGRN — # H L { - 984LTGRN FUEL INJECT CONTROL
USD - 985 RED — {
1
985 RED
FUEL INJECT SIGNAL
FUEL 339 PNK —
SOLENOID
DRIVER
• 950
GRN/BLK CLOSURE GROUND
39 PNK/BLK
ENGINE HARNESS
CONNECTOR (8 PIN) TO GENERATOR
TO M I L - * ^ CONNECTOR TO WATER IN
FUEL SENSOR
BLK ALT
^ TO GLOW
PLUG RELAY
20 AMP
TO WASTE TO VSS BUFFER
fc—4 • — R E D GATE SOLENOID MODULE
FUEL
SOLENOID TO TO CRUISE
IGNITION TO AUTO CONTROL
SWITCH PARK BRAKE SWITCH
r-
PCM CONN. ID
I-
J PC/PD - PINK - 24 PIN 1-3-94
1 BC/BD - BLUE - 32 PIN PS 17509
CHART A-3
This chart assumes that battery condition and engine cranking speed are OK, adequate fuel i n the tank and
Chart Test Description: Number(s) below refer to Diagnostic Aids: I f no trouble is found in the fuel
circled number(s) on the diagnostic chart. pump circuit and the cause of a "Engine Cranks But
and ignition 12 volts to PCM. No MIL may be due • Basic engine problem.
to a PCM problem and CHART A-2 will diagnose
the PCM. NOTICE:
2. This step will check to see i f there is an inject • I f crankshaft position sensor and optical sensor
command coming from the PCM. are disconnected or inoperable at the same time,
3. This step will check ground circuit. this will cause a "Engine Cranks But W i l l Not
Run" condition.
CHART A-3
© •
•
IGNITION "ON."
YES NO
IE
INSTALL SCAN T O O L REFER TO CHART A-1.
YES NO
I E
LOOSEN INJECTION UNE AT INJECTOR. REFER TO CHART A-2.
CRANK ENGINE.
NO YES
T
DISCONNECT OPTICAL/FUEL TEMP SENSOR. INJECTION SYSTEM OK, REFER
T
NO YES
JO
© RECONNECT OPTICAL/FUEL TEMP SENSOR.
WITH J 39200 CONNECTED TO GROUND, PROSE

HARNESS TERMINAL "A".
CRANK ENGINE.
NO
T
© • PROBE TERMINAL " B " AT FUEL SOLENOID

OR
LIGHT CONNECTED T O B * . FAULTY PCM CONNECTION
FAULTY PCM.
YES NO
PROBE TERMINAL " C " AT FUEL SOLENOID OPEN CKT 950

FAULTY PCM.
YES NO
ZE
m
OPEN CKT 339.
11-1-93
NS 15748
PCM
440 ORN BATTERY F E E D
JO
806PPLWHT
STARTER
450 BLK/WHT
1
120 GRY
FUEL PUMP
120 GRY
i PCM CONN. SO I
> . 4
I PA/PB - PINK - 32 PIN J
PC/PD - PINK - 24 PIN j
i BC/BD - BLUE - 32 PIN I 12-9-93
PS 17589
CHART A-5
FUEL PUMP RELAY CIRCUIT DIAGNOSIS
When the ignition switch is in the "CRANK" position, the lift pump circuit is completed through the relay
contacts. During this time, oil pressure is building to the point of closing the contacts of the oil pressure switch.
A minimum of 28 kPa (4 psi) is required to close the switch contacts. When the ignition switch is returned to the
"RUN" position, the oil pressure of the running engine maintains electrical power to the lift pump.
Chart Test Description: Number(s) below refer to Diagnostic Aids: If engine oil pressure drops below
circled number(s) on the diagnostic chart. 28 kPa (4 psi), the engine will run poorly or stall when
1. This procedure applies direct voltage to run the the lift pump circuit opens.
fuel pump. If the pump runs, it may be a fuel pump
relay circuit problem which the following step will
locate.
2. This step checks voltage from the battery and the
ground circuit to the relay.
3. This test determines if there is voltage from the
battery, terminal "A" to terminal "D" on the relay
connector.
4. This completes the fuel pump relay circuit. Oil
pressure switch should also be diagnosed.
CHART A-5
FUEL PUMP RELAY
© •
•
APPLY FUSED 12 VOLTS TO FUEL PUMP TEST TERMINAL
LISTEN FOR FUEL PUMP.
CIRCUIT DIAGNOSIS
DOES FUEL PUMP RUN?
| YET NO
© •
•
DISCONNECT PUMP RELAY.
IGNITION "OH," ENGINE STOPPED.
1
OPEN IN CKT 120 OR CKT450 OR CKT 490
TO THE FUEL PUMP OR FAULTY PUMP.
• PROBE RELAY HARNESS CONNECTOR TERMINAL
IS TEST LIGHT-ON"?
1
NO
© • CONNECT TEST LIGHT BETWEEN HARNESS

CONNECTOR TERMINAL "A" AND " E " .
REPAIR OPEN CKT 440.
IS TEST LIGHT "ON"?
3L
YES NO
T
• CONNECT TEST LIGHT BETWEEN TERMINAL " F " AND GROUND. REPAIR OPEN GROUND CKT 450.
• CRANK ENGINE.
IS TEST LIGHT "ON"?
YES NO
m
© • FAULTY CONNECTION AT RELAY, OPEN IN CKT450 OR FAULTY RELAY.

CONTINUE TESTING OIL PRESSURE SWITCH.
OPEN IN CKT 806.
• ENGINE RUNNING.
• ENGINE AT NORMAL OPERATING TEMPERATURE. '
• OIL PRESSURE NORMAL
• DISCONNECT FUEL PUMP RELAY.
• WITH J 39200 CONNECTED TO GROUND, PROBE FUEL PUMP RELAY
HARNESS CONNECTOR TERMINAL " E " .
IS THERE B + VOLTAGE?
YES NO
zc
• RECONNECT FUEL PUMP RELAY. OPEN IN CKT 440 OR 120 TO THE OIL PRESSURE
• IGNITION "OFF." SWITCH OR FAULTY OIL PRESSURE SWITCH.
• PROBE FUEL PUMP RELAY TERMINAL " E " WITH A TEST
LIGHT TO GROUND.
IS TEST LIGHT "ON"?
NO YES
NO TROUBLE FOUND. FAULTY OIL PRESSURE SWITCH.
10-29-93
TFT TO ECT, IAT ANO PCM

SENSOR TO BOOST CRANKSHAFT
(A/TONLY) SENSOR POSITION SENSOR
A
452 BLK/WHT I SENSOR GROUND

BARO SENSOR 433GRY/BLK BARO SIGNAL
416 GRY -W^ SVOLT
REFERENCE
r-—•—------ - -~§
J PCM CONN. ID J
! PA/PB • PINK - 32 PIN !
i PC/PD - PINK - 24 PIN i TO BOOST
i BC/BD - BLUE - 32 PIN i SENSOR
L. I 12-9-93
PS 17505

An EGR control pressure/BARO sensor is used to monitor the amount of vacuum in the EGR circuit. It senses
reading.
Chart Test Description: Number(s) below refer to Check vacuum hose to sensor for leaking or
Important NOTICE: Make sure electrical connector remains

Be sure to use the same diagnostic test equipment securely fastened.
for all measurements.
4. Disconnect sensor from bracket and twist sensor
1. Checks sensor output voltage to the PCM. This by hand (only) to check for intermittent
voltage, without engine running, represents a connection. Output changes greater that .1 volt
barometer reading to the PCM. indicates a bad connector or connection. If OK,
• When comparing Tech 1 scan readings to a replace sensor.
known good vehicle, it is important to compare
page.
a faulty sensor.

OUTPUT CHECK
© •
•
IF ANY DTC(s) ARE STORED. REFER TO THOSE CHARTS FIRST.
-
IGNITION " O N , ENGINE "OFF."
• TECH t SCAN TOOL SHOULD DISPLAY A SENSOR VOLTAGE.
SEE FACING PAGE TEST DESCRIPTION, STEP 1.
VOLTAGE READING SHOULD BE WITHIN ± . 4 VOLT.
IS IT?
NO
(T) DISCONNECT AND PLUG VACUUM SOURCE TO SENSOR.

• DIS REPLACE EGR
• CO CONTROL
START ENGINE. PRESSURE/BARO
NOTE SENSOR VOLTAGE. SENSOR.
APPLY 34 kPa (10" Hg) OF VACUUM AND NOTE VOLTAGE CHANGE.
SHOULD BE GREATER THAN 1.5 VOLTS.
IS IT?
© NO TROUBLE FOUND. CHECK SENSOR VACUUM

SOURCE FOR LEAKAGE OR RESTRICTION.
© CHECK SENSOR CONNECTION.
IF OK, REPLACE EGR CONTROL
HOT-STAMPED <
NUMBER
COLOR
KEYED INSERT
LS 8963-6E LS9045-6E
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. PS m l !
PCM
ALT
TO .
IGNITION
20 A
- 39 PNK/BLK
"ON/OFF"
- 3 9 7 GRY — BD3 REQUEST SIGNAL
- 83DKGRN BD11 RESUME/ACCELERATOR

REQUEST SIGNAL
SET/COAST
- 84 DK BLU BD15
REQUEST SIGNAL
CRUISE CONTROL SWITCH

i PCM CONN. ID i
i 4
• PA/PB - PINK - 32 PIN •
PC/PD - PINK - 24 PIN
I BC/BD - BLUE - 32 PIN i 12-9-93
PS 17581

Circuit Description;
The cruise on/off, seVcgastand resume/accel signals are inputs to the fuel control portion of the PCM. These
inputs allow the PCM to control and hold a requested speed.
If cruise is inoperative, and no DTC(s) are stored, check for faulty cruise switch, wiring harness for opens or
faulty connections. *
The cruise control switch on the clutch pedal stuck in the open position will cause a "NO CRUISE" complaint.
PCM
HIGH PRESSURE CUTOUT

A/C CONTROL SWITCH
SWITCH
TO 59 DKGRN -59 DK G R N - J p B 4 A/C SIGNAL
IGNITION
SWITCH - e
59 DKGRN
A 150 BLK —
A/C COMPRESSOR i PCM CONN. ID i

CLUTCH I 4
J PA/PB - PINK - 32 PIN |
j PC/PD - PINK - 24 PIN j
i BCBD - BLUE - 32 PIN i 12-7-93
PS 17B31
A / C SIGNAL DIAGNOSIS
terminal *PB4" of the PCM to increase and maintain idle speed.
The PCM does not control the A/C compressor clutch. Therefore, i f A/C does not function, refer to the A/C
DIAGNOSIS:
2. I f there are no obvious reasons for the excessive backpressure, the catalytic converter is suspected to be
3-9-S3
8S3984

The MIL (Service Engine Soon) will be "ON" i f an emission malfunction exists. I f the malfunction clears, the
[T] Important
SECTION 10B. Remember, always start with the lowest numerical engine DTC first. When diagnosing
DTC 13 - Engine Shutoff Solenoid 3 DTC 23 - Accelerator Pedal 3

DTC 14 - Engine Coolant 3 *DTC 24 - Vehicle Speed Sensor 10B (4L80E)

Temperature (ECT) Sensor Circuit Circuit Low (Output Speed Signal)
Low (High Temperature Indicated)
DTC 15 - Engine Coolant 3 DTC 25 - Accelerator Pedal 3

Temperature (ECT) Sensor Circuit Position 2 Circuit High
High (Low Temperature Indicated)
DTC 16 - Vehicle Speed Sensor 3 DTC 26 - Accelerator Pedal 3

Buffer Fault Position 2 Circuit Low
DTC 17 - High Resolution Circuit 3 DTC 27 - Accelerator Pedal 3

Fault Position 2 Circuit Range Fault
DTC 18 - Pump Cam Reference 3 *DTC 28 - Trans Range Pressure 10B (4L80E)
Pulse Switch Circuit
Error
3 DTC 29 - Glow Plug Relay Fault 3
DTC 19 - Crankshaft Position
Reference Error
3 DTC 31 - Baro Sensor Circuit Low 3
DTC 21 - Accelerator Pedal (High Vacuum)
Position 1 Circuit High
3
5-12-93
PS 17312

The MIL (Service Engine Soon) will be "ON* i f an emission malfunction exists. I f the malfunction clears, the
fT| Important
DTC NUMBER AND NAME SECTION DTC NUMBER A N D NAME SECTION
DTC 33 - Baro Sensor Circuit High 3 DTC 48 - Intake Air Temperature 3

Sensor Circuit High (Low Temp
Indicated)
DTC 34 - Injection Timing Stepper 3
Motor Fault
DTC 49 - Service Throttle Soon 3
Lamp Circuit Fault
Error (Response Time Short)
DTC 51-PROM Error 3
Error (Response Time Long) •DTC 52 - System Voltage High 10B (4L80E)
Long
*DTC 37 - TCC Brake Switch Stuck 10B(4L80E)
w
ON" •DTC 53 - System Voltage High 10B (4L80E)
•DTC 38 - TCC Brake Switch Stuck 10B (4L80E) DTC 54 - PCM Fuel Circuit Error 3
"OFF*
DTC 56 - Injection Pump Calibration 3
•DTC 39 - TCC Stuck "OFF" 10B(4L80E) Resistor Error
DTC 41 - Brake Switch Circuit Fault 3 DTC 57 - PCM 5 Volt Shorted 3
DTC 42 - Fuel Temperature Circuit 3 •DTC 58 - Trans Fluid Temp Circuit 10B (4L80E)
Low (High Temp Indicated) Low
DTC 43 - Fuel Temperature Circuit 3 •DTC 59 - Trans Fluid Temp Circuit 10B (4L80E)
High (Low Temp Indicated) High
DTC 46 - Malfunction Indicator 3 DTC 61 - Turbo Boost Sensor Circuit 3

Lamp Circuit Fault High
DTC 47 - Intake Air Temperature 3 DTC 62 - Turbo Boost Sensor Circuit 3

Sensor Circuit Low (High Temp Low
Indicated)
12-21-93
P S 17659

lamp will go "OFF" and the DTC will be stored in the PCM. Any DTCs stored will be cleared if no problem
| 9 | Important
• All DTCs with the sign * are transmission related DTCs and have descriptions, diagnostic charts are in
DTC 63 - Accelerator Pedal 3 •DTC 83 - TCC Pwm Solenoid 10B (4L80E)

Position 3 Circuit High Circuit
DTC 64 - Accelerator Pedal 3
Position 3 Circuit Low •DTC 84 - Accelerator Pedal 10B (4L80E)
Position Circuit Fault
Position 3 Circuit Range Fault •DTC 85 - Undefined Ratio Error 10B (4L80E)
•DTC 68 - Trans Component 10B (4L80E)
Slipping •DTC 86 - Low Ratio Error 10B (4L80E)
•DTC 69 - TCC Stuck "ON" 10B (4L80E)
•DTC 87 - High Ratio Error 10B (4L80E)
DTC 71 - Set/Coast Switch Fault 3
DTC 88 - TDC Offset Error 3
•DTC 72 - Vehicle Speed Sensor 10B (4L80E)
Circuit Loss (Output Speed Signal) DTC 91 - Cylinder Balance Fault 3
#1 Cyl
•DTC 73 - Pressure Control 10B (4L80E)
Solenoid Circuit DTC 92-Cylinder Balance Fault 3
#2 Cyl
•DTC 74 - Trans Input Speed Sensor 10B (4L80E)
Circuit DTC 93 - Cylinder Balance Fault 3
#3 Cyl
•DTC 75 - System Voltage Low 10B (4L80E)
DTC 94 - Cylinder Balance Fault 3
#4 Cyl
DTC 76 - Resume/Accel Switch 3
Fault DTC 95 - Cylinder Balance Fault 3
#5 Cyl
DTC 78 - Wastegate Solenoid Fault 3
#6 Cyl
•DTC 79 - Trans Fluid Overtemp 10B (4L80E)
#7 Cyl
•DTC 81 - 2-3 Shift Solenoid Circuit 10B (4L80E)
#8 Cyl
•DTC 82 -1-2 Shift Solenoid Circuit 10B (4L80E)
Position 2 (5 Volt Reference Fault)
5-12-»
PS 17816
ENGINE HARNESS PCM

(15 PIN)
ENGINE SHUTOFF
ENGINE SHUTOFF SOLENOID SOLENOID CONTROL
— 981 BLU/WHT
• Q
— 339 PNK
F/SOL
TO IGNITION SWITCH
20 AMP
i PCM CONN. ID 1
L . 4
TO
! PA/PB - PINK - 3 2 PIN |
FUEL DRIVER
PC/PD - PINK - 2 4 PIN
NS14042
DTC 13
CIRCUIT FAULT
w
When the ignition switch is in the "OFF" position, the engine shutoff solenoid is in the No Fuel" position. By

• Ignition voltage on CKT 981 when PCM is requesting engine shutoff solenoid "ON."
OR
• No ignition voltage on CKT 981 when PCM is requesting engine shutoff solenoid "OFF."
Action Taken (PCM will default to): A current and history DTC 13 will be stored.
DTC 13 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled *OFF" then
"ON."
refer to circled number(s) on the diagnostic chart. cause a DTC 13. Also a no start condition will exist.
1. Check for open circuit from ignition switch to the The Tech 1 scan tool has the ability to turn the engine
solenoid. shutoff solenoid "ON" and "OFF." This can be used as
2. Check CKT 981 from solenoid to PCM for open. a quick operational check.
DTC 13
CIRCUIT FAULT
© •
•
IGNITION "OFF."
• IGNITION "ON."
• PROBE ENGINE SHUTOFF HARNESS TERMINAL " B " WITH
YES NO
JO H
© PROBE ENGINE SHUTOFF

HARNESS TERMINAL "A" WITH
CHECK FOR OPEN OR SHORT TO
GROUND IN CKT 339.
TEST LIGHT CONNECTED TO B • .
YES NO
IT-
OR OR
SHUTOFF SOLENOID.

PCM
ENGINE
COOLANT 410 YEL E C T SIGNAL
TEMPERATURE
T O
(ECT) SENSOR
TO TFT
SENSOR
(A/T ONLY)
INTAKE AIR -452 BLK PD6 SENSOR GROUND

TEMPERATURE
(IAT) SENSOR 472 TAN W2 IAT SIGNAL
^ PCM CONN. ID ]
TO BOOST SENSOR •
BARO SENSOR f PA/PB PINK 32 PIN "J
| PC/PD PINK 24 PIN
J^BC/BD BLUE 32 PIN J 11-6-93
PS 17514
DTC 14
DTC 14 Will Set W h e n : Engine coolant temperature greater than 151°C (304°F) as measured engine coolant
temp.
Action Taken (PCM will default to): The PCM will use 77°C (171°F) as measured engine coolant temp.
1. This step determines if DTC 14 is a hard failure or After engine is started, the coolant temperature
2. This test will determine if CKT is shorted to The PCM default value will flash intermittently
ground. on the data list.
DTC 14

TEMPERATURE OF 130°C(266°F) OR HIGHER?
1
NO
i
ENGINE COOLANT TEMPERATURE TO "DIAGNOSTIC AIDS* ON FACING PAGE.
BELOW-30°C(-22°F).
DOES IT?
1
YES NO

OR
DIAGNOSTIC AID OR
FAULTY PCM.
(APPROXIMATE)
°C °F OHMS
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
* 40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
10-29-93
ENGINE HARNESS CONNECTOR ( • P I N )

PCM
ENGINE
COOLANT
TEMPERATURE •iGli 410 YEL E C T SIGNAL
(EOT) SENSOR
TOTFT
SENSOR
(A/TONLY)
_ t 452 BLK SENSOR G R O U N D

INTAKE AIR -KEN
TEMPERATURE
(IAT) SENSOR
tiiatt 472 TAN —I I A T SIGNAL
| PCM CONN. ID 1
TO M O S T SENSOR-
BARO SENSOR f PA/PB PINK 3 2 P I N ]
1
BC/BD BLUE 32 PIN 1
11-S-93
PS 17514
DTC1S
ENGINE COOLANT TEMPERATURE (EOT) SENSOR CIRCUIT HIGH

Action Taken (PCM will default to):

• The PCM will use 18°C (64°F) as measured engine coolant temp.
• Idle increase.
1. This test determines i f DTC 15 is a hard failure or ECT temperature should rise steady to about 85°C
2. This test will determine i f CKT 410 is open or a the data screen.
faulty PCM.
DTC 15
(T)| • DOES TECH 1 SCAN TOOL DISPLAY E g OF •30X(-22'F) OR LESS?
]
YES NO
m
• DISCONNECT ECT SENSOR. DTC 15 IS INTERMITTENT. IF NO
DOES IT?
YES
m
© •
•
DOES IT?
YES NO
zn I
OPEN E a SENSOR GROUND CIRCUIT, FAULTY OPEN CKT 410, FAULTY
FAULTY PCM.
DIAGNOSTIC AID
(APPROXIMATE )
°C °F OHMS
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
IF PCM IS FAULTY AND MUST BE REPLACED, "TDC OFFSET" MUST
45 113 1188
40 104 1459 BE PROGRAMMED INTO THE NEW PCM.
35 95 1802 REFER TO "ON-VEHICLE SERVICE* IN THIS SECTION.
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
10-28-93
OUTPUT SPEED
AND — 1232 LTBLU PCM
VEHICLE SPEEDS-
•
SENSOR
(VSS) — 1233 DK GRN/YEL
VSS INPUT ENGINE

>K GROUND
GROUND C8 - 150 BLK
IGNITION FEED C9 - 39 PNK/BLK
C10
VSS BUFFER
MODULE C11
VSS INPUT C12 - 1232 LTBLU

TRANS. OUTPUT C13 - 437 BRN TRANSMISSION OUTPUT
PC15 SPEED SIGNAL
VSS OUTPUT C14 - 817 DK GRN/WHT VEHICLE SPEED
BD8
SIGNAL
VSS OUTPUT C15 - 824 LT BLU/BLK —* rTO SPEEDO
ALT
TO IGNITION
SWITCH-
20 AMP
i PCM CONN. ID I
4000 _ L . , . — 4
PULSES 40 ! PA/PB - PINK - 32 PIN |
PER/MILE PULSES | PC/PD - PINK - 2 4 PIN J
PER/MILE i BC/BD - BLUE - 32 PIN i
12-9-93
PS 17630
DTC 16
to the PCM. The CKT 437 circuit relays the transmission output speed which is used to control shift points, line
pressure, TCC, DTC 24 and DTC 72. The CKT 817 relays the vehicle speed which is used to control engine
occur.

• Greater than 20 mph. • CKT 817 open or grounded.
• 1000 to 4400 RPM. • All conditions must be met for 2 seconds.
Action Taken (PCM Will default to): No cruise control or fuel cutoff.
then "ON."
DTC Chart Test Description: Number(s) below 4. This tests for a signal from VSS buffer to the PCM.
1. This tests for B + at VSS buffer. Diagnostic Aids: Check connections at VSS buffer
2. This tests for proper ground path for vehicle speed and PCM. Refer to "4L80E Diagnostic Trouble Codes,"
sensor signal buffer. SECTION 10 if DTC 24 or DTC 72 is also set.
3. This tests for vehicle speed sensor signal buffer
signal to PCM.
DTC 16
BUFFER FAULT
INSTALL TECH 1.
RECORD, THEN CLEAR DTC(s).
RAISE DRIVE WHEELS.
ENGINE OPERATING.
TRANSMISSION IN ANY DRIVE RANGE.
WITH DRIVE WHEELS ROTATING, DOES "VEHICLE SPEED"
YES
© TRANSMISSION IN PARK.
"DIAGNOSTIC AIDS."
CONNECTOR TERMINAL " C 9 " WITH A TEST UGHT TO
GROUND.
IS TEST UGHT " O N " ?
YES NO
HZ H

CONNECTOR TERMINAL " C 9 " TO TERMINAL " C 8 "
WITH A TEST LIGHT.
j VIS NO

CONNECTOR TERMINAL " C 7 " TO TERMINAL
VSS BUFFER MODULE.
"C12" WITH 139200 DVM ON A/C SCALE.
DOES VOLTAGE INCREASE ON J 39200 DVM
NO
H
© • DOES TECH 1 DISPLAY TRANS OUTPUT SPEED

(MPH) INCREASE WITH DRIVE WHEEL SPEED
CHECK CKTs 821 OR 822 FOR OPEN
SHORT TO GROUND OR FAULTY
INCREASE? CONNECTIONS. IF OK, REPLACE VSS.
YES NO
CHECK CKT 817 FOR OPEN, SHORT, OR FAULTY CHECK VSS BUFFER CONNECTIONS.
CONNECTIONS AT VSS SIGNAL BUFFER CONNECTOR IF OK, REPLACE VSS BUFFER.
AND PCM CONNECTOR. IF OK, REPLACE PCM.
IF PCM IS FAULTY AND MUST BE REPLACED, "TLX OFFSET" MUST BE PROGRAMMED INTO THE NEW PCM.
1-6-94
ENGINE HARNESS
OPTICAL FUEL
TEMPERATURE SENSOR
\ 5 VOLT
< - J W V ^REFERENCE
CAM SIGNAL
SENSOR GROUND
1578 YEL
T
987 WHT 5 VOLT

REFERENCE
r
I TERMPERATURE
SIGNAL
f PA/PS PINK 32 PIN 1
PC/PD PINK 24 PIN
11-4-93
NS 14321
DTC 17
The optical/fuel temperature sensor provides a high resolution signal to the PCM by counting pulses on the
sensor disk located in the injection pump. The high resolution signal is one of the most important inputs by the
PCM for fuel control and timing.
DTC 17 Will Set W h e n : 8 pump cam reference pulses without and increase in high resolution counts
(internal to PCM).
DTC 17 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled ÔFF" then
w
ON."
1. This step will determine i f there is a 5 volt 18 is also stored, there is a possible problem with CKTs
reference. 474 or 987. It's possible DTC 17 may set i f there is air
2. This step checks the ground circuit. in the fuel system. Refer to SECTION 4.
3. This step will see i f the sensor is sending a signal
back to the PCM.
DTC 17
HIGH RESOLUTION
CIRCUIT FAULT
© •
•
IGNITION "OFF."
DISCONNECT OPTICAL/FUEL TEMPERATURE SENSOR.
• IGNITION "ON."
• PROBE TERMINAL " A " ON SENSOR HARNESS
CONNECTOR WITH J 39200 CONNECTED TO GROUND.
IS THERE 5 VOLTS?
NO
CD •WITH TEST LIGHT

m
CONNECTED CHECK FOR OPEN IN CKT 474
TO B + , PROBE SENSOR OR
FAULTY PCM.
X
YES NO
3Z ZH
© •
•
RECONNECT SENSOR.
CHECK FOR OPEN IN CKT 9B7
OR
• BACKPROBE PCM CONNECTOR TERMINAL "PD9" FAULTY CONNECTIONS
WITH J 39200 CONNECTED TO GROUND. OR
1
YES NO
3 Z
OR OR
FAULTY PCM. FAULTY OPTICAL/FUEL TEMPERATURE SENSOR
CONNECTION
OR
10-28-03
ENGINE HARNESS
OPTICAL FUEL
TEMPERATURE SENSOR
5 VOLT
_ J W L REFERENCE
CAM SIGNAL
SENSOR GROUND
1578 Y E L
r r v
987 WHT SVOLT

REFERENCE
-FUEL
TERMPERATURE
SIGNAL
PA/PS PINK 32 PIN .
PC/PD PINK 24 PIN
1
BC/BD BLUE 32PINJ 11-4-93
NS 14321
DTC 18
Circu it Description:
The optical/fuel temperature sensor also provides a Pump Cam signal to the PCM by counting pulses on the
sensor disk located in the injection pump. The Pump Cam reference signal is one of the most important inputs
used by the PCM for timing and start of injection.
DTC 18 Will Set W h e n I 8 pump cam reference pulses missed for every crankshaft position pulse.
DTC 18 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled ÔFF" then
« Q N »
refer to circled number(s) on the diagnostic chart. test idle and poor performance problems will exist. I f
1. This step determines i f i t is the result of a hard DTC 17 is stored, there is a possible problem with
failure or intermittent. CKTs 474 or 987.
4. This step checks to see i f the optical/fuel
temperature sensor is sending a signal to. the PCM.
DTC 18
CAM REFERENCE PULSE
ERROR
© •
•
INSTALL SCAN TOOL.
PULSES MISSED?
YES NO
T
© IGNITION "OFF."
DISCONNECT OPTICAUFUEL TEMPERATURE
PROBE SENSOR HARNESS TERMINAL " A " WITH
J 39200 TO GROUND.
IS THERE 5 VOLTS?
YES NO
JEZ
m
WITH A TEST LIGHT CONNECTED T O B + .
OR
OR
FAULTY PCM.
YES NO
© •
•
RECONNECT SENSOR.
OR
BACKPROBE PCM TERMINAL "PD15". FAULTY PCM.
IS THERE 60 Hz ( ± 3 Hz)?
1
YES NO
I I
OR OR
OR
12-1-93
PCM
TO ECT AND IAT SENSORS
CRANKSHAFT
643DKBLU/WHT j PD13 POSITION SIGNAL
IrTtiGl i
416 GRY fpcio" 5V REFERENCE
>-
i
A i
BOOST
SENSOR B
C
HeI
i 1
432 LTGRN { PC7
BOOST SIGNAL
(TURBO ONLY)
L J
i PCM CONN. ID t
i . . . 4
! PA/PB - PINK - 32 PIN | BARO SENSOR
! PC/PD - PINK - 24 PIN J 12-S-93
i BC/BD - BLUE - 32 PIN i PS 17521
DTC 19
The crankshaft position sensor is a hall effect type sensor that monitors crankshaft position and speed. There
are four teeth 90° apart on the front of the crankshaft sprocket that induce a pulse in the sensor which is
DTC 19 Will $6t W h e n : 8 crankshaft position pulses missed for every pump cam reference pulse.
DTC 19 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled " O F F then
"ON.*
refer to circled number(s) on the diagnostic chart. idle and poor performance will exist. Check for good
1. This step will determine if DTC 19 is the result of a connection at crankshaft position sensor and at PCM.
DTG19
CRANKSHAFT POSITION
REFERENCE ERROR
© •
•
NO
X
© IGNITION " O F F . "
IF NO ADDITIONAL DTC(s) ARE STORED.
IGNITION "ON," ENGINE "OFF." REFER TO "DIAGNOSTIC AIDS."
PROBE SENSOR HARNESS TERMINAL " C " WITH
J 39200 TO GROUND.
IS THERE 5 VOLTS?
NO
E E

OR
IS TEST LIGHT " O N " ? FAULTY CONNECTIONS.
OR
FAULTY PCM.
YES NO
H I
© •
•
RECONNECT SENSOR.
CHECK FOR OPEN IN CKT452.
OR
IS THERE 4 VOLTS?
X
YES NO
JO JL
OR OR
OR
PCM
-997 WHT/BLK • BD2 SV REFERENCE
APP1
SENSOR - 992 DK BLU PC4 APP 1 SIGNAL
998 BRN PD4 GROUND
ACCELERATOR
PEDAL -996 TAN PB7 5V REFERENCE
POSITION APP 2
•993 LTBLU PC3 APP 2 SIGNAL
(APP) SENSOR
MODULE — 999 PPL PD3 GROUND SENSOR
~995 YEL/BLK PD11 5V REFERENCE

SENSOR 994 DKGRN
961 GRY PD5 GROUND SENSOR
i POM CONN. ID
L ;
' PA/PB - PINK - 32 PIN
j PC/PD - PINK - 24 PIN
1-10-94
PS 17504
DTC 21
"ON."
1. This step determines if DTC 21 is the result of a closed and ignition "ON" or at idle. Voltage should
hard failure or an intermittent condition. increase at a steady rate as throttle is moved toward
3. This will check for an open in ground CKT 998. Also, 90% pedal travel is acceptable for correct
APP operation.
should vary from about .74 volt when throttle was
A DTC 21 will result if CKT 998 is open or CKT
992 is shorted to voltage.
Refer to "Intermittents," in SECTION 2.
DTC 21
CIRCUIT HIGH
© •
•
1
NO
X
© •
•
APP 1 VOLTAGE OF .25V OR STORED, REFER TO "DIAGNOSTIC
YES NO
X
© •
•
APP MODULE DISCONNECTED.
PROBE APP 1 HARNESS
OR
TERMINAL " A " WITH TEST FAULTY PCM.
LIGHT CONNECTED TO B • .
• TEST LIGHT SHOULD LIGHT.
1
TEST LIGHT "ON" TEST LIGHT "OFF"
T I
OR OR
4-16-93
PCM
-997 WHT/BLK BD2 5V REFERENCE
APP1
SENSOR -992 DK BLU PC4 APP 1 SIGNAL
998 BRN PD4 GROUND
ACCELERATOR
POSITION APP 2
-993 LTBLU PC3 APP 2 SIGNAL
(APP) SENSOR
MODULE 999 PPL PD3 GROUND SENSOR
-995 YEUBLK PD11 5V REFERENCE

994 DKGRN
SENSOR
PCM CONN. ID
PA/PB - PINK - 32 PIN

PC/PD - PINK - 24 PIN 1-10-94
BC/BD - BLUE - 32 PIN PS 17504
DTC 22
1. This step determines if DTC 22 is the result of a Scan TP sensor while depressing accelerator pedal
hard failure or an intermittent condition. with engine stopped and ignition "ON." Display
3. This step will determine if there is a faulty closed to about 3.7 volts when throttle is held at Wide
connection or sensor. Open Throttle (WOT) position.
4. This step will check the ground circuit. A DTC 22 will result if CKT 997 is open or CKT
992 is shorted to ground.
Diagnostic Aids: A scan tool reads APP 1 position Refer to "Intermittents," in SECTION 2.
in volts. Should read about .45 to .95 volt with throttle
DTC 22
CIRCUIT LOW
© THROTTLE CLOSED.
OF .25V OR L E S S ?
YES NO
© •
•
SCAN TOOL SHOULD DISPLAY APP 1 VOLTAGE REFER TO "DIAGNOSTIC A I D S -
GREATER THAN 4.0V.
DOES IT?
1 _
NO YES
© • PROBE CKT 992 WITH A TEST LIGHT

CONNECTED TO B +.
© POOR CONNECTION OR FAULTY
APP SENSOR.
GREATER THAN 4.0V.
DOES IT?
NO
YES

OR
OR
FAULTY CONNECTION
OR
OR
FAULTY PCM.
FAULTY PCM.
4-16-93
PCM
• §97 WHT/BLK - BD2 5V REFERENCE
APP1
SENSOR ' -992 DK BLU PC4 APP1 SIGNAL
— 998 BRN PD4 GROUND
ACCERLERATOR
PEDAL 996 TAN PB7 5V REFERENCE
POSITION APP 2
•993 LTBLU PO APP 2 SIGNAL
(APP) SENSOR

APP 3 PB10 APP3 SIGNAL
SENSOR 994 DK ORN
i PCM CONN. ID
L .
| PA/PB - PINK - 32 PIN
I PC/PD - PINK - 24 PIN 1-10-94
PS 17504
DTC 23
APP 3.
only one malfunction present. If there are two APP malfunctions present, the PCM will turn "ON" the "Service
Throttle Soon" lamp and limit power. If a third APP malfunction is present, the "Service Throttle Soon" lamp
will be "ON" and only allow the engine to operate at idle.
"ON."
1. This step determines if there is a good 5 volt Scan APP 2 sensor while depressing accelerator
2. This step will check for an open in the ground should vary from about 4.5 volts when throttle was
circuit. closed to about 1.5 volts when throttle is held at Wide
Diagnostic Aids: A scan tool reads APP 1 position
in volts. Should read about .45 to .95 volt with throttle
-
DTC 23
CIRCUIT RANGE FAULT
© •
•
HARNESS TERMINALS " G " , " D " AND " E " .
NO
JL
CKT(s) 997,996 OR 995 OPEN
OR
" A " , "B^ AND " J " . SHORTED TO GROUND
IS TEST LIGHT "ON* (ALL OR
YES NO
JL JL
OR 998,999,961
APP MODULE. OR
OR
FAULTY PCM.
4-16-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. m 1 5 5 2 7
PCM
-997 WHT/BLK - BD2 5V REFERENCE
APP1
998 BRN PD4 GROUND
ACCERLERATOR
POSITION APP 2
(APP) SENSOR
• 995 YEUBLK PD11 5V REFERENCE

SENSOR MAN -994 DKGRN
r — 9 6 1 GRY PD5 GROUND SENSOR
PCM CONN. ID
1.
! PA/PB - PINK 32 PIN
J PC/PD - PINK 24 PIN
1-10-94
i BC/BD - BLUE 32 PIN
PS 17504
DTC 25
will set but i t will not turn on the "Service Throttle Soon" lamp. The throttle will operate normally as long as
1. This step determines if DTC 25 is a hard failure or Eefer to SECTION 2 for "Intermittents."
2. This step checks the PCM and wiring. pedal with engine stopped and ignition "ON." Display
3. This will check for an open in ground CKT 999. should vary from about 4.5 volts when throttle was
closed, to about 1.5 volts when throttle is held at Wide
Diagnostic Aids: A Tech 1 scan tool reads APP 2 Open Throttle (WOT) position.
toward (WOT).
DTC 25
© IGNITION "ON/* ENGINE "OFF."

1
YES NO
X X
© •
•
PROBE APP 2 HARNESS
TERMINAL " B " WITH TEST LIGHT STORED, REFER TO "DIAGNOSTIC
CONNECTED TO B +. AIDS" ON FACING PAGE.
IS TEST LIGHT "ON"?
X
YES NO
X X
CKT 999 OPEN
OR
FAULTY PCM.
1
YES NO
x X
OR OR
OR
FAULTY PCM.
4-19-93
PCM
APP 1
SENSOR -992 DK BLU PC4 APP1 SIGNAL
998 BRN PD4 GROUND
ACCERLERATOR
POSITION APP 2
(APP) SENSOR

SENSOR 994 DKGRN
PD5 GROUND SENSOR
961 GRY
PCM CONN. ID

I PC/PD - PINK - 24 PIN
1-10-94
PS 17504
DTC 26
Action Taken (PCM Will default to): The input from the sensor is ignored. A current and history DTC
"ON."
1. This step determines if DTC 26 is the result of a throttle closed and ignition "ON" or at idle. Voltage
hard failure or an intermittent condition. should decrease at a steady rate as throttle is moved
2. This step checks the PCM and wiring. toward (WOT).
3. This will check the PCM and CKT 993 for an open. An open or short to ground in CKT 996 or 993 will
result in a DTC 26.
DTC 26
©[ DOES SCAN TOOL DISPLAY APP 2 LESS THAN .25 VOLTS?
3t NO
© •
•
IS THERE 5 VOLTS ( ± .2 V)?
NO
H

PROBE HARNESS TERMINAL " C " .
OR
OR
FAULTY PCM.
1
YES NO
X
FAULTY APP CONNECTION
IE
OR OR
OR
FAULTY PCM.
4-16-93
PCM
- 997 WHT/BLK • BD2 5V REFERENCE
-992 DK BLU PC4 APP 1 SIGNAL
998 BRN PD4 GROUND
ACCELERATOR
POSITION
(APP)
-995 YEUBLK PD11 SV REFERENCE
994 DKGRN PB10 APP 3 SIGNAL

PCM CONN. ID
J PA/PB PINK 32 PIN

J PC/PD PINK 24 PIN
1-10-94
i BC/BD BLUE 32 PIN
PS 17504
DTC 27
APP 3.
only one malfunction present. If there are two APP malfunctions present, the PCM will then turn "ON" the
lamp will be "ON" and will only allow the engine to operate at idle.
"ON."
1. This step determines if there is a good 5 volt throttle closed and ignition "ON" or at idle. Voltage
reference. should decrease at a steady rate as throttle is moved
2. This step will check for open ground circuits. toward (WOT).
Also, 90% pedal travel is acceptable for correct
APP operation.
DTC 27
CIRCUIT RANGE FAULT
© •
•
IGNITION QU, ENGINE " O F F . "
m m

HARNESS TERMINALS " G " , " D " AND " E " .
1
YES NO
JL
B + . PROBE HARNESS TERMINALS
CKT(s) 997,996 OR 995 OPEN
OR
1
YES NO
JLZ JL
OR 998,999,961
APP MODULE. OR
OR
FAULTY PCM.
4-16-93
DTC 29
engine operation. The PCM controls the glow plug system by sending a voltage signal.

OR
• Glow plugs "OFF" and "glow plug volts" is greater that .8 volt.
OR
DTC Chart Test Description: Number(s) below 6. This step will check relay and wiring.
1. This step will determine if DTC 29 is a hard Diagnostic Aids: If glow plug relay was stuck in
failure. the "ON" position, check for proper operation of glow
2. The Tech 1 scan tool may not display system plugs (refer to SECTION 7).
voltage. The important thing is that the PCM is When glow plugs are commanded "ON" by the
cycling voltage "ON" and "OFF," indicating that Tech 1, an internal PCM timer protects the glow plugs
the PCM is OK. from damage by cycling them "ON" for 3 seconds, and
3. This step will check relay feed circuit. the "OFF" for 12 seconds.
4. This step will check relay ground.
5. This step will determine if CKT 505 is open.
DTC 29
© •
•
• DOES "GLOW PLUG VOLTS" DISPLAY B *
NO YES
© •
•
OTHER DTCs ARE STORED,
VOLTAGE CYCLING "ON" AND " O F F " ? REFER TO "DIAGNOSTIC AIDS."
YES NO
© •
•
OR
• WITH TEST LIGHT CONNECTED TO GROUND, PROBE PCM.
GLOW PLUG RELAY HARNESS TERMINAL " A " .
IS TEST LIGHT "ON"?
3
YES NO
© CONNECT TEST LIGHT BETWEEN GLOW PLUG HARNESS TERMINALS " A " AND " C "
IS TEST LIGHT "ON"?
OPEN CKT 39.
YES NO
ZIZ
© •
•
WITH TEST LIGHT CONNECTED TO GROUND, PROBE HARNESS TERMINAL " B "
OPEN CKT 150.

IS TEST LIGHT "ON"?
YES NO
Z2ZZ
© •
•
WITH TEST LIGHT CONNECTED TO GROUND, PROBE GLOW PLUG SIDE OF RELAY.
OPEN CKT 505
OR
PCM.
YES NO
T
OR OR
OR OR
12-2-93
TFT TO ECT, IAT AND PCM

(A/T ONLY) SENSOR POSITION SENSOR

BARO SENSOR 433GRY/BLK BARO SIGNAL
416 GRY --AAJt 5 VOLT
REFERENCE
PCM CONN. ID J
PA/PB - PINK 32 PIN
PC/PD PINK 24 PIN i TO BOOST
BC/BD • BLUE 32 PIN ' SENSOR
I . . 1 12-9-93
PS 17505
DTC 31
BARO SENSOR CIRCUIT LOW
The BARO sensor represents barometric pressure and is used to compensate for altitude difference. The PCM
receives this information as a signal voltage.
DTC 31 Will Set W h e n : BARO pressure is less than 15 kPa for 2 seconds.
Action Taken (PCM will default to): A fixed BARO value.
DTC 31 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled "OFF" the
"ON."
refer to circled number(s) on the diagnostic chart. engine stopped, the BARO pressure is equal to
an intermittent condition. high. The information is used by the PCM as an
important thing is that the PCM recognized the result in a DTC 31.
DTC 31
BARO SENSOR CIRCUIT LOW
© IGNITION "ON."
DOES TECH 1 DISPLAY BARO PRESSURE VOLTAGE BELOW 1.0 VOLT?
YES NO
T
© •
•
IGNITION "OFF."
ADDITIONAL DTCs WERE STORED,
• JUMPER HARNESS TERMINALS " B " TO " C " . REFER TO "DIAGNOSTIC AIDS."
• IGNITION "ON."
• BARO PRESSURE VOLTAGE SHOULD READ OVER
4.0 VOLTS.
DOES IT?
NO YES
H
© •
•
IGNITION "OFF."
REMOVE JUMPER WIRE.
FAULTY CONNECTION
OR
• PROBE TERMINAL " B " (CKT 433) WITH A TEST SENSOR.
• IGNITION "ON."
• TECH 1 SHOULD READ BARO PRESSURE OVER
4 VOLTS.
DOES IT?
YES NO
ZC
CKT 41S OPEN, CKT 433 OPEN
SHORTED TO GROUND OR
OR CKT 433 SHORTED TO GROUND
FAULTY PCM. OR
OR
FAULTY PCM.
4-23-93
PS 17507
3-S6 DRIVEABILITY AND EMISSIONS (DIESEL)

(A/TONLY) SENSOR POSITION SENSOR

BARO SENSOR 433 GRY/BLK BARO SIGNAL
416 GRY —A/W 5 VOLT
REFERENCE
| PCM CONN. ID J
| PA/PB - PINK - 32 PIN J
i PC/PD • PINK 24 PIN i TO BOOST
i BC/BD - BLUE . 32 PIN i SENSOR
12-9-93
i .—i
PS 17505
DTC 33
BARO SENSOR CIRCUIT HIGH
The BARO sensor represents barometric pressure and is used to compensate for altitude difference. The PCM
receives this information as a signal voltage.
DTC 33 Will Set W h e n : BARO is greater than 105 kPa for 2 seconds.
Action Taken (PCM will default to): Fixed BARO value.
"ON."
PCM recognizes the change, the PCM and C K T 433 is shorted to voltage or to CKT 416.
engine stopped, the manifold pressure is equal to securely fastened.
high. This information is used by the PCM as an Refer to "EGR Control Pressure/BARO Sensor
DTC 33
BARO SENSOR CIRCUIT HIGH
© •
•
INSTALL SCAN TOOL.
ENGINE IDLING.
• DOES SCAN TOOL DISPLAY BARO PRESSURE
NO
H I
© •
•
IGNITION "OFF."
DOES IT?
YES NO
• PROBE SENSOR HARNESS TERMINAL CKT 433 SHORTED TO VOLTAGE

OR
FAULTY PCM.
YES NO
PLUGGED OPEN CKT 452.

OR
FAULTY BARO CONNECTION
OR
FAULTY BARO SENSOR.
4-23-S3
ENGINE HARNESS
PCM
CONNECTOR CIS PIN)
564 TAN/BLK 564 TAN/BLK ITS COIL 1 LOW

INJECTION
TIMING 565 RED/BLK 565 RED/BLK PM ITS COIL 1 HIGH
STEPPER
(ITS) 566 ORN/BLK 566 ORN/BLK PA10 ITS COIL 2 LOW
MOTOR 567 YEUBLK 567 Y E U B L K PA11 ITS COIL 2 HIGH
T PCM CONN. ID _ ]
BC/BD BLUE 32 PIN > 11*93
NS14055
DTC 34

• Engine operating at a steady RPM.
'• A 5° difference between measured and desired injection timing for 20.8 seconds.

refer to circled number(s) on the diagnostic chart. performance problem will exist.
1. This step determines if DTC 34 is a hard failure or Measured injection timing will freeze at the point
an intermittent. of the fault.
2. This step is checking for an open or short in CKTs
564 and 565.
3. This step is checking for an open or short in CKTs
566 and 867.
sending a pulsing voltage, this will indicate that
DTC 34
© INSTALL TECH 1 SCAN T O O L

SCAN INJECTION TIMING AT IDLE AND AT 1500 RPM.
s
DOES SCAN TOOL DISPLAY A 5 DIFFERENCE BETWEEN
MEASURED INJECTION TIMING AND DESIRED INJECTION
TIMING AT IDLE OR AT 1500 RPM?
| YES NO
© IGNITION - O F F . *
DISCONNECT PCM.
• DTC 34 IS INTERMITTENT.
MEASURE RESISTANCE BETWEEN PCM HARNESS TERMINAL REFER TO "DIAGNOSTIC AIDS."
** PA8* AND "PA9".
DOES RESISTANCE MEASURE BETWEEN 10 AND 60 OHMS?
YES NO

" P A H " AND **PA10*\
OR
DOES RESISTANCE MEASURE BETWEEN 10 AND 60 OHMS? FAULTY STEPPER MOTOR.
YES NO
3 1
© RECONNECT PCM.
DISCONNECT INJECTION TIMING STEPPER MOTOR.
OR
START AND IDLE ENGINE. FAULTY STEPPER MOTOR.
USING TECH 1, COMMAND *TDC TIME SET" "ON."
WITH J 39200 CONNECTED TO GROUND CHECK FOR A
PULSING VOLTAGE ON TERMINALS "A", " B " , "t","D"
DOES VOLTAGE PULSE ON ALL CIRCUITS?
1
YES NO
3Z 31
FAULTY INJECTION PUMP. CHECK FOR A GROUNDED
CIRCUIT
OR
FAULTY CONNECTION
OR
FAULTY PCM.
IF PCM IS FAULTY AND MUST BE REPLACED, "TDC OFFSET** MUST BE PROGRAMMED INTO THE NEW PCM.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. pVl6983
ENGINE HARNESS
CONNECTOR (15 PIN)
TO ENGINE • PCM
SHUTOFF 339PNK
SOLENOID
FUEL
984 LTGRN
- 985 RED
4ft 984 LTGRN
984 LTGRN
985 RED
BC14
BD13
FUEL INJECT CONTROL
FUEL INJECT CONTROL
FUEL INJECT SIGNAL
SOLENOID
DRIVER 950
39 PNK/BLK
ENGINE HARNESS
TO MIL-* v CONNECTOR TO WATER IN
7BLK FUEL SENSOR
TO GLOW
PLUG RELAY
TO VSS BUFFER
FUEL RED MODULE
r"
i PCM CONN. ID

j PC/PD - PINK - 24 PIN 1-3-94
PS 17509
DTC 35
to inform it when the fuel solenoid has actually seated. This injection pulse width signal is measured in
milliseconds.

• Engine coolant temperature greater than 20°C (68°F).
• Injection pulse width less than 1.2 milliseconds.
Action Taken (PCM Will default to): Afixedinjection pulse width value of 1.95.
"ON."
DTC 35
© •
•
1
YES NO
i
• DOES INJECTION PULSE WIDTH FLUCTUATE? REFER TO "DIAGNOSTIC AIDS* ON
FACING PAGE.
YES NO
i
F A U L T Y FUEL SOLENOID CONNECTION OPEN CKT 985
OR OR
F A U L T Y FUEL SOLENOID. FAULTY CONNECTION
OR
FAULTY PCM.
W H E N ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. NYI 5532
ENGINE HARNESS
CONNECTOR (15 PIN)
TO ENGINE PCM
SHUTOFF 339 PNK r 1
SOLENOID
984 LTGRN BC14 FUEL INJECT CONTROL
p a
—984LTGRN — 4 j - _L_ { - 984LTGRN BD13 FUEL INJECT CONTROL
—t 985 RED 1- p 985 RED —
PC2 FUEL INJECT SIGNAL
FUEL - 4 - = U 3 9 PNK jf7
SOLENOID
DRIVER L. I 950
39 PNK/BLK
ENGINE HARNESS
[0
TOMIL-* v CONNECTOR TO WATER IN
7BLK FUEL SENSOR
TO GLOW
PLUG RELAY
TO VSS BUFFER
FUEL RED MODULE
r-
i PCM CONN. ID

! PC/PD - PINK - 24 PIN
1-3-94
PS 17509
DTC 36
to inform it when the fuel solenoid has actually seated. This injection pulse width signal is measured in micro
seconds.

Action Taken (PCM Will default to): Fixed injection pulse width value of 1.95.
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: If the scan value fluctuates, C K T
refer to circled number(s) on the diagnostic chart. 985 is OK.
1. This step determines if DTC 36 is a hard failure or A weak (mechanical failure) fuel solenoid will
2. This step sill determine if the solenoid is at fault,
DTC 36
© ENGINE IDLING.
YES NO
i i
• DOES INJECTION PULSE WIDTH FLUCTUATE? REFER TO "DIAGNOSTIC AIDS'* ON
FACING PAGE.
1
YES NO
i
OR OR
OR
FAULTY PCM.
12-2-93
BULKHEAD
CONNECTOR
PCM
STOP-HAZ •
B+-«—•^X*— 140 ORN
15 AMP TOCHMSL
TO TURN TO
N.O./^"" SIGNAL HAZARD
STOP LAMP/ FLASHER
140 ORN STOPLAMP/
BRAKE SWITCH
- 820 YEL CRUISE CONTROL
BRAKE SIGNAL
420 PPL I TCC BRAKE SIGNAL

TCC BRAKE
-39 PNK/BLK
SWITCH TO TRANS SHIFT
LOCK CONTROL
TO GENERATOR
TO ENGINE
~ SHUT-OFF
SOLENOID
TO MIL AND "SERVICE TO FUEL HEATER

THROTTLE SOON" LAMP
^ TO VSS BUFFER
TO ALT
IGNITION ^ 39 PNK/BLK TO GLOW PLUG RELAY
SWITCH
20 AMP
4 TO WASTE- w TO AUTO PARK
PCM CONN. ID BULKHEAD GATE SOLENOID BRAKE
1
PA/PB - PINK - 32 PIN CONNECTOR T 0 G L 0 W P L U G
TO CRUISE
! PC/PD - PINK - 24 PIN RELAY -*r- CONTROL SWITCH 12-9-93
i BC/BD - BLUE - 32 PIN PS 17510
DTC 41
The TCC normally closed brake switch supplies a B + signal on CKT 420 to the PCM. The signal voltage is
opened when the brakes are applied.
The stoplamp/cruise control normally open brake switch supplies a B + signal on C K T 820 to the PCM when

OR
• TCC and C/C brake switches not toggling "open" and "closed," during 6 brake applications on same
ignition cycle.
Action Taken (PCM Will default to): An incorrect brake signal can affect TCC, fourth gear operation in hot
mode and cruise control.

refer to circled number(s) on the diagnostic chart. • Refer to "PCM Intermittent Diagnostic
switch.
being applied.
DTC 41
APPLY BRAKES.
DOES SCAN TOOL DISPLAY C/C BRAKE SWITCH "CLOSED"
1
NO YES
JL X
I DOES SCAN TOOL DISPLAY TCC BRAKE SWITCH "OPEN*
© IGNITION STILL "ON."

WITH TEST LIGHT CONNECTED TO GROUND,

PROBE HARNESS TERMINAL " B " .
1
NO YES
IS TEST LIGHT "ON"?
JO
CHECK FUSE. DTC 41 IS INTERMITTENT.
NO I STORED, REFER TO
x © IGNITION STILL "ON."
© JUMPER HARNESS
TERMINALS " C " AND
OPEN IN CKT 140.
WITH TEST LIGHT CONNECTED
FACING PAGE.
" B " TOGETHER.

TERMINAL "A".
SCAN TOOL SHOULD
IS TEST LIGHT "ON"?
DISPLAY C/C BRAKE
SWITCH "CLOSED."
DOES IT? 1
YES NO
JO JLZ
NO YES
© JUMPER HARNESS
TERMINALS " A " AND
OPEN IN CKT 39.
" B " TOGETHER.

X
OPEN CKT 820
x
FAULTY CONNECTION
SCAN TOOL SHOULD
DISPLAY TCC BRAKE
OR AT BRAKE SWITCH SWITCH "CLOSED."
FAULTY PCM OR DOES IT?
CONNECTION STOPLAMP/CRUISE
CONTROL
OR
FAULTY PCM. BRAKE SWITCH.
1
NO YES
X X
OPEN CKT 420 FAULTY CONNECTION
OR AT BRAKE SWITCH
OR BRAKE SWITCH.
FAULTY PCM.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. ps 17110
ENGINE HARNESS
OPTICAL FUEL
TEMPERATURE SENSOR
SVOLT
- j y y ^ i ? ™ N c i
CAM SIGNAL

SENSOR GROUND
1578 Y E L
r
V S . VVOLT
OI
987 WHT
REFERENCE
r• POM CONN. ID TERM PER ATURE

I _ _ SIGNAL
^PAIPB PINK 32 PIN ^
PC/PD PINK 24 PIN
^ K / B ^ B L ^ ^ P I N J 11-4-13
NS 14321
DTC 42
Action Taken (PCM will default to): Poor idle quality during hot conditions.
DTC 42 Will Clear When: The fault condition(s) no longer exist.
2. This test will determine i f CKT 1578 is shorted to 987 will result in a DTC 43.
ground. The Temperature To Resistance Value" scale at
DTC 42

1
ED NO
i
FUEL TEMPERATURE BELOW -26°C (-15°F). TO "DIAGNOSTIC AIDS" ON FACING PAGE.
DOES IT?
YES NO
H
FAULTY OPTICAL/FUEL TEMPERATURE SENSOR. CKT 1578 SHORTED TO GROUND
OR
OR
FAULTY PCM.
DIAGNOSTIC AID IF PCM IS FAULTY AND MUST BE REPLACED, "TDC

OFFSET" MUST BE PROGRAMMED INTO THE NEW
FUEL TEMPERATURE SENSOR PCM. REFER TO "ON-VEHICLE SERVICE* IN THIS
SECTION.
(APPROXIMATE)
°C °F OHMS
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 •4 28680
-30 -22 52700
-40 -40 100700
11-15-93
N S 1
ENGINE HARNESS
OPTICAL FUEL
TEMPERATURE SENSOR
\ 5 VOLT
-jyyyd^PERENCE
JB^ CAM SIGNAL

SENSOR GROUND
E 1578 Y E L f
F T 5 . VOLT
r 987 WHT
REFERENCE
r PCM CONN. ID ] TERM PERATURE

SIGNAL
• PC/TO PINK 24 PIN
[BC/BD BLUE 32 PINJ 11^-83
NS 14321
DTC 43

• Fuel temperature less than -14°C (6°F).
Action T a k e n (PCM Will default to): Poor idle quality during hot conditions.

1. This step determines if DTC 43 is a hard failure or started, the temperature should rise steadily.
2. This test simulates a DTC 42. If the PCM 987 will result in a DTC 43.
recognizes the low signal voltage (high temp) and The Temperature To Resistance Value" scale at
the Tech 1 scan reads 144°C (291°F) or above, the the right may be used to test the fuel sensor at various
PCM and wiring are OK. temperature levels to evaluate the possibility of a
3. This test will determine if CKT 1578 is open. "skewed" (mis-scaled) sensor.
There should be 5 volts at sensor connector if
measured with J 39200. This will determine if
there is a wiring problem or a faulty PCM.
DTC 43
©[ • DOES TECH 1 SCAN TOOL DISPLAY FUEL TEMP OF -14°C (6°F) OR LESS?
3
YES NO
© •
•
DISCONNECT SENSOR.
JUMPER HARNESS TERMINALS "IT AND "f TOGETHER.
DOES IT?
NO YES
© •
•
FAULTY CONNECTION
OR OPTICAUFUEL
DOES IT? TEMPERATURE SENSOR.
1
YES NO
OPEN SENSOR GROUND CIRCUIT, FAULTY

m
OPEN CKT 1578, FAULTY
FAULTY PCM.
DIAGNOSTIC AID
(APPROXIMATE)
°c °F OHMS
100 212 177
90 194 241
80 17S 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
5-7-93
PCM
TO VSS
SUFFER
WASTEGATE
SOLENOID
TO GENERATOR
TO ENGINE
SHUTOFF
SOLENOID
TO IGNITION
SWITCH
MIL "SERVICE
ENGINE SOON*
CONTROL
"SERVICE THROTTLE
SOON " L A M P
CONTROL
, PA/PB - PINK - 32 PIN

i PC/PD - PINK 24 PIN CRUISE -< 39 PNK/BLK
i BC/BD - BLUE - 32 PIN i CONTROL ^rwivBi-n. 12-13-93
L. . . I PS 17S13
DTC 46
MIL "SERVICE ENGINE SOON* CIRCUIT FAULT
There should always be a MIL "Service Engine Soon" when the ignition is "ON" and the engine "OFF." The
PCM will control the MIL and turn it "ON" by providing a ground path.

• Ignition voltage on CKT 419 when PCM is requesting MIL "ON."
OR
• No ignition voltage on CKT 419 when PCM is requesting MIL "OFF."
Action Taken (PCM will default to): No MIL.
refer to circled number(s) on the diagnostic chart. open i n CKT 419 will cause a DTC 46 to set.
command the MIL.
ignition feed circuit.
DTC 46
© •
•
IGNITION "ON," ENGINE "OFF. 1

MIL "ON."
DOES MIL COME "ON"?
YES
© •
•
IGNITION " O F F . "
-
• IGNITION "ON. * FACING PAGE.
• CONNECT TEST LIGHT TO PCM
HARNESS TERMINAL * B C 5 " TO
GROUND.
DOES MIL COME "ON"?
1
YES NO
I
mCHECK:
OR - FUSE.
PCM. - FAULTY BULB.
- OPEN CKT 419.
12-16-93
1
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. **$ ^752

PCM
ENGINE
T O
COOLANT • 410 YEL E C T SIGNAL
TEMPERATURE
(ECT) SENSOR
TO TFT
SENSOR
(ATT ONLY)
INTAKE AIR
TEMPERATURE
Si •452 BLK SENSOR GROUND
(IAT) SENSOR
'WIST 472 TAN IAT SIGNAL
p
C M CONN. ID
TO BOOST SENSOR-
BARO SENSOR PA/PB PINK 32 PIN
PC/PD PINK 24 PIN
11-6-93
[BC/Bl^l^jaPJNJ PS 17514
DTC 47

• Engine coolant temperature less than 38°C (100°F).
Action Taken (PCM will default to): Poor performance during cold weather operation.

an intermittent condition. degrees centigrade. A faulty connection or an open in
2. This test will determine if CKT 472 is shorted to CKTs 452 and 472 will result in a DTC 47.
the right may be used to test the intake air
DTC 47
© DOES TECH 1 SCAN TOOL DISPLAY IAT OF 96°C (205°F) OR HIGHER?
YES NO
X JL
LESS THAN-26°C(-15°F). AIDS" ON FACING PAGE.
DOES IT?
YES NO
T
I
OR
OR FAULTY PCM.
DIAGNOSTIC AID

(APPROXIMATE)
°C °F OHMS
100 212 177

90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
11-15-93
N S

PCM
ENGINE
COOLANT
TEMPERATURE tEK 410 YEL —I E C T SIGNAL
(ECT) SENSOR
TO TFT
SENSOR
(A/T ONLY)
INTAKE A I R
TEMPERATURE
•Eli •452 BLK —I SENSOR GROUND
(IAT) S E N S O R
t+Ett 471 TAN —I IAT SIGNAL
| P O M CONN. ID |
TO BOOST SENSOR *
BARO SENSOR f PA/PB PINK 3 2 P I N ]
| PC/PD PINK 24 PIN |
[ B C / B D B L U E 32 PIN J 11-6-93
PS 17514
DTC 48
DTC 48 Will Set W h e n : Intake air temperature less than ~38°C (-39°F) for 2 minutes.
Action Taken (PCM Will default to): Possible poor performance during cold weather operation.
an intermittent condition. degrees centigrade. After engine is started, the
2. This test will determine if CKT 472 is shorted to temperature should rise steadily to about 47°C (115°F)
ground. then stabilize. A faulty connection or an open in CKTs
3. This test will determine if there is a wiring 472 and 452 will result in a DTC 14.
problem or a faulty PCM. Refer to "Intermittents" in SECTION 2.
the right may be used to test the intake air
DTC 48
© • DOES TECH 1 SCAN TOOL DISPLAY IAT -38°C (-39°F) OR COLDER?
YES NO
TOGETHER. STORED, REFER TO 'DIAGNOSTIC
TECH 1 SCAN TOOL SHOULD AIDS* ON FACING PAGE.
130°C(266°F).
DOES IT?
YES NO
JL
© •
•
e
130 C(266°F).
DOES IT?
DIAGNOSTIC AID 3L
TEMPERATURE VS. RESISTANCE VALUES IE X

°C °F OHMS
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973
45 113 1188
40 104 1459
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
4-23-93
PCM
TO VSS
BUFFER
WASTE GATE
SOLENOID
TO GENERATOR
TO ENGINE
SHUTOFF
SOLENOID
TO IGNITION
SWITCH TO FUEL HEATER
TO WATER
IN FUEL
SENSOR
TO GLOW
PLUG RELAY
419 BRN/WHT MIL "SERVICE

ENGINE SOON"
CONTROL
"SERVICE THROTTLE
960 ORN SOON " LAMP
CONTROL
f , 1
J PCM CONN. ID J
! PA/PB - PINK • 32 PIN , TO
i PC/PD - PINK - 24 PIN i CRUISE 39 PNK/BLK
i BC/BD . BLUE - 32 PIN i CONTROL 12-13-93
i . . i PS 17513
DTC 49
1
"SERVICE THROTTLE SOON LAMP CIRCUIT FAULT
There should be a "Service Throttle Soon" lamp when the ignition is "ON" and the engine "OFF" for 2
seconds. The PCM will control the "Service Throttle Soon" lamp and turn it "ON" by providing a ground path.

• Ignition voltage on CKT 960 when PCM is requesting "Service Throttle Soon" lamp "ON."
OR
• No ignition voltage on CKT 960 when PCM is requesting "Service Throttle Soon" lamp "ON."
Action T a k e n (PCM will default to): A current and history DTC 49 will set, but it will not turn on the MIL.

2. This test will determine if there is an open in
ignition feed circuit, or CKT 960.
DTC 49
'SERVICE THROTTLE SOON" LAMP CIRCUIT FAULT
© •
•
INSTALL SCAN TOOL.
IGNITION "ON", ENGINE " O F F " .
DOES "SERVICE THROTTLE SOON"
COME ON?
NO YES
T
© •
•
IGNITION "OFF."
DISCONNECT 24 PIN (PINK) PCM CONNECTOR.
• IGNITION "ON." REFER TO "DIAGNOSTIC AIDS."
PROBE PCM HARNESS TERMINAL "PA5".
CHECK:
FUSE.
FAULTY BULB.
OPEN CIRCUIT.
- CKT 960 SHORTED TO VOLTAGE.
- OPEN IGNITION FEED TO BULB.
NS14761
DTC 51
PROM ERROR
4-23-93
DTC 54
* CHECK TO SEE IF A DTC 17 IS ALSO STORED. IF THERE IS REFER TO THAT
CHART FIRST, IF NOT, REPLACE PCM.
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. p$ 20090
ENGINE HARNESS
CONNECTOR (15 PIN)
TO ENGINE
SHUTOFF 339 PNK PCM
SOLENOID
9S4 LTGRN 8C14 FUEL INJECT CONTROL
984 LTGRN BD13 FUEL INJECT CONTROL
985 RED FUEL INJECT SIGNAL
pa
FUEL
SOLENOID
DRIVER 950
TO GENERATOR
TO FUEL HEATER
TO WATER IN
FUEL SENSOR
^ TO GLOW
PLUG RELAY
J O VSS BUFFER
FUEL MODULE
SOLENOID TO CRUISE
TO AUTO CONTROL
PARK BRAKE SWITCH
r"
i PCM CONN. ID
— - „ - „ - . --4
I PA/PB PINK - 32 PIN '
J PC/PD • PINK - 24 PIN J 1-3-94
BC/BD - BLUE - 32 PIN i PS 17509
DTC 56
INJECTION P U M P CALIBRATION RESISTOR ERROR
DTC 56 Will Set W h e n : PCM has lost its memory and is unable to read a resistor value on CKT 960 on the
next ignition cycle.
"ON"
refer to circled number(s) on the diagnostic chart. driver. Clear DTC, and cycle ignition. I f DTC clears,
1. This step will determine if there is a problem with treat condition as an intermittent.
the connection at the fuel solenoid driver or a
faulty fuel injection pump.
DTC 56
RESISTOR ERROR
©[ ARE THERE ANY OTHER ENGINE D T C s STORED?
YES NO

CONNECTION
OR
5-7-93
P S 1 6 7 5 6

(A/T ONLY) SENSOR POSITION SENSOR
452 BLK/WHT 1 SENSOR GROUND

BARO SENSOR 433 GRY/BLK BARO SIGNAL
416 GRY —AAAA—s VOLT
REFERENCE
r , „ .„.—««,
J PCM CONN. ID J
| PA/PB - PINK - 32 PIN |
i PC/PD • PINK - 24 PIN i TO BOOST
i BC/BD . BLUE 32 PIN i SENSOR
l . 1 12-0-S3
PS 17505
DTC 57
PCM 5 VOLT SHORTED
Action Taken (PCM Will default to): Backup fuel, no EGR and no turbo boost.
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: At time fault is present multiple
refer to circled number(s) on the diagnostic chart. DTCs that share a 5 volt reference may also set.
1. Checks to confirm that a DTC is still present.
2. Checks to determine if there is a 5 volt reference
from the PCM.
3. Checks to determine if there is a short-to-ground
in CKT 416 or C K T 474, or a short-to-ground in
the PCM.
DTC 57
PCM 5 VOLT SHORTED
© INSTALL SCAN TOOL.

IGNITION " O N . - ENGINE "OFF."
RECORD AND CLEAR DTCs.
CRANK ENGINE FOR 15 SECONDS OR START UP.
DOES DTC 57 RESET?
1
NO
I
© •
•
DISCONNECT EGR CONTROL PRESSURE/BARO SENSOR.
REFER TO "DIAGNOSTIC AIDS.'
NO
© •
•
DISCONNECT POM 32 PIN PINK CONNECTOR ONLY.
REPLACE EGR CONTROL
• WITH TEST UGHT CONNECTED TO B + , PROBE PCM
TERMINALS " P O O " AND "PD10".
IS TEST LIGHT " O N " IN EITHER CIRCUIT?
NO YES

IN CKT 416 OR 474.
1M-93
NS 14545
PCM
CRANKSHAFT
643 DK BLU/WHT PD13 POSITION SIGNAL
416 GRY PC10 5V REFERENCE
A
BOOST
SENSOR B BOOST SIGNAL
432 LTGRN
(TURBO ONLY)
C
i PCM CONN. ID i
I"-— 4
• PA/PB - PINK - 32 PIN J BARO SENSOR
j PC/PD - PINK - 24 PIN j
I BC/BD - BLUE - 32 PIN i 12-9-93
PS 17521
DTC 61

• Boost signal voltage greater than 3.9 volts.
• RPM less than 3500.
Action Taken (PCM will default to): No turbo boost.
1. This step will determine if DTC 61 is the result of a pressure with the signal voltage being high.
432 are OK. same ± .4 volt.
3. This step will check for an open in the ground Very little boost can be attained by revving the
circuit. engine in neutral.
DTC 61
0 • ENGINE IDLING.
1
NO
m
CD ••• IGNITION "OFF.*
• IGNITION " O N " "DIAGNOSTIC AIDS" ON FAQNG PAGE.
• TECH 1 SHOULD DISPLAY BOOST VOLTAGE OF
1 VOLT OR LESS.
DOES IT?
1
NO
© • PROBE HARNESS TERMINAL "A" WITH A

TEST LIGHT TO B * .
CHECK CKT 432
SHORTED TO VOLTAGE
• TEST LIGHT SHOULD LIGHT. OR
DOES IT? FAULTY PCM.
1
YES NO
PLUGGED SENSOR FITTING OPEN CKT 452.

OR
FAULTY BOOST SENSOR.
10-28-93
PCM
CRANKSHAFT
643 DK BLU/WHT
POSITION SIGNAL
416 GRY 5V REFERENCE
BOOST
SENSOR BOOST SIGNAL
432 LTGRN (TURBO ONLY)
L -J
i PCM CONN. ID i
i . „ - 4
! PA/PB - PINK - 3 2 PIN | BARO SENSOR
j PC/PD - PINK - 2 4 PIN j
12-9-93
t _ _ _ _ — —— — - — — — J PS17S21
DTC 62
J>TC 62 Will Set W h e n : Boost signal voltage less than .8 volt.
Actipn Taken (PCM will default to): No turbo boost and limited fuel, poor performance.
DTC Chart Test Description: Number(s) below Diagnostic Aids: With the ignition ON" and the
w
416 and CKT 432 are OK. same ± .4 volt.
Very little boost can be attained by revving the
engine in neutral.
DTC 62
VOLTAGE LESS THAN .8 VOLT?
1
YES NO
m
© •
•
IGNITION "OFF."
• JUMPER HARNESS TERMINALS " B " AND " C " TOGETHER. "DIAGNOSTIC AIDS".
• IGNITION "ON."
DOES BOOST VOLTAGE READ GREATER THAN 4.0 VOLTS?
1
NO YES
X X
• IGNITION "OFF." FAULTY CONNECTION
• REMOVE JUMPER WIRE. OR SENSOR.
• IGNITION "ON."
• PROBE TERMINAL " B" WITH TEST LIGHT T O B + .
• TECH 1 SHOULD READ OVER 4 VOLTS.
DOES IT?
1
YES NO
X X
OPEN CKT 416 CHECK FOR OPEN IN CKT 432
OR OR
OR
OR
FAULTY PCM.
11-15-93
NS15536
PCM
APP1
SENSOR - 992 DK BLU PC4 APP1 SIGNAL
998 BRN PD4 GROUND
ACCERLERATOR
POSITION APP 2
-993 LTBLU PO APP 2 SIGNAL
CAPP) SENSOR
PD11 5V REFERENCE
-995 YEUBLK
SENSOR 994 DKGRN
PD5 GROUND SENSOR
961 GRY
i PCM CONN. ID
L „ .
| PA/PB - PINK 32 PIN
i PC/PD - PINK 24 PIN 1-10-94
i BOBD BLUE - 32 PIN PS 17504
DTC 63
Soon* lamp will light and the PCM will limit power. If three APP sensors have a malfunction present, the
refer Jtimreled number(s) on the diagnostic chart. in volts. Should read about 4.0 volts with throttle
3. This will check for an open in CKT 994 and PCM. Also, 90% pedal travel is acceptable for correct
APP operation.
should vary from about 4.0 volts when throttle closed
DTC 63
CIRCUIT HIGH
© IGNITION "ON." ENGINE " O F F . *

NO
m
© DISCONNECT APP MODULE.
WITH TEST LIGHT CONNECTED TO B • . TO "DIAGNOSTIC AIDS" ON FACING PAGE.
IS TEST UGHT "ON"?
j YES NO
m

CKT 961 OPEN
OR
FAULTY PCM.
YES NO
mFAULTY APP CONNECTION OPEN CKT 994 OR SHORTED

OR OR
OR
FAULTY PCM.
4-23-93
NS 15537
PCM
- §97 WHT/BLK - BD2 5V REFERENCE
APP1
998 BRN PD4 GROUND
ACCERLERATOR
POSITION APP 2
(APP) SENSOR
-995YEL/BLK PD11 SV REFERENCE

SENSOR 994 DK ORN
r-
i PCM CONN. ID
I-
' PA/PB - PINK - 32 PIN
J PC/PD - PINK - 24 PIN 1-10-94
l BCBD - BLUE - 32 PIN PS 17504
DTC 64
3. This will check the PCM and CKT 994 for an open. Also, 90% pedal travel is acceptable for correct
APP operation.
A DTC 64 will result i f CKT 995 is open or CKT
994 is shorted to ground.
Refer to Intermittents," in SECTION 2.
DTC 64
CIRCUIT LOW
(T) I DOES SCAN TOOL DISPLAY APP 3 LESS THAN .25 VOLTS?
1 1
NO
IE
© •
•
WERE STORED REFER TO 'DIAGNOSTIC AIDS"
IS THERE 5 VOLTS (±2\!}7
Ejj] NO
© WITH J 39200 CONNECTED TO GROUND,

PROBE HARNESS TERMINAL "K".
OR
OR
FAULTY PCM.
YES NO
X
OR OR
OR
FAULTY PCM.
4-23-93
PS 17508
PCM
• 997 WHT/BLK • BD2 5V REFERENCE
APP1
SENSOR -992 DK BLU PC4 APP1 SIGNAL
998 BRN PD4 GROUND
ACCERLERATOR
POSITION APP 2 APP2 SIGNAL
-993 LTBLU PC3
(APP) SENSOR
PD11 5 V REFERENCE
•995 YEUBLK
SENSOR ! 994 DKGRN
PCM CONN. ID
• PA/PB - PINK 32 PIN

J PC/PD - PINK 24 PIN
1-10-94
i BC/BD - BLUE 32 PIN
PS 17504
DTC 65
Action T a k e n (PCM will default to): The input from APP 3 sensor is ignored. A current and history DTC
will set but it will not turn "ON" a "Service Throttle Soon" lamp. Throttle will operate normally as long as there
is only one malfunction present. If there are two APP malfunctions present the PCM will then turn "ON" the
1. This step determines if DTC 65 is the result of a closed and ignition "ON" or at idle. Voltage should
2. This step will check the wiring and the PCM for a Wide Open Throttle (WOT).
fault. Also, 90% pedal travel is acceptable for correct
APP operation.
DTC 65
CIRCUIT RANGE FAULT
© IGNITION -ON," ENGINE " O F F "

WITH J 39200 CONNECT TO GROUND, PROBE
HARNESS TERMINALS " G " , "D" AND " E " .
X
NO

CKT(s) 997,996 OR 995 OPEN
OR
YES NO
JL X
OR 998,999,961
APP MODULE. OR
OR
FAULTY PCM.
4-16-93
N S 1 5 5 2 7
PCM
ALT
TO m
IGNITION
20 A
- 39 PNK/BLK - J
"ON/OFF*
397 GRY • REQUEST SIGNAL
RESUME/ACCELERATOR
- 8 3 DKGRN
REOUEST SIGNAL
SET/COAST
- 84DKBLU
REQUEST SIGNAL

i PCM CONN. ID i
l> • 4
! PA/PB - PINK - 3 2 PIN «
j PC/PD - PINK - 2 4 P I N j
i B0BD - BLUE - 32 PIN i 12-9-93
PS 17581
DTC 71
The cruise "ON/OFF," "set/coast" and "resume/aeceF switches are inputs to the fuel control portion of the
PCM when "set/coast" is depressed.

w w
• Cruise control O N .
• Ignition voltage on terminal "BDIS" for more than 25.5 seconds.
affected.
DTC 71 Will Clear W h e n : The fault condition(s) no longer exist, and the ignition switch is cycled OFF then
w w
"ON."
1. This step determines i f CKT 84 is shorted to
voltage.
fault.
DTC 71
© •
•
NOTE TEST LIGHT.
1
1
© • WITH PROBE STILL CONNECTED, ENGAGE AND RELEASE

SET/COAST SWITCH.
OR
DOES TEST LIGHT COME " O N " AND GO " O F F " WHEN FAULTY CRUISE SWITCH.
NO YES

OR
FAULTY PCM.
IF PCM IS FAULTY AND MUST BE REPLACED, "TDC OFFSET" MUST BE PROGRAMMED INTO THE NEW K M .
10-28-93
NS15540
PCM
ALT
TO .
IGNITION
20 A
1
39 PNK/BLK —
"ON/OFF"
397 GRY BD3 REQUEST SIGNAL
RESUME/ACCELERATOR
- 83DKGRN BD11 REOUEST SIGNAL
SET/COAST
- 84 DK BLU BD15
REQUEST SIGNAL

i PCM CONN. ID i
j —. — — - 4
! PC/PD - PINK - 24PIN J
i BC/BD - BLUE - 32 PIN i 12-9-93
PS 17581
DTC 76
PCM.

ff
• Ignition voltage on terminal BD1V for more than 25.5 seconds.
Action Taken (PCM Will default to): The PCM will disallow all cruise inputs. TCC shift schedules may be
affected.
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: Check for a "set/coast" switch
refer to circled number(s) on the diagnostic chart. stuck in the engage position, or CKT 83 shorted to
1. This step determines i f CKT 83 is shorted to voltage.
voltage.
fault.
DTC 76
© •
•
D I S C O N N E C T P C M 3 2 PIN B L U E C O N N E C T O R .
HARNESS WITH A T E S T LIGHT C O N N E C T E D TO
GROUND.
NOTE T E S T LIGHT.
TEST LIGHT " O F F " TEST LIGHT "ON"
1 1
© WITH P R O B E STILL C O N N E C T E D , E N G A G E
AND CKT 83 SHORTED TO VOLTAGE
OR
DOES TEST UGHT COME "ON" AND G O "OFF" FAULTY CRUISE SWITCH.
W H E N R E S U M E / A C C E L S W I T C H IS R E L E A S E D ?
NO YES
^JL
OR
FAULTY PCM.
IF P C M IS F A U L T Y A N D M U S T B E R E P L A C E D , " T D C O F F S E T " M U S T B E P R O G R A M M E D I N T O T H E N E W PCM.

W H E N A L L D I A G N O S I S A N D R E P A I R S A R E C O M P L E T E D , C L E A R DTC(s) A N D V E R I F Y P R O P E R O P E R A T I O N . NV 15858
PCM
TO
VACUUM
p
TURBO UMP
WASTE GA1
ACTUATOR
12-20-93
PS 17519
DTC 78
Circuit Description;
The PCM operates a solenoid to eontrol boost. This solenoid is normally open. By providing a ground path the
PCM energizes the solenoid which then allows vacuum to pass to the wastegate.
During normal operation, the PCM compares its wastegate duty cycle signal with the boost signal and makes
corrections in the duty cycle accordingly.

• Fuel rate greater than 20 mm.
• Boost pressure greater than 8 kPa from desired (internal to PCM).
Action Taken (PCM will default to): Boost will shut down. Reduce maximum fuel.
1. This step will check for a good vacuum source. lines and components connected to the hoses for leaks
2. This step will check for a faulty vacuum line or or sharp bends.
pump. Check vacuum source. A possible DTC 32 will
3. This step checks the wastegate solenoid. store if there is a problem with the vacuum source.
DTC 78
© •
•
INSTALL VACUUM GAGE IN PLACE OF WASTEGATE.
OBSERVE VACUUM AT IDLE.
IS1T?
YES
•
•
DISCONNECT ELECTRICAL CONNECTOR.
OBSERVE VACUUM GAGE AT IDLE.
© CHECK VACUUM SOURCE AT SOLENOID ASSEMBLY.
IS THERE VACUUM? I • 1
ABOUT 50 kPa (15") VACUUM. BELOW 50 kPa (15") VACUUM.
I i :
YES NO
© DISCONNECT WASTEGATE CHECK FOR PLUGGED
X
FAULTY
i
SYSTEM OK, REFER TO
SOLENOID CONNECTOR.
OR LEAKY VACUUM
HOSE TOTHE
HARNESS CONNECTOR VACUUM PUMP.
WASTEGATE SECTION 6J FOR
TERMINALS. IF OK, CHECK
SOLENOID. FURTHER DIAGNOSIS.
IGNITION "ON," ENGINE "OFF." VACUUM PUMP
IS TEST LIGHT "ON"? OUTPUT AND REPAIR.
1
YES NO
I
CONNECT TEST LIGHT FAULTY SOLENOID
BETWEEN HARNESS CONNECTION
TERMINAL " A " AND GROUND. OR
IS TEST LIGHT "ON"? FAULTY SOLENOID.
NO YES
m
OPEN CKT 972 OPEN CKT 439.
OR
OR
FAULTY PCM.
10-29-93
PCM
• 997 WHT/BLK - BD2 5V REFERENCE
APP 1
998 BRN PD4 GROUND
ACCELERATOR
POSITION APP 2
•993 LTBLU PO APP 2 SIGNAL
(APP) SENSOR
MODULE — 9 9 9 PPL PD3 GROUND SENSOR

SENSOR 994 DKGRN
PCM CONN. ID

PC/PD - PINK - 24 PIN
I BC/BD - BLUE - 32 PIN 1-10-94
PS 17504
DTC 84
faults stored.
Action Taken (PCM Will default to): When DTC 84 is set, a current and history DTC will set, but will not
"ON."
refer to circled number(s) on the diagnostic chart. APP module and PCM.
DTC 84
CIRCUIT FAULT
• CHECK COMPLETE APP HARNESS FOR INTERMITTENT SHORTS OR OPENS.

• IF OK, REPLACE APP MODULE.
• IF DTC RESETS, REPLACE PCM.
5-7-93
WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETED, CLEAR DTC(s) AND VERIFY PROPER OPERATION. PS1S7S7
DTC 88
TDC OFFSET ERROR
DTC 88
TDC OFFSET ERROR
• THIS DTC WILL SET IF TDC OFFSET IS GREATER THAN * 2.0°, OR THE PCM HAS LOST MEMORY (TDC
3-17-93
DTC 91

CYLINDER #7.

DTC 92
DIAGNOSE ALL OTHER DTC(s) BEFORE PROCEEDING.

DTC 92 INDICATES THERE IS A POSSIBLE MECHANICAL OR FUEL DELIVERY PROBLEM WITH
CYLINDER # 2 .
DTC 92 WILL NOT TURN ON THE MIL, BUT WILL BE STORED AS A CURRENT AND HISTORY DTC.

DTC 93

CYLINDER #6.

11-3-93
PS 1 i 7 5 5
DTC 94

• DTC §4 INDICATES THERE IS A POSSIBLE MECHANICAL OR FUEL DELIVERY PROBLEM WITH
CYLINDER # 5 .

DTC 95

CYLINDER # 4 .

DTC 96

CYLINDER # 3 .
* CHECK : FOR BASIC ENGINE MECHANICAL OR CYLINDER FUEL

11-3-93
PS 20091
DTC 97


DTC 98
• DIAGNOSE ALL OTHER DTC(S) BEFORE PROCEEDING.

DEUVERY PROBLEM WITH CYLINDER # 8 .

11-4-93
PS 20092
PCM
-997 WHT/BLK- BD2 5V REFERENCE
-992 DK BLU PC4 APP 1 SIGNAL
• — 9 9 8 BRN PD4 GROUND
ACCELERATOR
POSITION
(APP)
-993 LTBLU pa APP2 SIGNAL
999 PPL PD3 GROUND SENSOR
•
MODULE
- 99S YEL/BLK PD11 5V REFERENCE
994 DK ORN PB10 APP3 SIGNAL

r-
i PCM CONN. ID
!•-
• PA/PB - PINK - 32 PIN
J PC/PD - PINK - 24 PIN 1-10-94
i BC/BD - BLUE - 32 PIN PS 17504
DTC 99
Action Taken (PCM Will default to): If DTC 99 is present, the PCM will turn "ON" the "Service Throttle
"ON."
DTC Chart Test Description: Number(s) below Diagnostic Aids: A Tech l scan tool reads APP 2
refer to circled number(s) on the diagnostic chart. position in volts. It should read about 4.5 volts with
1. This check will determine if the reference voltage throttle closed and ignition "ON" or at idle. Voltage
is shorted. should decrease at a steady rate as throttle is moved
A short to ground in CKT 996 will result in a DTC
99.
Scan APP 2 signal while depressing accelerator
DTC 99
© •
•
-
IGNITION "ON." ENGINE "OFF. *
• WITH J 39200 CONNECTED TO GROUND,
PROBE APP HARNESS TERMINAL " D " .
YES NO
CKT 996 SHORTED TO GROUND DTC 99 IS INTERMITTENT. IF NO OTHER

4-23-93
PS 17111
PCM
451 WHT/BLK DIAGNOSTIC
PA12
ENGINE REQUEST
G R 0 U W P
j-lSOBLK - ^ | - , 450WHT/BLK 450 BLK/WHT i PC1 SYSTEM GROUND
B A TO FUEL
jpJF | E
| ° [ C
| | [5] PUMP» RELAY
DCI A V *—
* S 0 BLK/WHT -|PD1 SYSTEM GROUND
DATA LINK
CONNECTOR (DLC) 1061 ORN/BLK SERIAL DATA
ECM-CRNK
TO
439 PNK/BLK 4 PA1 IGNITION FEED
IGNITION
ECM-BAT 10 AMP
SWITCH
B+ < • \ ^ -
10 AMP
OIL PRESSURE
SWITCH
JO
806PPL/WHT
STARTER
120 GRY
FUEL
PUMP PRIME < <
•I- - » •
450 BLK/WHT
1
FUEL
PUMP > UUUJ
RELAY
FUEL PUMP
120 GRY -
G 997 WHT/BLK BD2 5V REFERENCE

APP 1 > A A K
F 992 DK BLU PC4 APP1 SIGNAL
SENSOR V^W^—
998 BRN PD4 GROUND
A
ACCELERATOR
PEDAL D 996 TAN PB7 5V REFERENCE
POSITION APP 2
<Âfsh— C
> A A K
(APP) SENSOR 993 LTBLU PC3 APP 2 SIGNAL

MODULE
999 PPL PD3 GROUND SENSOR
B
995 YEUBLK PD11 5V REFERENCE
E
APP 3 S AAA,
994 DKGRN PB10 APP 3 SIGNAL
SENSOR ^ - V r — K
J ENGINE HARNESS
CONNECTOR (15 PIN)
OPTICAL
FUEL TEMP/ A 474 GRY PD10 5V REFERENCE
SENSOR/ B 982 PNK PD15 CAM SIGNAL
> C -
- 983 RED PD9 HIRES. SIGNAL
D 987 WHT PD14 GROUND
E 1578 YEL PB11 FUEL
F 987 WHT TEMPERATURE
SIGNAL
12-9-93

ENGINE HARNESS CONNECTOR (B PIN)

PCM
ENGINE
COOLANT A ECT SIGNAL
TEMPERATURE
(ECT) SENSOR
B
INTAKE SENSOR GROUND

AIR
TEMPERATURE
CRANKSHAFT
POSITION SIGNAL
5V REFERENCE
BOOST SIGNAL
BARO SIGNAL
ITS COIL 1 LOW

ITS COIL 1 HIGH
ITS COIL 2 LOW
ITS COIL 2 HIGH
ENGINE SHUT-OFF
SOLENOID CONTROL
FUEL INJECT CONTROL

FUEL INJECT CONTROL
FUEL INJECT SIGNAL
CLOSURE GROUND
FUEL
SOLENOID
12-9-93
Figure 3-11 - PCM Wiring Diagram S.5L Diesel (2 of 6)

BULKHEAD
CONNECTOR
PCM
STOP-HAZ
B+^- **\J*— 140 ORN
15 AMP TOCHMSL
TO TURN JO
A SIGNAL
STOPLAMP/ HAZARD
CRUISE CONTROL SWITCH FLASHER
B 140 ORN
BRAKE SWITCH
C 820 YEL - PA7 BRAKE SIGNAL
TCCBRAKE
SWITCH
"•I B
C
420 PPL
-39 PNK/BLK "

—
TO TRANS SHIFT
LOCK CONTROL
BRAKE SIGNAL
D TO GENERATOR
TO ENGINE
SHUT-OFF
SOLENOID
TO FUEL HEATER
TO MIL AND "SERVICE
THROTTLE SOON" LAMP
O VSS BUFFER
A
TO ALT
IGNITION * - T O GLOW PLUG RELAY
SWITCH 39 PNK/BLK
20 AMP
TO AUTO PARK
BULKHEAD BRAKE
TO WASTE-
CONNECTOR G SOLENOID
A T i
TO CRUISE
CONTROL SWITCH
JUNCTION I — 3 9 PNK/BLK— 1
BLOCK ——505 Y E L - — GLOW PLUG RELAY

B+ < • * 2 RED CONTROL
150 BLK
GLOW
PLUG
G L O W PLUG
RELAY
LEFT
GLOW
PLUGS
* *
503 ORN
-507 DK BLU" GLOW PLUG SIGNAL

"GLOW PLUG"
LAMP
BULKHEAD
CONNECTOR
RIGHT
GLOW
* FUSIBLE LINK PLUGS
12-9-93

OUTPUT SPEED
AND PCM
VEHICLE S P E E D f -
SENSOR L.
(VSS)
VSS BUFFER
MODULE
TO IGNITION
SWITCH
"SERVICE THROTTLE
SOON * LAMP
CONTROL
— -
CRUISE "ON/OFF"
CRUISE w w ^ REQUEST SIGNAL
CONTROL
SWITCH RESUME/ACCELERATE
— REQUEST SIGNAL
SET/COAST REQUEST
SIGNAL
A/C CONTROL
SWITCH
TO *m
IGNITION
SWITCH
— ~ — A
A/C COMPRESSOR
CLUTCH
12-9-93
REFER TO PCM CONNECTOR TERMINAL END VIEW FOR PCM CONNECTOR COLOR NS1586S

PCM
BULKHEAD
CONNECTOR
ALT
IGNITION
SWITCH"* 39 PNK/BLK
20 AMP
TO MIL AND "SERVICE

THROTTLE SOON" LAMP
TO CRUISE
CONTROL^
SWITCH
TO GENERATOR
TO ENGINE
SHUT-OFF
SOLENOID
TO FUEL H E A T E R S
TO WATER IN
FUEL SENSOR
TO GLOW
PLUG RELAY
TO VSS
BUFFER
MODULE
TO AUTO
PARK BRAKE
TO
VACUUM
TURBO PUMP .
WASTE GATE
ACTUATOR VALVE
TURBO
WASTE
GATE t— 39 PNK/BLK
SOLENOID WASTE GATE
972 YEL A3
SOLENOID CONTROL
4-23-93
NS 14204
REFER TO PCM CONNECTOR TERMINAL AND END VIEW FOR PCM CONNECTOR COLOR
PCM
-1493 DIC BLU 4 WHEEL DRIVE

4 WHEEL DRIVE LOW SIGNAL
LOW SWITCH N.O.
TRANSMISSION TRANSMISSION INPUT

• 1230 GRY/RED — PC12
INPUT SPEED [_ SPEED SIGNAL (HIGH)
SENSOR •1231 D K B L U / W H T — PD12 TRANSMISSION INPUT
SPEED SIGNAL (LOW)
TO EGR CONTROL TO ECT* IAT,
PRESSURE/BARO SENSOR CRANKSHAFT
(LESS THAN 8500 GVW) POSITION AND
BOOST SENSOR
A
TO BARO
TRANSMISSION SENSOR
CONNECTOR (GREATER
THAN 8500
GVW)
TRANSMISSION
FLUID SENSOR GROUND
TEMPERATURE
(TFT) TRANSMISSION
SENSOR FLUID
TEMPERATURE
(TFT) SIGNAL
TORQUE TCC SOLENOID
CONVERTER CONTROL (PWM)
CLUTCH
(TCC)
SOLENOID
1-2 SHIFT
SOLENOID
1-2 SHIFT
SOLENOID
CONTROL
2-3 SHIFT
SOLENOID
CONTROL
PRESSURE
CONTROL
PRESSURE SOLENOID
CONTROL (LOW)
SOLENOID
(PCS) PRESSURE
CONTROL
SOLENOID
(HIGH)
RANGE
SIGNAL " A "
TRANSMISSION
RANGE RANGE
PRESSURE SIGNAL
SWITCH
RANGE
SIGNALS

11-30-93
REFER TO PCM CONNECTOR TERMINAL END VIEW FOR PCM CONNECTOR COLOR. NS 14803
Figure3-15-PCM Wiring Diagram 6.5L Diesel (6of 6)


from a known good vehicle. The voltages you get may vary due to tow tottery charge or other reasons,
09
• Engine at operating temperature • Engine idling (for "Engine Operating column)
PINK 24 PIN PA-PB CONNECTOR
NORMAL VOLTAGE
"ON" OPERATING
A1 IGNITION FEED 439 PNK/BLK B* B + - NO START
A2 NOT USED - - - - - -
A3 WASTEGATE SOLENOID CONTROL 972 YEL B+ B + 62 NO TURBO BOOST
A4 NOT USED - - - - - -
AS "SERVICE THROTTLE SOON" LAMP 960 YEL 49 NO SERVICE THROTTLE
CONTROL SOON LAMP
A6 NOT USED - - - - - -
A7 CRUISE CONTROL BRAKE SWITCH
SIGNAL
820 YEL 0 0 37,38,4 -
A8 rrSMA(HI)(1) 565 RED/BLK .9 V B + 34 POOR PERFORMANCE
A9 ITSMA(LO)(1) 564 TAN/BLK B + JV 34 POOR PERFORMANCE
A10 ITSMA(LO)(2) 566 ORN/BLK B + JV 34 POOR PERFORMANCE
A11 ITSMA(HI)(2) 567 YEUBLK .IV B+ 34 POOR PERFORMANCE
A12 DIAGNOSTIC REQUEST 451 WHT/BLK 5V 5V NONE NO SCAN DATA
BACK VIEW
OF
(1) VARIES. CONNECTOR
(2) OPEN CIRCUIT.
(6) LESS THAN .5 VOLT (500 mV).
VEHICLE: P MOTOR HOME

ENGINE: 6.5L DIESEL VIN F(L65) 24 PIN A-B
CONNECTOR
TRANSMISSION: 4L80E (PINK)
12-10-93
PS 16550


This K M voltage chart is for use with a J 39200 to further aid in diagnosis. These voltages were derived
The "B • " symbol indicates a nominal system voltage of 12-14 volts.
PINK 24 PIN PA-PB CONNECTOR
NORMAL VOLTAGE
PIN PIN CKT WIRE DTQs) POSSIBLE
"ON" OPERATING
B1 NOT USED - - - - -
B2 NOT USED - - - -
B3 NOT USED - - - - - ... - ...
B4 A/C SIGNAL 59 DKGRN 0*A 0*A NONE A/C STATUS
B5 NOT USED - - - - - ...

B6 NOT USED - - - - - -
B7 APP 2 SENSOR SV REFERENCE 996 TAN 5V 4.3 V 25,26,27,84, POOR PERFORMANCE
B8 GLOW PLUG SIGNAL 507 DK BLU 0 29 NO GLOW PLUG LAMP

POOR PERFORMANCE
- - -
B9 NOT USED -
- -
B10 APP 3 SENSOR SIGNAL 994 DKGRN 4V 4V 64,65,84 POOR PERFORMANCE
B11 FUEL TEMP SIGNAL 1578 YEL (2) 1.5V(2) 42,43 POOR PERFORMANCE
(COLD TEMPS)
B12 IAT SIGNAL 4J2 TAN (2) 1.6 V ( 2 ) 47,48 POOR PERFORMANCE
(1) VARIES.
(3) OPEN CIRCUIT.
(4) GROUNDED CIRCUIT. BACK VIEW
OF
(5) OPEN/GROUNDED CIRCUIT. CONNECTOR
A B+ WITH A/C "ON."
VEHICLE: P MOTOR H O M E
ENGINE: 6.5L DIESEL VIN F(L65) 24 PIN A-B
CONNECTOR
TRANSMISSION: 4L80E (PINK)
12-10-93
PS 1 6 5 5 1
Figure 3-17- PCM Connector Terminal End View (2 of 6)


The "B * " symbol indicates a nominal system voltage of 12-14 volts.
NORMAL VOLTAGE
PIN PIN CKT WIRE DTC($) POSSIBLE
"ON* OPERATING
CI SYSTEM GROUND 450 WHT/BLK 0* 0* NONE -
a FUEL INJECT SIGNAL 985 RED 1.8 1.8 - -
a APP SENSOR 2 SIGNAL 993 LTBLU 4.3V 4.3V 26,27,84 POOR PERFORMANCE
C4 APP SENSOR 1 SIGNAL 992 DK BLU .5V .5V 22,23,84 POOR PERFORMANCE
C5 BARO SIGNAL 452 BLK 4.8V 4.8V 31,33 NO EGR
CS PRESSURE CONTROL SOLENOID 1228 RED/BLK 0* 6.3V 73 HARSH SHIFT

(HIGH)
C7 BOOST SIGNAL 432 LTGRN 1.4V 1.4V 61,62 NO TURBO BOOST
C8 ECT SIGNAL 410 YEL 3.4V 3.0V 14,15 EARLY TCC APPLY
C9 TRANSMISSION FLUID 1227 BLK/YEL 3.5V 2.8V 58,59,79 EARLY TCC APPLY
TEMPERATURE (TFT) SIGNAL
C10 CRANKSHAFT POSITION, BARO, AND 416 GRY SV 5V 19,31 BACK-UP FUEL
BOOST SENSOR 5V REFERENCE
C11 PRESSURE CONTROL SOLENOID 1229 LTBLU/ 0* 1.5V 73 HARSH SHIFT

(LOW) WHT
C12 TRANS INPUT SPEED SIGNAL (HIGH) 1230 GRY/RED 0* 0* 74 NO TCC APPLY
NO 4™ GEAR IN HOT MODE
C13 GLOW PLUG RELAY CONTROL 505 YEL B+ 0* 29 NO GLOW PLUG LAMP,
HARDSTART
C14 SERIAL DATA 1061 ORN/BLK 5V 5V NONE NO SCAN TOOL DATA

n d
C15 TRANSMISSION OUTPUT SPEED 437 BRN 0* 0* 24,72 2 GEAR ONLY
SIGNAL
C16 NOT USED - - - - - -

BACK VIEW
OF
CONNECTOR
(1) VARIES.
(3) OPEN CIRCUIT.
(4) GROUNDED ORCUIT.

ENGINE: 6.5L DIESEL VIN F (L65)
TRANSMISSION: 4L80E
32PINC-D 12-10-93
CONNECTOR (PINK) PS 16552


This K M voltage chart is for use with a J 39200 to further aid in diagnosis. These voltages were derived
PINK 32 PIN PC-PD CONNECTOR
NORMAL VOLTAGE.
PIN PIN CKT WIRE DTCCs) POSSIBLE
"ON" OPERATING
01 SYSTEM GROUND 450 BLK/WHT 0* 0* NONE -

02 CLOSURE GROUND 950 LTGRN (4) (4) - NO START
D3 APP 2 SENSOR GROUND 999 PPL 0 0 26,27,84 POOR PERFORMANCE
D4 APP 1 SENSOR GROUND 998 BRN 0 0 22,23,84 POOR PERFORMANCE
05 APP 3 SENSOR GROUND 961 RED 0 0 64,65,84 POOR PERFORMANCE
D6 ECT, IAT. CRANKSHAFT POSITION 452 BLK 0* 0* 14,47,19,58 FAST IDLE, EARLY TCC
AND TFT SENSOR GROUND BACK-UP FUEL
07 NOT USED - - - - -
08 NOT USED - - - - - -
D9 HIGH RESOLUTION SIGNAL 983 RED 5V 2.5V 17 BACK-UP FUEL
D10 OPTICAL SENSOR 5V REFERENCE 474 GRY 5V 5V 17,18 BACK-UP FUEL
011 APP 3 SENSOR 5V REFERENCE 995 YEUBLK 5V 5V 64,65,84 POOR PERFORMANCE
012 TRANSMISSION INPUT SPEED 1231 DK BLU/ 0* 0* 74 NO TCC APPLY

SIGNAL (LOW) WHT NO 4™ GEAR IN HOT
MODE
D13 CRANKSHAFT POSITION SIGNAL 643 BLU/WHT 5 V 4.3 V 19 BACK-UP FUEL
014 OPTICAL / FUEL TEMP SENSOR 987 GRN/WHT 0* 0* 17,18 BACK-UP FUEL
GROUND
015 OPTICAL SENSOR CAM SIGNAL 982 PNK * ,2 V .5 V 18 BACK-UP FUEL
010 NOT USED - - - - - -

(1) VARIES PROM 0 TO BATTERY VOLTAGE, DEPENDING ON POSITION OF DRIVE WHEELS.
B
ACKVIEW
(2) VARIES. OF
(3) OPENQRCUIT. 5ONN ECTOR
(4) GROUNDED CIRCUIT. Al \ pi\
1 • •
"Innl 1

ENGINE: 6.5L DIESEL VIN F (L65) =BK-:|
TRANSMISSION: 4L80E
32 PIN C-D
CON NECTOR (PINK)
12-10-93
PS 16553

PCM Connector and Driveability Symptoms identification

from a known good vehicle. The voltages you get may vary due to tow battery charge or other reasons,
but they should Be very close.
• Testterminal not grounded • Scan tool not installed
LT BLUE 32 PIN BC-BD CONNECTOR
NORMAL VOLTAGE
"ON" OPERATING
C1 BATTERY FEED 440 ORN B+ B + NONE NO START
C2 NOT USED - - - . - - -
C3 NOT USED - - - - -
C4 NOT USED - - - - - -
C5 MIL "SERVICE ENGINE SOON" CONTROL 419 BRN/WHT (5) (5) 46 NO SERVICE THROTTLE
SOON LAMP
C6 NOT USED - - - - - -
a 1-2 SHIFT SOLENOID CONTROL 1222 LTGRN B+ .4 V 82 NO 3^/4^ GEAR
C8 RANGE SIGNAL "A" 1224 PNK B+ B+ 24,28,72 -

C9 RANGE SIGNAL " B " 1225 DKBLU B + B+ 24,28,72 -
C10 RANGE SIGNAL ~ C " 1226 RED B+ B + 24,28,72 -
C11 TCC SOLENOID CONTROL 1350 TAN/BLK B+ .4V 67-4L60E NO TCC APPLY
83-4L80E
C12 NOT USED - - - - - -

C13 2-3 SHIFT SOLENOID CONTROL 1223 YEL/BLK B+ .4V 81 -
C14 FUEL INJECT CONTROL 984 LTGRN 0 1.9 V NONE NO START
C15 NOT USED - - - - - -

C16 ENGINE SHUT-OFF SOLENOID CONTROL 981 DKBLU/ B+ B+ 13 NO START
WHT
BACK VIEW OF
(D VARIES. CONNECTOR
(2) READS BATTERY VOLTAGE IN GEAR.
(3) OPEN CIRCUIT.
(4) (SRfltlNDPD CIRCUIT
m LESS THAN 1 VOLT.
VEHICLE: P MOTOR HOME m

ENGINE: 6.5L DIESEL VIN F (L65) H
TRANSMISSION: 4L80E |
—an."
32 PIN C-D
CONNECTOR 12-10-93
(LTBLUE) PS 16554


but tney snould Be very close.
LT BLUE 32 PIN BC-BD CONNECTOR
NORMAL VOLTAGE
OPERATING
01 NOT USED - - - - - -
02 APP 1 SENSOR 5V REFERENCE 997 WHT/BLK 5V 5V 21,22,23, POOR PERFORMANCE
84
D3 CRUISE "ON/OFF" REQUEST SIGNAL 397 GRY (2) (2) NONE NO CRUISE
D4 NOTUSED - - - - - -
05 TCC BRAKE SWITCH SIGNAL 420 PPL B + B + 37.38,41 NO TCC
06 NOTUSED - - - - - -
07 NOTUSED - - - - - -
08 NOTUSED - - - - - -
D9 NOTUSED - - - - - -
D10 NOT USED - - - - - -
D11 RESUME/ACCEL REQUEST SIGNAL 83 DKGRN (2) (2) 76 NO CRUISE
D12 NOT USED - - - - - -

D13 FUEL INJECT CONTROL 984 LTGRN 0 1.9 V NONE -
014 NOT USED - - - - - -
015 SET/COAST REQUEST SIGNAL 84 DKBLU (4) 71 NO CRUISE
016 NOT USED - - - - - -

(1) VARIES. BACK VIEW OF
(2) OPEN CIRCUIT. CONNECTOR
(3) GROUNDED CIRCUIT. / \ A

(4)
(5) OPEN/GROUNDED
LESS THAN 1 VOLT.CIRCUIT. £B$A
* LESS THAN .5 VOLT (500 mV). ::: :
E£=
VEHICLE: P MOTOR HOME ® " D•D•
ENGINE: 6.5L DIESEL VIN F (L65) 1 llII an
TRANSMISSION: 4L80E 1
32PIN C D
CONNECTOR 12-10-93
(LTBLUE) PS 16555

BLANK
ON-VEHICLE SERVICE
WIRE HARNESS If this happens, to the wrong terminal pair, it is
spliced, into a harness, use wire with high contains an assortment of flexible connectors, used to
the system, it is important that the best possible bond fuse and to adapt fuse holder, with a meter, for
Molded on connectors require complete to locate by sight, because oxidation, or terminal
new connector assembly into the harness. wiggling a connector on a sensor, or in the wiring
CONNECTORS AND TERMINALS also, be caused by oxidized or loose connections.
terminals in them. It is possible to short between connectors look similar, but are serviced differently.
opposite terminals.

DRAIN WIRE
Z OUTER JACKET
MYLAR

REMOVE MYLAR.
SPLICE AND SOLDER
3. SPLICE TWO WIRE TOGETHER USING SPLICE

3. UNTWIST CONDUCTORS. STRIP INSULATION AS
NECESSARY.
DRAIN WIRE
2
4. SPLICE WIRES USING SPLICE CLIPS AND ROSIN CORE
3
6. TAPE OVER WHOLE BUNDLE TO SECURE AS BEFORE. 4S 0570-6E

Micro-Pack To remove a terminal:

1. Slide the seal back on the wire.
Refer to Figure 3-23 and repair procedure for 2. Insert tool (3) BT-8518, or J 35689, or
replacement of a Micro-Pack terminal. W
equivalent, as shown in insert "A" and B," to
connector.
(2).
Weather-Pack

oxidation and deposits on the terminals. This
voltage and current levels found in the electronic
system.
2 TERMINAL 4 TOOL J 33095/BT8234-A Repair of a Weather-Pack terminal is shown in
7S3548-6E
Metri-Pack If removal is attempted with an ordinary pick,
because, to install a terminal on a wire, the wire is seated and all of the sealing rings in place, when
terminal pulled back into the connector to seat it in They are used to improve the connector reliability by
place. retaining the terminals, if the small terminal lock
Weather-Pack connector andterminalpackages.
*7S 3213-6E

1. OPEN SECONDARY LOCK HINGE ON CONNECTOR.

FEMALE MALE [T| Important
CONNECTOR CONNECTOR
PCM, a DTC 88 will be stored. It is important to
program T D C Offset" into the service PCM. Refer
SECONDARY- W
to TDC Offset Program Procedure"
LOCK HINGE
REMOVE TERMINAL USING TOOL.
[T"| Important
A PUSH TO
J W • RELEASE • When replacing the production PCM with a service
PCM (controller), it is important to transfer the
TERMINAL TOOL J 28742/BT8234-A
CUT WIRE IMMEDIATELY BEHINDCABLE SEAL. service PCM label. Please Do Not record on PCM
WIRE PCM parts throughout the service life of the
SEAL vehicle.
4. REPLACE TERMINAL
A. SLIP NEW SEAL ONTO WIRE. [T| Important
B. STRIP 5mm (.2") OF INSULATION FROM WIRE.
C CRIMP TERMINAL OVER WIRE AND SEAL. • To prevent internal PCM damage, the ignition
must be ^ O F F " when disconnecting or
SEAL cable, PCM pigtail, PCM fuse, jumper cables, etc.).
The ignition should be "OFF* for at least 30
5. PUSH TERMINAL AND CONNECTOR AND
seconds before disconnecting powertothe PCM.
ENGAGE LOCKING TANGS.
6. CLOSE SECONDARY LOCK HINGE.
7S3542-6E
Figure 3-25 - Weather-Pack Terminal Repair

Compact Three
The Compact Three connector, which looks similar

This type of connector, most likely, is used at the air
control solenoid. Use the standard method, when
repairing a terminal. Do not use the Weather-Pack
terminal tool J 28742, or BT-8234-A, as these will

replaced, the PROM and PCM should be checked first
to see if they are the correct parts. If they are, remove
the PROM from the faulty PCM and install it in the
new service PCM. THE SERVICE PCM WILL NOT
installed improperly or has malfunctioned. When
1 CONTROL MODULE
bent pins or pin not fully seated in the socket. If it is
installed correctly and DTC 51 is still displayed, 2 FLOOR AND DASH PANEL
replace the PROM.
3 BOLT
4 VSS BUFFER MODULE

PS 17914

|++J Install or Connect

[T] Important
• Gently press down on PROM.

4. ConnectorstoPCM.
Functional Check
w
1. Turn ignition ON."
is installed properly, and the P C M is
Figure 3-26 B. If DTC 51 occurs, or if the MIL (Service Engine
Soon) is W constantly with no DTC(s), the
Remove or Disconnect PROM is not fully seated or is defective.
1. Negative battery cable. • If not fully seated, press firmly on the ends
3. PCM mounting hardware. • If it is necessary to remove the PROM,
4. PCM from passenger compartment. follow the previous removal instructions. ^
|"Tj Important This procedure allows the PCM memory to be

used when removing it from the defective PCM been completed.
because it will be reused in the new PCM. Set up:
• Battery is fully charged.
NOTICE: To prevent possible electrostatic • Engine operating at idle.
circuit from carrier. • Select "OUTPUT TESTS" and "INJ PUMP."
fe
• Activate TDC LEARN."
• Verify 'TDC OFFSET" in data list.
| y | Inspect • DTC 88 will be stored if procedure has not been
done correctly.
• For alignment notches of the PROM and carefully
set it aside. NOTICE: If the PCM fails to program the TDC
Remove or Disconnect software version.
service number to make sure it is the same as the W
replace the PCM. Refer to PCM Replacement."
defective PCM.
2. Access cover.
1 FRONT COVER
NS 15745 NS 15749
Sensor
Engine Coolant Temperature (ECT) Sensor |<"»| Remove or Disconnect
Figure 3-28
sensor. Damage to sensor will affect proper 3. Sensor bolt.
|++| Remove or Disconnect Inspect

3. Electrical connector releasing locking tab. before installing
s
4. Sensor.
Install or Connect
1. Sensor in engine.
3. Refill coolant system.
Accelerator Pedal Position (APP) Module
Refer to SECTION 4 for replacement.
Optical/Fuel Temperature Sensor 1 IAT SENSOR (TYPICAL)
7S3263-6E
3-13S DRIVEABILITY AND EMISSIONS (DIESEL)
p7| Install or Connect

1. Sensor in engine.
2. Sensor bolt, tighten to 25 N-m (17 lb. ft.).
3. Sensor electrical connector.
|jH| important
• The procedure, called the 'TDC Offset Program
scam tool. This procedure must be done when a
"TDC Offset Program Procedure."
1 PLENUM PANEL
Figure 3-30 2 SENSOR PS 17309
Figure 3-31 - BARO Sensor

3. IAT sensor.
Install or Connect
1. IAT sensor.
BARO Sensor
Figure 3-31

[T^l Remove or Disconnect

1. Negatived battery cable.
3. Electrical connector releasing locking tab. BOOST SENSOR
BOLT
|++| Install or Connect

SEAL
1. Bolts (3.5 N-m 27 lb. in.) or snap sensor on
bracket. NS 15746
2. Electrical connector. Figure 3-32 - Boost Sensor
4. Negative battery cable. {<--»{ Remove or Disconnect
Boost Sensor 2. Vacuum harness assembly.
Figure 3-32 3. Electrical connector releasing locking tab.
4. Bolts.
Other than checking for loose electrical
connections, the only service possible is unit Install or Connect
1. Bolts (3.5 N-m 27 lb. in.).
3. Vacuum harness.
DRIVEABILITY A N D EMISSIONS ( D I E S E L ) 3-137
Install o r C o n n e c t
2. V a c u u m hoses.
3. Electrical connector tot h e solenoid.
5. Perform On-Board Diagnostic System Check."
w
Vehicle S p e e d Sensor ( V S S )
R e f e r t o S E C T I O N 10 f o r o n - v e h i c l e s e r v i c e o f t h e
transmission mounted VSS.
VSS Buffer M o d u l e
Figure 3 - 3 3
The V S S buffer m o d u l e is m o u n t e d i n t h e
instrument panel. Refer to S E C T I O N 8 C o f t h e
appropriate service m a n u a l foron-vehicle service.
1 CONTROL MODULE
Brake S w i t c h e s
2 FLOOR AND DASH PANEL Refer to S E C T I O N 5o f the appropriate service

3 BOLT m a n u a l foron-vehicle service o f the brake (stop lamp)
switches.
4 V S S BUFFER MODULE
PS 17914
Cruise C o n t r o l S w i t c h e s
Figure 3 - 3 3 - VSS Buffer Module
The cruise control switches are part of the multi-
f u n c t i o n t u r n s i g n a l l e v e r . R e f e r t o S E C T I O N 3F o f
PARTS INFORMATION
PART N A M E GROUP
Module, Eng. Cont 3.670

P R O M , E C M 3.670
Sensor, Engine Coolant T e m p 3.682
W A S T E G A T E SOLENOID
PS 17583
Figure 3 - 3 4 - Wastegate Solenoid
Wastegate Solenoid
Figure 3-34
|++| Remove or Disconnect

2. Electrical connector f r o m the solenoid.
3. V a c u u m hoses.

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C/K, G, P3

To reduce the chance of personal injury and/or property damage, the

The service procedures recommended and described in this service

Accordingly, anyone who intends to use a replacement part, service

It is important to note that this manual contains various 'Cautions' and

This manual has been prepared as a supplement

Any references to brand names in this manual is

GENERAL MOTORS CORPORATION

1994 G E N E R A L M O T O R S C O R P O R A T I O N A L L R I G H T S R E S E R V E D 2-94 L I T H O I N U.S.A.

Canada-(General Motors Deafer Employees Only)--

GM Service Technology Group

DTC 19 - Crankshaft Position Reference DTC 63 - Accelerator Pedal Position (APP) 3

POWERTRAIN CONTROL MODULE (PCM) PCM Learning Ability

OPERATING CONDITIONS SENSED SYSTEMS CONTROLLED

• A/C Status • Exhaust Gas Recirculation (EGR) Operation

Figure 3-1 - Control Module System

NOTICE: The PCM must be maintained at a

Electrostatic Discharge Damage

Electronic components used in control systems are

1 ACCELERATOR PEDAL POSITION (APP) MODULE

The fuel temperature sensor is part of the

Crankshaft Position Sensor

The crankshaft position sensor provides a signal

Figure 3-6 - Intake Air Temperature (IAT) Sensor

Fuel Inject Signal

The fuel injector driver receives an inject

Vehicle Speed Sensor (VSS)

The VSS is attached to the output shaft housing.

Figure 3-8 - Boost Sensor

DIAGNOSTIC INFORMATION "Service Throttle S o o n " Lamp

450 WHT/BLK —IPC! SYSTEM GROUND

F E 0 c B A TO VSS TO FUEL PUMP RELAY

ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK

ON-BOARD DIAGNOSTIC (OBD) SYSTEM

• IGNITION "ON." ENGINE "OFF."

© • WITH TECH 1 SCAN TOOL PERFORM

©[ DOES TECH 1 DISPLAY SCAN DATA? REFER TO CHART A-2.

©[ ARE ANY DTCs DISPLAYED? ! REFER TO CHART A-2. !

6 ) DOES ENGINE START?

TYPICAL TECH 1 ENGINE DATA VALUES

ENGINE TECH 1 DATA DEFINITIONS

TECH 1 SCAN T O O L PCM INFORMATION MODES

Cruise Control A/C Signal

VP HARNESS CONNECTOR (23 PIN)

450 WHT/BLK —| PC1 S Y S T E M GROUND

E D C B A TOVSS TO FUEL PUMP RELAY

440 O R N BATTERY FEED

960 ORN "SERVICE THROTTLE

FUSES OK OPEN FUSE

TEST LIGHT "ON" TEST LIGHT " O F F " ONE

PROBE CKT 419 WITH A TEST LIGHT LOCATE AND REPAIR

450 WHT/BLK — | PC1 SYSTEM GROUND

F E D C B • 7^ TO VSS TO FUEL PUMP RELAY

440 ORN BATTERY FEED

TO 960 ORN "SERVICE THROTTLE

© • IGNITION "OFF." © • IF PROBLEM WAS NO SERIAL DATA:

• IGNITION " O N " AND NOTE MIL (SERVICE

ENGINE HARNESS PCM

TO ENGINE SHUTOFF- 339 PNK

• LOOSEN INJECTION LINE AT INJECTOR. REFER TO CHART A-2.