Engine Engine Controls - 8.

1L 6-1

General Description important to use care when handling and testing electronic
components.
Visual / Physical Inspection
Engine Wiring
A careful visual and physical inspection must be
performed as part of any diagnostic procedure.This can When it is necessary to move any of the wiring, whether to
often lead to fixing a problem without further diagnostics. lift wires away from their harnesses or move harnesses to
Inspect all vacuum hoses for correct routing, pinches, cracks reach some component, take care that all wiring is replaced
or disconnects. Be sure to inspect hoses that are difficult to in its original position and all harnesses are routed correctly.
see. Inspect all the wires in the engine compartment for proper If clips or retainers break, replace them. Electrical problems
connections, burned or chafed spots, pinched wires or contact can result from wiring or harnesses becoming loose and
with sharp edges or hot manifolds. This visual/physical moving from their original positions, or from being rerouted.
inspection is very important. It must be done carefully and
thoroughly. Engine Control Module (ECM) Self-Diagnostics
The Engine Control Module (ECM) performs a continuous
Basic Knowledge and Tools Required self-diagnosis on certain control functions. This diagnostic
To use this manual most effectively, a general understanding capability is complemented by the diagnostic procedures
of basic electrical circuits and circuit testing tools is required. contained in this manual. The ECM’s language for
You should be familiar with wiring diagrams, the meaning of communicating the source of a malfunction is a system of
voltage, ohms, amps and the basic theories of electricity. Diagnostic Trouble Codes (DTC’s). The DTC’s are two digit
You should also understand what happens if a circuit numbers that can range from 12 to 81. When a malfunction
becomes open, shorted to ground or shorted to voltage. is detected by the ECM, a DTC is set and the Malfunction
Indicator Lamp (MIL) is illuminated.
To perform system diagnostics, several special tools and
equipment are required. Please become acquainted with the
Malfunction Indicator Lamp (MIL)
tools and their use before attempting to diagnose the system.
Special tools that are required for system service are The Malfunction Indicator Lamp (MIL) is part of the Diagnostic
illustrated in this section. Trouble Code (DTC) tool, or it can be a dash mounted warning
light on some applications.
Electrostatic Discharge Damage • If present, it informs the operator that a problem has
Electronic components used in control systems are often occurred and that the boat should be taken for service
designed to carry very low voltage, and are very susceptible as soon as reasonably possible.
to damage caused by electrostatic discharge. It is possible • It displays DTC’s stored by the ECM which help the
for less than 100 volts of static electricity to cause damage technician diagnose system problems.
to some electronic components. By comparison, it takes as As a bulb and system check, the light will come “ON” with
much as 4,000 volts for a person to feel the zap of a static the key “ON,” engine “OFF.” When the engine is started, the
discharge. light will turn “OFF.” If the light remains “ON,” the self-diagnostic
There are several ways a person can become statically system has detected a problem. If the problem goes away,
charged. The most common methods of charging are by the light will go out in most cases after 10 seconds, but a
friction and by induction. An example of charging by friction DTC will remain stored in the ECM.
is a person sliding across a seat, in which a charge of as When the light remains “ON” while the engine is running, or
much as 25,000 volts can build up. Charging by induction when a malfunction is suspected due to a drivability problem,
occurs when a person with well insulated shoes stands near the “On-Board Diagnostic (OBD) System Check” must be
a highly charged object and momentarily touches ground. performed as the first step. These checks will expose
Charges of the same polarity are drained off, leaving the malfunctions which may not be detected if other diagnostics
person highly charged with the opposite polarity. Static are performed prematurely.
charges of either type can cause damage. Therefore, it is

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6-2 Engine Controls - 8.1L Engine

Intermittent Malfunction Indicator Lamp (MIL) When the DTC tool is installed at the DLC and “service mode”
In the case of an “intermittent” problem, the Malfunction or “ON” is selected, the system will enter what is called the
Indicator Lamp (MIL) may light for 10 seconds, and then go “Service Mode.” In this mode, the ECM will:
out. However, the corresponding DTC will be stored in the • Display a DTC 12 by flashing the MIL, indicating that the
memory of the ECM. When DTC’s are set by an intermittent diagnostic system is working.
malfunction, they could be helpful in diagnosing the system. • Display any stored DTC’s by flashing the MIL. Each DTC
If an intermittent DTC is cleared, it may or may not reset. If it will be flashed two times, then DTC 12 will be flashed
is an intermittent failure, consult the “Diagnostic Aids” on the again.
facing page of the corresponding DTC table. Symptoms • The ignition timing is controlled to a fixed timing degree
section also covers the topic of “Intermittents.” A physical programmed in the ECM. This will allow base timing to
inspection of the applicable sub-system most often will resolve be adjusted on distributor ignition engines.
the problem.
• Control the Idle Air Control (IAC) valve to maintain
Reading Diagnostic Trouble Codes (DTC’s) approximately 1000 RPM.
The provision for communicating with the ECM is the Data
Link Connector (DLC) (Figure 1-1). It is part of the engine
Normal Mode
wiring harness, and is a 10-pin connector, which is electrically When the DTC tool is in the “normal mode” or “OFF,” it has
connected to the ECM. It is used in the assembly plant to no affect on the engine operation.
receive information in checking that the engine is operating
properly before it leaves the plant. The DTC(s) stored in the On-Board Diagnostic (OBD) System Check
ECM’s memory can be retrieved two different ways. One way After the visual/physical inspection, the “On-Board Diagnostic
is with a Diagnostic Trouble Code (DTC) tool. The preferred (OBD) System Check” is the starting point for all diagnostic
way is through a scan tool, a hand-held diagnostic scanner procedures.
plugged into the DLC.
The correct procedure to diagnose a problem is to follow two
basic steps:
1. Are the on-board diagnostics working? This is
A determined by performing the “On-Board Diagnostic
A B C D E B (OBD) System Check.” Since this is the starting point for
K J H G F
C the diagnostic procedures, always begin here. If the on-
D board diagnostics are not working, the OBD system
E
check will lead to a diagnostic table to correct the problem.
If the on-board diagnostics are working properly, the next
step is:
DATA LINK CONNECTOR (DLC) 2. Is there a DTC stored? If a DTC is stored, go directly to
6-18-93 the number DTC table. This will determine if the fault is
MS 13554
still present.
Figure 1-1 - Data Link Connector (DLC)
Once the DTC tool has been connected, and “service mode” DLC Scan Tools
or “ON” selected, the ignition switch must be moved to the The ECM can communicate a variety of information through
ignition “ON,” engine “OFF” position. At this point, the MIL the DLC. This data is transmitted at a high frequency which
should flash DTC 12 two times consecutively. This would be requires a scan tool for interpretation.
the following flash sequence: “flash, pause, flash-flash, long With an understanding of the data which the scan tool
pause, flash, pause, flash-flash.” DTC 12 indicates that the displays, and knowledge of the circuits involved, the scan
ECM’s diagnostic system is operating. If DTC 12 is not tool can be very useful in obtaining information which would
indicated, a problem is present within the diagnostic system be more difficult or impossible to obtain with other equipment.
itself, and should be addressed by consulting the “On-Board
Diagnostic (OBD) System Check.” A scan tool does not make the use of diagnostic tables
unnecessary, nor do they indicate exactly where the problem
Following the output of DTC 12, the MIL will indicate a DTC is in a particular circuit. Tables are provided for the use of a
two times if a DTC is present, or it will continue to flash DTC scan tool (scan diagnostics), or with the DTC tool (non-scan
12. If more than one DTC has been stored in the ECM’s diagnostics). The non-scan diagnostics are limited to basic
memory, the DTC’s will be flashed out from the lowest to the circuits. For complete diagnostics, a scan tool must be used.
highest, with each DTC being flashed two times. At the end
of the DTC’s, the ECM will simply go back and start over
with flashing DTC 12.

Service Mode
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Engine Engine Controls - 8.1L 6-3

Scan Tool Use With Intermittents 5 VOLTS

The scan tool provides the ability to perform a “wiggle test” XXXXXXXXXXXXXXX DEFAULTXXXXXXXXXXX
on wiring harnesses or components with the engine not
running, while observing the scan tool display. 4.6V

The scan tool can be plugged in and observed while driving V

the vehicle under the condition when the MIL turns “ON” or O
L
the engine drivability is poor. If the problem seems to be T TYPICAL SENSOR RANGE
related to certain parameters that can be checked on the A “WINDOW”
G
scan tool, they should be checked while driving the vehicle. E
If there does not seem to be any correlation between the
problem and any specific circuit, the scan tool can be checked 0.7V
on each position, watching for a period of time to see if there
is any change in the readings that indicates an intermittent XXXXXXXXXXXXXXX DEFAULTXXXXXXXXXXX
operation.
0 VOLTS 6-5-93
The scan tool is also an easy way to compare the operating MS 13553
parameters of a poorly operating engine with those of a known
good one. For example, a sensor may shift in value but not Figure 1-2 - Example of Sensor Normal Operation
set a DTC. Comparing the sensor’s readings with those of a
known good identical vehicle may uncover the problem. Clearing Diagnostic Trouble Codes (Non-Scan)
The scan tool has the ability to save time in diagnosis and 1. Install Diagnostic Trouble Code (DTC) tool.
prevent the replacement of good parts. The key to using the 2. Ignition “ON,” engine “OFF.”
scan tool successfully for diagnosis lies in the technicians
3. Switch DTC tool to “service mode” or “ON.”
ability to understand the system they are trying to diagnose,
as well as an understanding of the scan tool operation and 4. Move the throttle from 0% (idle) to 100% (WOT) and
limitations.The technician should read the tool manufacturer’s back to 0%.
operating manual to become familiar with the tool’s operation. 5. Switch DTC tool to “normal mode” or “OFF.” (If this step
is not performed, the engine may not start and run).
How Diagnostic Trouble Codes (DTC) Are Set 6. Turn ignition “OFF” for at least 20 seconds.
The ECM is programmed to receive calibrated voltage signals 7. Ignition “ON,” engine “OFF.”
from the sensors. The voltage signal from the sensor may 8. Switch DTC tool to “service mode” or “ON” and verify
range from as low as 0.1 volt to as high as 4.9 volts. The DTC 12 only. Remove DTC tool.
sensor voltage signal is calibrated for engine application.This
9. If original DTC(s) are still present, check “Notice” below
would be the sensor’s operating parameter or “window.” The
and repeat the DTC clearing procedure.
ECM and sensors will be discussed further in the ECM and
Sensor section. 10. If new DTC(s) are displayed, perform the OBD system
check.
If a sensor is within its operating or acceptable parameters
(Figure 1-2), the ECM does not detect a problem. When a NOTICE: When clearing DTC’s with or without the use of a
sensor voltage signal falls out of this “window,” the ECM no scan tool, the ignition must be cycled to the “OFF” position
longer receives a signal voltage within the operating “window.” after codes are cleared or the DTC’s will not clear.
When the ECM does not receive the “window” voltage for a
calibratible length of time, a DTC will be stored. The MIL will
be illuminated and a known default value will replace the
sensor value to restore limited engine performance.

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6-4 Engine Controls - 8.1L Engine

Clearing Diagnostic Trouble Codes (Scan) To identify a sensor that is out of range, you may unplug the
sensor electrical connector while the engine is running. After
1. Install scan tool.
about 2 minutes, the DTC for that sensor will set, illuminate
2. Start engine. the MIL, and replace the sensed value with a calibrated default
3. Select “clear DTC’s” function. value. If at that point, a noticeable performance increase is
4. Clear DTC’s. observed, the non-scan DTC table for that particular sensor
should be followed to correct the problem.
5. Turn ignition “OFF” for at least 20 seconds.
NOTICE: Be sure to clear each DTC after disconnecting and
6. Turn ignition “ON” and read DTC’s. If DTC’s are still
reconnecting each sensor. Failure to do so may result in a
present, check “Notice” below and repeat procedure
misdiagnosis of the drivability concern.
following from step 2.
NOTICE: When clearing DTC’s with or without the use of a LOW TEMP - 5 VOLTS
scan tool, the ignition must be cycled to the “OFF” position
after codes are cleared or the DTC’s will not clear. XXXXXXXXXXXXXXX DEFAULTXXXXXXXXXXX

Non-Scan Diagnosis Of Drivability Concerns T ------50 -4.2V OUT OF RANGE SENSOR

E
(No DTC’s Set) M
P
If a drivability concern still exists after following the OBD E
R
system check and reviewing the Symptoms tables, an out of A
range sensor may be suspected. Because of the unique T
U
design of the MEFI system, the ECM will replace sensed R
values with calibrated default values in the case of a sensor E ------150 -1.7V ACTUAL COOLANT TEMPERATURE
or circuit malfunction. By allowing this to occur, limited engine
performance is restored until the vehicle is repaired. A basic XXXXXXXXXXXXXXX DEFAULTXXXXXXXXXXX
understanding of sensor operation is necessary to be able
HIGH TEMP - 0 VOLTS 6-5-93
to diagnose an out of range sensor.
MS 13552
If the sensor is out of range, but still within the operating
“window” of the ECM, the problem will go undetected by the Figure 1-3 - Example of Shifted Sensor Operation
ECM and may result in a drivability concern.
A good example of this would be if the coolant sensor was
reading incorrectly and indicating to the ECM that coolant
temperature was at 50°F, but actual coolant temperature was
at 150°F (Figure 1-3). This would cause the ECM to deliver
more fuel than what was actually needed by the engine. This
resulted in an overly rich condition, causing rough running.
This condition would not have caused a DTC to set, as the
ECM interprets this as within the operating “window.”

MEFI 4
Engine Engine Controls - 8.1L 6-5
Service Precautions 8. Before attempting any electric arc welding on the vehicle,
The following requirements must be observed when working disconnect the battery leads and the ECM connector(s).
on MEFI equipped engines. 9. When steam cleaning engines, do not direct the nozzle
1. Before removing any ECM system component, at any ECM system components. If this happens,
disconnect the negative battery cable. corrosion of the terminals or damage of components
2. Never start the engine without the battery being solidly can take place.
connected. 10. Use only the test equipment specified in the diagnostic
3. Never separate the battery from the on-board electrical tables, since other test equipment may either give
system while the engine is running. incorrect test results or damage good components.
4. Never separate the battery feed wire from the charging 11. All measurements using a multimeter must use a digital
system while the engine is running. meter with a rating of 10 megaohm input impedance.
5. When charging the battery, disconnect it from the 12. When a test light is specified, a “low-power” test light
vehicle’s electrical system. must be used. Do not use a high-wattage test light. While
a particular brand of test light is not suggested, a simple
6. Ensure that all cable harnesses are connected solidly
test on any test light will ensure it to be safe for system
and the battery connections are thoroughly clean.
circuit testing (Figure 1-4). Connect an accurate ammeter
7. Never connect or disconnect the wiring harness at the (such as the high-impedance digital multimeter) in series
ECM when the ignition is switched “ON.” with the test light being tested, and power the test light
ammeter circuit with the vehicle battery.

testlight

DC Amps * +
BATTERY

If the ammeter indicates less than 3/10 amp(.3A) current flow,

the testlight is safe to use.
If the ammeter indicates more than 3/10 amp(.3A) current flow,
the testlight is not safe to use.
I 22307

Figure 1-4 - Test Light Amperage Draw Test

Tools Needed To Service The System

Refer to Special Tools in this section for engine control tools for servicing the system.

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6-6 Engine Controls - 8.1L Engine

Abbreviations
BARO - BAROMETRIC PRESSURE INJ - INJECTOR
BAT - BATTERY, BATTERY POSITIVE I/O - INPUT/OUTPUT
TERMINAL, BATTERY OR SYSTEM
kPa - KILOPASCAL
VOLTAGE
KS - KNOCK SENSOR
B+ - BATTERY POSITIVE
KV - KILOVOLTS
CEFI - COMMERCIAL ELECTRONIC FUEL
INJECTION MAP - MANIFOLD ABSOLUTE PRESSURE
CKT - CIRCUIT MFI - MULTIPORT FUEL INJECTION
CONN - CONNECTOR MIL - MALFUNCTION INDICATOR LAMP
CYL - CYLINDER MSEC - MILLSECOND
DEG - DEGREES N/C - NORMALLY CLOSED
DI - DISTRIBUTOR IGNITION N/O - NORMALLY OPEN
DIAG - DIAGNOSTIC OBD - ON-BOARD DIAGNOSTIC
DIST - DISTRIBUTOR OPT - OPTIONAL
DLC - DATA LINK CONNECTOR PFI - PORT FUEL INJECTION
DTC - DIAGNOSTIC TROUBLE CODE PWM - PULSE WIDTH MODULATION
DVOM - DIGITAL VOLT OHMMETER RAM - RANDOM ACESS MEMORY
ECM - ENGINE CONTROL MODULE REF HI - REFERENCE HIGH
ECT - ENGINE COOLANT TEMPERATURE REF LO- REFERENCE LOW
EEPROM- ELECTRONIC ERASABLE ROM - READ ONLY MEMORY
PROGRAMMABLE READ ONLY MEMORY
SLV - SLAVE
EI - ELECTRONIC IGNITION
SW - SWITCH
EMI - ELECTROMAGNETIC INTER-
TACH - TACHOMETER
FERENCE
TBI - THROTTLE BODY INJECTION
ENG - ENGINE
TERM - TERMINAL
E-STOP - EMERGENCY STOP
TP - THROTTLE POSITION
GND - GROUND
V - VOLTS
GOV - GOVERNOR
VAC - VACUUM
GPH - GALLONS PER HOUR
VSS - VEHICLE SPEED SENSOR
HO2 - HEATED OXYGEN SENSOR
WOT - WIDE OPEN THROTTLE
IAC - IDLE AIR CONTROL
“ HG - INCHES OF MERCURY
IAT - INTAKE AIR TEMPERATURE
IC - IGNITION CONTROL
IGN - IGNITION

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Engine Engine Controls - 8.1L 6-7

Diagnosis • Tendency for connectors to come apart due to vibration

and/or temperature cycling.
The diagnostic tables and functional checks in this manual • Terminals not fully seated in the connector body.
are designed to locate a faulty circuit or component through
logic based on the process of elimination. The tables are • Inadequate terminal crimps to the wire.
prepared with the requirement that the system functioned
correctly at the time of assembly and that there are no multiple
failures.
Engine control circuits contain many special design features
not found in standard vehicle wiring. Environmental protection
is used extensively to protect electrical contacts. Proper
splicing methods must be used when necessary.
The proper operation of low amperage input/output circuits
depend upon good continuity between circuit connectors. It
is important before component replacement and/or during
normal troubleshooting procedures that a visual inspection
of any questionable mating connector is performed. Mating
surfaces should be properly formed, clean and likely to make
proper contact. Some typical causes of connector problems
are listed below:
• Improperly formed contacts and/or connector housing.
• Damaged contacts or housing due to improper
engagement.
• Corrosion, sealer or other contaminants on the contact
mating surfaces.
• Incomplete mating of the connector halves during initial
assembly or during subsequent troubleshooting
procedures.

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6-8 Engine Controls - 8.1L Engine

MEFI 4
Engine Engine Controls - 8.1L 6-9

Engine Controls - 8.1L

Specifications

Temperature vs. Resistance Temperature vs. Resistance (cont’d)

°C °F OHMS °C °F OHMS
Temperature vs Resistance Values (Approximate) 25 77 2796
100 212 177 20 68 3520
90 194 241 15 59 4450
80 176 332 10 50 5670
70 158 467 5 41 7280
60 140 667 0 32 9420
50 122 973 -5 23 12300
45 113 1188 -10 14 16180
40 104 1459 -15 5 21450
35 95 1802 -20 -4 28680
30 86 2238 -30 -22 52700
-40 -40 100700

Ignition System Specifications

Specifications
Application Metric English
Firing Order 1-8-7-2-6-5-4-3
Spark Plug Wire Resistance 10,000 ohms per foot
Spark Plug Torque 15 N.m 11 lb ft
Spark Plug Gap 1.52 mm .060 in
Spark Plug Type TJ14R-P15 (Denso plug type)

Fastener Tightening Specifications

Specifications
Application Metric English
Camshaft Position (CMP) Sensor Bolt .
25 N m 18 lb ft
Crankshaft Position (CKP) Sensor Bolt 25 N.m 18 lb ft
Engine Control Module (ECM) Mounting Screws .
10-14 N m 88-124 lb in
Engine Coolant Temperature (ECT) Sensor .
17 N m 13 lb ft
Engine Sight Shield Bolts .
10 N m 89 lb in
Engine Sight Shield Bracket Bolts 10 N.m 89 lb in
Fuel Filter Fitting .
30 N m 22 lb ft
Fuel Rail Attaching Bolts .
10 N m 89 lb in
Idle Air Control (IAC) Valve Attaching Screws
Ignition Coil Attaching Bolts 12 N.m 106 lb in
Knock Sensor (KS) 20 N.m 15 lb ft
Throttle Body Attaching Bolts 10 N.m 88.5 lb in
Throttle Position (TP) Sensor Attaching Screws

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6 - 10 Engine Controls - 8.1L Engine
Engine Scan Tool Data List Important: A scan tool that displays faulty data should not
The Engine Scan Tool Data List contains all engine related be used. The scan tool problem should be reported to the
parameters that are available on the scan tool. Use the manufacturer. Use of a faulty scan tool can result in
Engine Scan Tool Data List only after the following is misdiagnosis and unnecessary parts replacement.
determined: Only the parameters listed below are referenced in this
service manual for use in diagnosis. If all values are within
• On-Board Diagnostic System Check is completed.
the typical range described below, refer to Symptoms for
• No Diagnostic Trouble Codes (DTCs). diagnosis.
• On-board diagnostics are functioning properly.
Scan tool values from a properly running engine may be
used for comparison with the engine you are diagnosing.
The Engine Scan Tool Data List represents values that
would be seen on a normal running engine.

Engine Scan Tool Data List - Standard

Scan Tool Parameter Units Parameter Range
Calibration ID Numeric 0-255. Identification number assigned to a specific calibration.
Calibration Checksum Numeric 0-65535
Engine Speed RPM 0-6000
Desired Idle RPM 0-1600
ECT °C, °F -40°C - 151°C , -40°F - 304°F
IAT °C, °F -40°C - 151°C , -40°F - 304°F
MAP kPa / Volts 8 - 207 kPa, 0.00 - 4.98 volts
Baro kPa / Volts 8 - 207 kPa, 0.00 - 4.98 volts
TP Sensor Volts 0.00 - 4.98 volts
Throttle Angle Percent 0 - 100%
Injector A Pulse Width Milliseconds 0.0 - 500 ms
Injector B Pulse Width Milliseconds 0.0 - 500 ms
Spark Advance Degrees -20° - 69.6484°
Cam Retard Degrees 0° - 90°
Knock Retard Degrees 0° - 89.6484°
KS System Enabled Yes / No Yes / No
Knock Signal Yes / No Yes / No
IAC Position Counts 0 - 255 Counts
IAC Throttle Follower Counts 0 - 255 Counts
Closed Throttle Yes / No Yes / No
Vessel Speed MPH 0 - 255 mph
Battery / Ignition Voltage Volts 0.0 - 25.5 Volts
System Voltage Warning Discrete OK / Low Voltage
J1-20 Input Discrete On / Off
J2-21 Input Discrete On / Off
Emergency Stop Mode Discrete On / Off
Troll RPM Limit Discrete On / Off
Malfunction Indicator Lamp Discrete On / Off
Fuel Pump Relay Discrete On / Off
Cause Power Reduction Discrete On / Off
Power Reduction Discrete Yes / No
Overheat Detection Discrete Yes / No

MEFI 4
Engine Engine Controls - 8.1L 6 - 11
Engine Scan Tool Data List - Standard (cont’d)
Scan Tool Parameter Units Parameter Range
Oil Pressure Input Discrete OK / Low Press
J1-9 Output Discrete On / Off
Oil Level Input Discrete OK / Low
Low Oil Level Lamp Discrete On / Off
Buzzer Discrete On / Off
J1-19 Input Discrete On / Off
J1-22 Output Discrete On / Off
J1-4 Input Discrete On / Off
J1-23 Output Discrete On / Off
Master / Slave Discrete Master / Slave
J1-7 RPM Output Discrete On / Off
Time From Start Hours:Minutes:Seconds 00:00:00 - 18:12:15
Engine Hour Meter Hours 0.0 - 1193046,47 hours
Fuel Consumption Gallons per Hour 0.0 - 255 gph

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6 - 12 Engine Controls - 8.1L Engine
Engine Scan Tool Data List - Governor
Scan Tool Parameter Units Parameter Range
Calibration ID Numeric 0-255. Identification number assigned to a specific calibration.
Calibration Checksum Numeric 0-65535
Engine Speed RPM 0-6000
Desired Idle RPM 0-1600
ECT °C, °F -40°C - 151°C , -40°F - 304°F
IAT °C, °F -40°C - 151°C , -40°F - 304°F
MAP kPa / Volts 8 - 207 kPa, 0.00 - 4.98 volts
Baro kPa / Volts 8 - 207 kPa, 0.00 - 4.98 volts
TP Sensor Position Volts 0.00 - 4.98 volts
Throttle Angle Percent 0 - 100%
Injector A Pulse Width Milliseconds 0.0 - 500 ms
Injector B Pulse Width Milliseconds 0.0 - 500 ms
Spark Advance Degrees -20° - 69.6484°
Cam Retard Degrees 0° - 90°
Knock Retard Degrees 0° - 89.6484°
KS System Enabled Yes / No Yes / No
Knock Signal Yes / No Yes / No
IAC Position Counts 0 - 255 Counts
IAC Throttle Follower Counts 0 - 255 Counts
Closed Throttle Yes / No Yes / No
Vessel Speed MPH 0 - 255 mph
Battery / Ignition Voltage Volts 0.0 - 25.5 Volts
System Voltage Warning Discrete OK / Low Voltage
J1-20 Input Discrete On / Off
J2-21 Input Discrete On / Off
Emergency Stop Mode Discrete On / Off
Troll RPM Limit Discrete On / Off
Malfunction Indicator Lamp Discrete On / Off
Fuel Pump Relay Discrete On / Off
Cause Power Reduction Discrete On / Off
Power Reduction Discrete Yes / No
Overheat Detection Discrete Yes / No
Oil Pressure Input Discrete OK / Low Press
J1-9 Output Discrete On / Off
Oil Level Input Discrete OK / Low
Low Oil Level Lamp Discrete On / Off
Buzzer Discrete On / Off
J1-19 Input Discrete On / Off
J1-22 Output Discrete On / Off
J1-4 Input Discrete On / Off
J1-23 Output Discrete On / Off
Master / Slave Discrete Master / Slave
J1-7 RPM Output Discrete On / Off
Time From Start Hours:Minutes:Seconds 00:00:00 - 18:12:15

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Engine Engine Controls - 8.1L 6 - 13
Engine Scan Tool Data List - Governor (cont’d)
Scan Tool Parameter Units Parameter Range
Engine Hour Meter Hours 0.0 - 1193046.47 hours
RPM Control Discrete Yes / No
Over RPM Lamp Discrete On / Off
MPH Control Discrete Yes / No
Over MPH Discrete Yes / No
Desired Throttle Percent 0 - 100%
Governor Duty Cycle Percent 0 - 100%

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6 - 14 Engine Controls - 8.1L Engine
Engine Scan Tool Data List - Oxygen (O2) Sensor
Scan Tool Parameter Units Parameter Range
Calibration ID Numeric 0-255. Identification number assigned to a specific calibration.
Calibration Checksum Numeric 0-65535
Engine Speed RPM 0-6000
Desired Idle RPM 0-1600
ECT °C, °F -40°C - 151°C , -40°F - 304°F
IAT °C, °F -40°C - 151°C , -40°F - 304°F
MAP kPa / Volts 8 - 207 kPa, 0.00 - 4.98 volts
Baro kPa / Volts 8 - 207 kPa, 0.00 - 4.98 volts
Oil Pressure / Catalyst Temp Volts 0 - 5 volts
TP Sensor Position Volts 0.00 - 4.98 volts
Throttle Angle Percent 0 - 100%
Fuel Consumption Gallons per Hour 0.0 - 255 gph
Injector A Pulse Width Milliseconds 0.0 - 500 ms
Injector B Pulse Width Milliseconds 0.0 - 500 ms
Spark Advance Degrees -20° - 69.6484°
Knock Retard Degrees 0° - 89.6484°
KS System Enabled Yes / No Yes / No
Knock Signal Yes / No Yes / No
IAC Position Counts 0 - 255 Counts
IAC Throttle Follower Counts 0 - 255 Counts
Closed Throttle Yes / No Yes / No
Vessel Speed MPH 0 - 255 mph
Battery / Ignition Voltage Volts 0.0 - 25.5 Volts
System Voltage Warning Discrete OK / Low Voltage
J1-20 Input Discrete On / Off
J2-21 Input Discrete On / Off
Emergency Stop Mode Discrete On / Off
Troll RPM Limit Discrete On / Off
Malfunction Indicator Lamp Discrete On / Off
Fuel Pump Relay Discrete On / Off
Cause Power Reduction Discrete On / Off
Power Reduction Discrete Yes / No
Overheat Detection Discrete Yes / No
Oil Press/Catalyst Temp Input Discrete OK / Low Press
J1-9 Output Discrete On / Off
Oil Level Input Discrete OK / Low
Low Oil Level Lamp Discrete On / Off
Buzzer Discrete On / Off
J1-19 Input Discrete On / Off
J1-22 Output Discrete On / Off
J1-4 Input Discrete On / Off
J1-23 Output Discrete On / Off
Master / Slave Discrete Master / Slave
J1-7 RPM Output Discrete On / Off

MEFI 4
Engine Engine Controls - 8.1L 6 - 15
Engine Scan Tool Data List - Oxygen (O2) Sensor (cont’d)
Scan Tool Parameter Units Parameter Range
Time From Start Hours:Minutes:Seconds 00:00:00 - 18:12:15
Engine Hour Meter Hours 0.0 - 1193046.47 hours
Closed Loop Fuel Discrete Yes / No
O2 Sensor 1 Voltage 0 - 1.25 volts
O2 Sensor 2 Voltage 0 - 1.25 volts
O2 Sensor 1 Status Discrete Rich / Lean
O2 Sensor 2 Status Discrete Rich / Lean
O2 Sensor 1 Cross Counts Counts 0 - 255 counts
O2 Sensor 2 Cross Counts Counts 0 - 255 counts
O2 Sensor 1 Blk Lrn Corr Multiplier 0 - 1.99
O2 Sensor 2 Blk Lrn Corr Multiplier 0 - 1.99
Block Learn Cell Numeric 0 - 255

MEFI 4
6 - 16 Engine Controls - 8.1L Engine
Engine Scan Tool Data List - Exhaust Gas Recirculation (EGR)
Scan Tool Parameter Units Parameter Range
Calibration ID Numeric 0-255. Identification number assigned to a specific calibration.
Calibration Checksum Numeric 0-65535
Engine Speed RPM 0-6000
Desired Idle RPM 0-1600
ECT °C, °F -40°C - 151°C , -40°F - 304°F
IAT °C, °F -40°C - 151°C , -40°F - 304°F
MAP kPa / Volts 8 - 207 kPa, 0.00 - 4.98 volts
Baro kPa / Volts 8 - 207 kPa, 0.00 - 4.98 volts
TP Sensor Position Volts 0.00 - 4.98 volts
Throttle Angle Percent 0 - 100%
Injector A Pulse Width Milliseconds 0.0 - 500 ms
Injector B Pulse Width Milliseconds 0.0 - 500 ms
Spark Advance Degrees -20° - 69.6484°
Knock Retard Degrees 0° - 89.6484°
KS System Enabled Yes / No Yes / No
Knock Signal Yes / No Yes / No
IAC Position Counts 0 - 255 Counts
IAC Throttle Follower Counts 0 - 255 Counts
Closed Throttle Yes / No Yes / No
Vessel Speed MPH 0 - 255 mph
Battery / Ignition Voltage Volts 0.0 - 25.5 Volts
System Voltage Warning Discrete OK / Low Voltage
J1-20 Input Discrete On / Off
J2-21 Input Discrete On / Off
Emergency Stop Mode Discrete On / Off
Troll RPM Limit Discrete On / Off
Malfunction Indicator Lamp Discrete On / Off
Fuel Pump Relay Discrete On / Off
Cause Power Reduction Discrete On / Off
Power Reduction Discrete Yes / No
Overheat Detection Discrete Yes / No
Oil Pressure Input Discrete OK / Low Press
J1-9 Output Discrete On / Off
Oil Level Input Discrete OK / Low
Low Oil Level Lamp Discrete On / Off
Buzzer Discrete On / Off
J1-19 Input Discrete On / Off
J1-22 Output Discrete On / Off
J1-4 Input Discrete On / Off
J1-23 Output Discrete On / Off
Master / Slave Discrete Master / Slave
J1-7 RPM Output Discrete On / Off
Time From Start Hours:Minutes:Seconds 00:00:00 - 18:12:15
Engine Hour Meter Hours 0.0 - 1193046.47 hours

MEFI 4
Engine Engine Controls - 8.1L 6 - 17
Engine Scan Tool Data List - Exhaust Gas Recirculation (EGR) (cont’d)
Scan Tool Parameter Units Parameter Range
Desired EGR Position Percent 0 - 100%
Actual EGR Position Percent 0 - 100%
EGR Error Percent 0 - 100%
EGR Duty Cycle Percent 0 - 100%

MEFI 4
6 - 18 Engine Controls - 8.1L Engine
Engine Scan Tool Data List - Fuel Pressure
Scan Tool Parameter Units Parameter Range
Calibration ID Numeric 0-255. Identification number assigned to a specific calibration.
Calibration Checksum Numeric 0-65535
Engine Speed RPM 0-6000
Desired Idle RPM 0-1600
ECT °C, °F -40°C - 151°C , -40°F - 304°F
IAT °C, °F -40°C - 151°C , -40°F - 304°F
MAP kPa / Volts 8 - 207 kPa, 0.00 - 4.98 volts
Baro kPa / Volts 8 - 207 kPa, 0.00 - 4.98 volts
TP Sensor Position Volts 0.00 - 4.98 volts
Throttle Angle Percent 0 - 100%
Fuel Consumption Gallons per Hour 0.0 - 255 gph
Injector A Pulse Width Milliseconds 0.0 - 500 ms
Injector B Pulse Width Milliseconds 0.0 - 500 ms
Spark Advance Degrees -20° - 69.6484°
Knock Retard Degrees 0° - 89.6484°
KS System Enabled Yes / No Yes / No
Knock Signal Yes / No Yes / No
IAC Position Counts 0 - 255 Counts
IAC Throttle Follower Counts 0 - 255 Counts
Closed Throttle Yes / No Yes / No
Vessel Speed MPH 0 - 255 mph
Battery / Ignition Voltage Volts 0.0 - 25.5 Volts
System Voltage Warning Discrete OK / Low Voltage
J1-20 Input Discrete On / Off
J2-21 Input Discrete On / Off
Emergency Stop Mode Discrete On / Off
Troll RPM Limit Discrete On / Off
Malfunction Indicator Lamp Discrete On / Off
Fuel Pump Relay Discrete On / Off
Cause Power Reduction Discrete On / Off
Power Reduction Discrete Yes / No
Overheat Detection Discrete Yes / No
Oil Pressure Input Discrete OK / Low Press
J1-9 Output Discrete On / Off
Oil Level Input Discrete OK / Low
Low Oil Level Lamp Discrete On / Off
Buzzer Discrete On / Off
J1-19 Input Discrete On / Off
J1-22 Output Discrete On / Off
J1-4 Input Discrete On / Off
J1-23 Output Discrete On / Off
Master / Slave Discrete Master / Slave
J1-7 RPM Output Discrete On / Off
Time From Start Hours:Minutes:Seconds 00:00:00 - 18:12:15

MEFI 4
Engine Engine Controls - 8.1L 6 - 19
Engine Scan Tool Data List - Fuel Pressure (cont’d)
Scan Tool Parameter Units Parameter Range
Engine Hour Meter Hours 0.0 - 1193046.47 hours
Fuel Pressure Volts Volts 0.00 - 5.00 volts
Low Fuel Pressure Warning Discrete OK / Low Pressure
Fuel Temp Volts 0 - 5 volts

MEFI 4
6 - 20 Engine Controls - 8.1L Engine
Engine Scan Tool Data List - Electronic Throttle Control (ETC)
Scan Tool Parameter Units Parameter Range
Calibration ID Numeric 0-255. Identification number assigned to a specific calibration.
Calibration Checksum Numeric 0-65535
Engine Speed RPM 0-6000
Desired Idle RPM 0-1600
ECT °C, °F -40°C - 151°C , -40°F - 304°F
IAT °C, °F -40°C - 151°C , -40°F - 304°F
MAP kPa / Volts 8 - 207 kPa, 0.00 - 4.98 volts
Baro kPa / Volts 8 - 207 kPa, 0.00 - 4.98 volts
Oil Press / Catalyst Temp Volts 0 - 5 volts
TP Sensor Position Volts 0.00 - 4.98 volts
Throttle Angle Percent 0 - 100%
Fuel Consumption Gallons per Hour 0.0 - 255 gph
Injector A Pulse Width Milliseconds 0.0 - 500 ms
Injector B Pulse Width Milliseconds 0.0 - 500 ms
Spark Advance Degrees -20° - 69.6484°
Knock Retard Degrees 0° - 89.6484°
KS System Enabled Yes / No Yes / No
Knock Signal Yes / No Yes / No
IAC Position Counts 0 - 255 Counts
IAC Throttle Follower Counts 0 - 255 Counts
Closed Throttle Yes / No Yes / No
Vessel Speed MPH 0 - 255 mph
Battery / Ignition Voltage Volts 0.0 - 25.5 Volts
System Voltage Warning Discrete OK / Low Voltage
J1-20 Input Discrete On / Off
J2-21 Input Discrete On / Off
Emergency Stop Mode Discrete On / Off
Malfunction Indicator Lamp Discrete On / Off
Fuel Pump Relay Discrete On / Off
Cause Power Reduction Discrete On / Off
Power Reduction Discrete Yes / No
Overheat Detection Discrete Yes / No
Oil Press/Catalyst Temp Input Discrete OK / Low Press
J1-9 Output Discrete On / Off
Oil Level Input Discrete OK / Low
Low Oil Level Lamp Discrete On / Off
Buzzer Discrete On / Off
J1-19 Input Discrete On / Off
J1-22 Output Discrete On / Off
J1-4 Input Discrete On / Off
J1-23 Output Discrete On / Off
Master / Slave Discrete Master / Slave
J1-7 RPM Output Discrete On / Off
Time From Start Hours:Minutes:Seconds 00:00:00 - 18:12:15

MEFI 4
Engine Engine Controls - 8.1L 6 - 21
Engine Scan Tool Data List - Electronic Throttle Control (ETC) (cont’d)
Scan Tool Parameter Units Parameter Range
Engine Hour Meter Hours 0.0 - 1193046.47 hours
ETC Pedal Angle Percent 0 - 100%
ETC Desired Throttle Percent 0 - 99.609375%
ETC Raw Pedal Counts 0 - 65535 counts
ETC Raw Desired Counts 0 - 65535 counts
ETC Raw Throttle Counts 0 - 65535 counts

MEFI 4
6 - 22 Engine Controls - 8.1L Engine

EngineScan Tool Data Definitions This is the gallons per hour of fuel that the engine is
consuming.
The Engine Scan Tool Data Definitions contains a brief
description of all engine related parameters available on the INJ. PULSE WIDTH - Scan Tool Range 0-1000 msec. -
scan tool. Indicates the amount of time the ECM is commanding the
injectors “ON” during each engine cycle. A larger injector
ECM Data Descriptions pulse width will cause more fuel to be delivered. Inj. Pulse
Width should increase with increased engine load.
CALIBRATION ID - Scan Tool Range 0-255 - This is an
identification number given to each calibration by the OEM. SPARK ADVANCE - Scan Tool Range -90° to 90°- This is
a display of the spark advance (IC) calculations which the
CALIBRATION CHECKSUM - Scan Tool Range 0-65535 -
ECM calculates and then provides all spark advance to the
This number is automatically calculated by the ECM. This
ignition system. The ECM computes the desired spark
number may also be used as a calibration identifier.
advance using data such as engine temperature, RPM,
ENGINE SPEED - Scan Tool Range 0-9999 RPM - Engine engine load, vessel speed, and operating mode. There is no
speed is computed by the ECM from the Ignition Control adjustment for spark advance. The ECM also uses spark
reference input. It should remain close to the desired idle advance to help maintain idle speed. Under normal operating
under various engine loads with engine idling. condition, with the engine warmed up and 0% throttle angle,
DESIRED IDLE - Scan Tool Range 0-3187 RPM - The idle it is normal to see timing vary continuously.
speed that is commanded by the ECM. The ECM will KNOCK RETARD - Scan Tool Range 0.0°-45.5° - Indicates
compensate for various engine loads based on engine the amount of spark the ECM is removing from IC spark
coolant temperature to keep the engine at the desired speed. advance in response to the signal from the knock sensor (KS).
ECT - Scan Tool Range -40°C to 151°C, -40°F to 304°F - KS ENABLED - Scan Tool Displays “YES” or “NO” - This
The Engine Coolant Temperature (ECT) sensor is mounted is informing you whether or not the Knock System is enabled.
in the coolant stream and sends engine temperature
KNOCK SIGNAL - Scan Tool Displays “YES” or “NO” -
information to the ECM. The ECM supplies 5 volts to the
Indicates whether or not a knock signal is being detected by
ECT sensor circuit.The sensor is a thermistor which changes
the ECM. Should display “NO” at idle.
internal resistance as temperature changes. When the sensor
is cold (internal resistance high), the ECM monitors a high KNOCK SENSOR 1 - Scan Tool Displays “OK” or “Fault” -
signal voltage and interprets it as a cold engine. As the sensor Indicates whether or not a fault is being detected on the knock
warms (internal resistance decreases), the voltage signal sensor 1 circuit.
will decrease and the ECM will interpret the lower voltage as KNOCK SENSOR 2 - Scan Tool Displays “OK” or “Fault” -
a warm engine. Indicates whether or not a fault is being detected on the knock
IAT - Scan Tool Range -40°C to 151°C, -40°F to 304°F - sensor 2 circuit.
The ECM converts the resistance of the intake air temperature IAC POSITION - Scan Tool Range 0-255 - Displays the
sensor to degrees. Intake Air Temperature (IAT) is used by commanded position of the idle air control pintle in counts. A
the ECM to adjust fuel delivery and spark timing according larger number of counts means that more air is being
to incoming air density. (Big Block Multiport Fuel Injection commanded through the idle air passage. Idle air control
Application Only). should respond fairly quickly to changes in engine load to
MAP - Scan Tool Range 10-210 kPa/0.00-5.00 Volts - The maintain desired idle RPM.
Manifold Absolute Pressure (MAP) sensor measures the IAC THROTTLE FOLLOWER - Scan Tool Range 0-255 -
change in the intake manifold pressure from engine load and When the throttle is moved from the closed throttle position,
speed changes. As intake manifold pressure increases, intake some idle air control counts are added to prevent stalling
vacuum decreases resulting in a higher MAP sensor voltage when returned to the closed throttle position.
and kPa reading. CLOSED THROTTLE - Scan Tool Displays “YES” or “NO” -
BARO - Scan Tool Range 10-105 kPa/0.00-5.00 Volts - Indicates whether the throttle is in the closed position.
The Barometric Pressure reading displayed is measured from VESSEL SPEED - ScanTool Range 0-255 MPH - Indicates
the MAP sensor signal monitored at ignition “ON,” engine the speed of the vessel in MPH.
“OFF” and WOT conditions. The Barometric Pressure is used
BATTERY / IGNITION VOLTAGE - Scan Tool Range
to compensate for altitude differences.
0.0 - 25.5 volts - This represents the system voltage
TP SENSOR - Scan Tool Range 0.00-5.00 Volts - This is
SYSTEM VOLTAGE WARNING - Scan Tool Displays “OK”
the voltage being monitored by the ECM on the TP sensor
or “LOW VOLTAGE” - Indicates if there may be a fault in the
signal circuit.
charging system.
TP ANGLE - Scan Tool Range 0% - 100% - TP Angle is
J2-9 INPUT - Scan Tool Displays “ON” or “OFF” - This is a
computed by the ECM from the TP Sensor voltage. TP Angle
discrete input to the ECM that is determined and calibratible
should display 0% at idle and 100% at wide open throttle.
per OEM.
FUEL CONSUMPTION - Scan Tool Range 0-100 gph -
J2-20 INPUT - Scan Tool Displays “ON” or “OFF” - This is

MEFI 4
Engine Engine Controls - 8.1L 6 - 23
a discrete input to the ECM that is determined and calibratible was in the “ON” or “RUN” position. Once the key has been
per OEM. cycled to the “OFF” position, this counter will reset to 00:00.
EMERGENCY STOP MODE - Scan Tool Displays “YES” ENGINE HOUR METER - Scan Tool Range 00:00:00-
or“NO” - Indicates whether you are in emergency stop mode 99:99:99 Hrs:Min:Sec - Indicates the engine run time.
or not.
TROLL RPM LIMIT - Scan Tool Displays “ON” or “OFF” -
This is a discrete input to the ECM which limits the RPM for
such things as trolling.This RPM limit is calibratible by the OEM.
MIL - Scan Tool Displays “ON” or “OFF” - Indicates the
ECM commanded state of the Malfunction Indicator Lamp.
FUEL PUMP RELAY - Scan Tool Displays “ON” or “OFF” -
Indicates the ECM commanded state of the fuel pump relay
driver circuit.
CAUSE POWER REDUCTION - Scan Tool Displays “YES”
or “NO” - Indicates whether or not the ECM has recognized
a fault which would put the engine into Power Reduction when
the appropriate RPM is achieved.
POWER REDUCTION - Scan Tool Displays “YES” or “NO” -
Indicates whether or not the ECM is functioning in Power
Reduction mode. During this mode, the ECM only triggers
one injector driver resulting in fuel to only half of the cylinders.
OVERHEAT DETECTED - Scan Tool Displays “YES” or
“NO” - Indicates if the ECM has recognized an overheat
condition with the engine.
OIL PRESSURE WARNING - Scan Tool Displays “OK” or
“LOW PRESSURE” - Indicates if the ECM has recognized
a fault in the oil pressure circuit.
CHECK GAUGES LAMP - Scan Tool Displays “ON” or
“OFF” - Indicates the ECM commanded state of the Check
Gauges lamp.
OIL LEVEL WARNING - Scan Tool Displays “OK” or
“LOW” - Indicates if the ECM has recognized a fault in the
oil level circuit.
BUZZER - Scan Tool Displays “ON” or “OFF” - Indicates
the ECM commanded state of the Buzzer.
GENERAL WARNING 1 - Scan Tool Displays “OK” or
“Fault Detected” - This is a discrete input to the ECM that is
determined and calibratible per OEM.
J1-21 OUTPUT - Scan Tool Displays “ON” or “OFF” -
Indicates the ECM commanded state of this output circuit.
GENERAL WARNING 2 - Scan Tool Displays “OK” or
“Fault Detected” - This is a discrete input to the ECM that is
determined and calibratible per OEM.
J1-22 OUTPUT - Scan Tool Displays “ON” or “OFF” - ECM
driven output that is determined and calibratible per OEM.
ECM MASTER / SLAVE - Scan Tool Displays “MASTER”
or “SLAVE” - Indicates whether you are receiving data from
a master or a slave engine.
J1-8 RPM OUTPUT - Scan Tool Displays “ON” or “OFF” -
ECM driven output that is determined and calibratible per OEM.
TIME FROM START - Scan Tool Range 00:00:00-99:99:99
Hrs:Min:Sec - Indicates the amount of time the ignition key

MEFI 4
6 - 24 Engine Controls - 8.1L Engine

MEFI 4
Engine Engine Controls - 8.1L 6 - 25

MEFI 4
6 - 26 Engine Controls - 8.1L Engine
ECM Diagnostic Trouble Codes
The Malfunction Indicator Lamp (MIL) will be “ON” if the malfunction exists under the conditions listed below. If the malfunction
clears, the lamp will go out and the Diagnostic Trouble Code (DTC) will be stored in the ECM. Any DTC’s stored will be erased
if no problem reoccurs within 50 engine starts. The amount of time after the malfunction occurs before the MIL illuminates is
calibratible. (Instantly or up to one minute).
Many of the DTC tables include a functional check of the system that may pinpoint a problem. However, it is important to
remember that the DTC tables are specifically designed for use only when a DTC is set. Therefore, a thorough understanding
of the normal operation of the system being diagnosed is necessary, and use of the tables for this purpose is at the discretion
of the technician.
NOTICE: Some DTC’s are referred as “Latching Codes.” A latching code will cause the MIL lamp to stay “ON” during an
ignition cycle whether the malfunction is corrected or not. This also means you can not clear the DTC during the same ignition
cycle.

Diagnostic Trouble Code (DTC) Table

DTC Description
DTC 13 Oxygen (O2) Sensor 1 Circuit Inactive
DTC 13 Oxygen (O2) Sensor 2 Circuit Inactive
DTC 14 Engine Coolant Temperature (ECT) Sensor Circuit.
Low Temperature Indicated.
DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit.
High Temperature Indicated.
DTC 21 Throttle Position (TP) Sensor Circuit.
High Signal Voltage Indicated.
DTC 22 Throttle Position (TP) Sensor Circuit.
Low Signal Voltage Indicated.
DTC 23 Intake Air Temperature (IAT) Sensor Circuit.
Low Temperature Indicated.
DTC 24 Vehicle Speed Sensor (VSS) Circuit Inactive.
DTC 25 Intake Air Temperature (IAT) Sensor Circuit.
High Temperature Indicated.
DTC 31 Governor System Inactive
DTC 32 Exhaust Gas Recirculation (EGR) Valve Circuit Inactive.
DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit.
High Signal Voltage Indicated.
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit.
Low Signal Voltage Indicated.
DTC 41 Ignition Control (IC) H Fault.
DTC 41 Ignition Control (IC) G Fault.
DTC 41 Ignition Control (IC) F Fault.
DTC 41 Ignition Control (IC) E Fault.
DTC 41 Ignition Control (IC) D Fault.
DTC 41 Ignition Control (IC) C Fault.
DTC 41 Ignition Control (IC) B Fault.
DTC 41 Ignition Control (IC) A Fault.
DTC 44 Knock Sensor (KS) 1 Circuit Inactive.
DTC 44 Knock Sensor (KS) 2 Circuit Inactive.
DTC 51 Calibration Checksum Failure.
DTC 54 Oxygen (O2) Sensor 1 Low Voltage.
Lean Exhaust Indicated.

MEFI 4
Engine Engine Controls - 8.1L 6 - 27
Diagnostic Trouble Code (DTC) Table (cont’d)
DTC Description
DTC 54 Oxygen (O2) Sensor 2 Low Voltage.
Lean Exhaust Indicated.
DTC 55 Oxygen (O2) Sensor 1 Low Voltage.
Rich Exhaust Indicated.
DTC 55 Oxygen (O2) Sensor 2 Low Voltage.
Rich Exhaust Indicated.
DTC 61 High Fuel Pressure Indicated.
DTC 62 Low Fuel Pressure Indicated.
DTC 63 High Fuel Temperature Indicated.
DTC 64 Low Fuel Temperature Indicated.
DTC 81 Crankshaft Position (CKP) Sensor Circuit Fault.
DTC 81 Camshaft Position (CMP) Sensor Circuit Fault.
DTC 81 Throttle Actuator Control (TAC) Malfunction - ETC Applications.
DTC 81 Fuel Pump High, Low or Open.
DTC 81 Injector Driver A Circuit High, Low or Open.
DTC 81 Injector Driver B Circuit High, Low or Open.
DTC 81 Recirc J1-32 Fault.
DTC 81 5 Volt Reference Circuit Out of Range.
DTC 81 DEPSPWR Circuit Out of Range.
DTC 81 CAN Bus Fault
DTC 81 Oil/Catalyst Temperature High.
DTC 81 Throttle Position (TP) Sensor 2 Out of Range - ETC Applications.
DTC 81 Throttle Position (TP) Sensor 1 Out of Range - ETC Applications.
DTC 81 Pedal Position Sensor (PPS) 3 Out of Range - ETC Applications.
DTC 81 Pedal Position Sensor (PPS) 2 Out of Range - ETC Applications.
DTC 81 Pedal Position Sensor (PPS) 1 Out of Range - ETC Applications.
DTC 81 Bad Checksum - ETC Applications.
DTC 81 No TAC Module Reply - ETC Applications.
DTC 81 CAN Bus Contention.
DTC 81 Serial Communication Fault - ETC Applications.
DTC 81 Throttle Position (TP) Sensor 1 / 2 Correction - ETC Applications
DTC 81 Pedal Position Sensor (PPS) 2 / 3 Correction - ETC Applications.
DTC 81 Pedal Position Sensor (PPS) 1 / 3 Correction - ETC Applications.
DTC 81 Pedal Position Sensor (PPS) 1 / 2 Correction - ETC Applications.
DTC 81 Limited Authority - ETC Applications.
DTC 81 Actuation Fault - ETC Applications.
DTC 81 Process Fault - ETC Applications.
DTC 81 Not Tracking - ETC Applications.
DTC 81 Throttle Return Fault - ETC Applications.

MEFI 4
6 - 28 Engine Controls - 8.1L Engine
Logged Warnings Clearing Diagnostic Trouble Codes - Scan
These warnings will be displayed following the Diagnostic 1. Install scan tool.
Trouble Codes. They can be cleared the same as the trouble 2. Start engine.
codes. Unlike trouble codes, these warnings can not be 3. Select “Clear DTC’s” function.
flashed out through the MIL using the DTC tool.
4. Clear DTC’s.
Description 5. Turn ignition “OFF” for at least 20 seconds.
Overheat 6. Turn ignition “ON” and read DTC’s. If DTC’s are still
present, check “Notice” below and repeat procedure
Low Oil Pressure / Catalyst Temperature
following from step 2.
Low System Voltage
NOTICE: When clearing DTC’s with or without the use of a
Low Oil Level scan tool, the ignition must be cycled to the “OFF” position or
General Warning 1 (J1-19) the DTC’s will not clear.
General Warning 2 (J1-4)
Low Fuel Pressure
Stop Engine Warning

Clearing Diagnostic Trouble Codes - Non Scan

1. Install Diagnostic Trouble Code (DTC) tool.
2. Ignition “ON,” engine “OFF.”
3. Switch DTC tool to “service mode” or “ON.”
4. Move the throttle from 0% (idle) to 100% (WOT) and
back to 0%.
5. Switch DTC tool to “normal mode” or “OFF.” (If this step
is not performed, the engine may not start and run).
6. Turn ignition “OFF” for at least 20 seconds.
7. Ignition “ON,” engine “OFF.”
8. Switch DTC tool to “service mode” or “ON” and verify
DTC 12 only. Remove MDTC tool.
9. If original DTC’s are still present, check “Notcice” below
and repeat the DTC clearing procedure.
10. If new DTC’s are displayed, perform the “On-Board
Diagnostic” (OBD) system check.

System Configuration Options

Scan Tool Parameter Units Parameter Range
Cam Sensor Discrete Yes / No
58x Crank Sensor Discrete Yes / No
7x Crank Sensor Discrete Yes / No
24x Encoded Crank Sensor Discrete Yes / No
TAC Module Present Discrete Yes / No
Knock Sensor Discrete Yes / No
Intake Air Temp Sensor Discrete Yes / No
Linear EGR Discrete Yes / No
GPH Calculation Enabled Discrete Yes / No
Alternate Fuel Spark Curve Discrete Yes / No
2 Atmosphere MAP Discrete Yes / No
MPH Sensor Discrete Yes / No

MEFI 4
Engine Engine Controls - 8.1L 6 - 29
System Configuration Options (cont’d)
Scan Tool Parameter Units Parameter Range
Governor Discrete Yes / No
Load Anticipate 1 Discrete Yes / No
Load Anticipate 2 Discrete Yes / No
RPM Change State Discrete Yes / No
Troll Mode Discrete Yes / No
Shift Interrupt Discrete Yes / No
Transmission Upshift Discrete Yes / No
Twin Engine Shift Sync. Discrete Yes / No
Emergency Stop Discrete Yes / No
Canister Purge Discrete Yes / No
Power Balance Discrete Yes / No
Oxygen Sensor 1 Present Discrete Yes / No
Oxygen Sensor 2 Present Discrete Yes / No
Fuel Temperature Sensor Discrete Yes / No
Fuel Pressure Sensor Discrete Yes / No
Bosch IAT/MAP Sensor Discrete Yes / No

Fuel System Specifications Therefore, you should not have to add anything to the fuel.
Use regular unleaded gasoline rated at 87 octane or In addition, gasolines containing oxygenates, such as
higher. It is recommended that the gasoline meet ethers and ethanol, and reformulated gasolines may be
specifications which were developed by the American available in your area to help clean the air. General Motors
Automobile Manufacturers Association for better vehicle recommends that you use these gasolines if they comply
performance and engine protection. Gasoline meeting the with the specifications described earlier.
AAMA specification could provide improved driveability Notice: Your vehicle was not designed for fuel that
and emission control system protection compared to other contains methanol. Don’t use it. It can corrode metal parts
gasolines. in your fuel system and also damage plastic and rubber
Be sure the posted octane is at least 87. If the octane is parts.
less than 87, you may get a heavy knocking noise when
you drive. If it’s bad enough, it can damage your engine. Fuels in Foreign Countries (Gasoline
If you are using fuel rated at the recommended octane or Engines)
higher and you still hear a heavy knocking, you engine If you plan on operating this engine in another country
needs service. But don’t worry if you hear a little pinging outside the United States and Canada, the proper fuel may
noise when you’re accelerating. That’s normal, and you be hard to find. Never use leaded gasoline or any other
don’t have to buy a higher octane fuel to get rid of pinging. fuel not recommended in the previous text on fuel.
It’s the heavy, constant knock that means you have a
problem.
Some gasolines that are not reformulated for low
emissions contain an octane-enhancing additive called
methylcyclopentadlenyl manganese tricarbonyl (MMT);
ask your service station operator whether or not this fuel
contains MMT. General Motors does not recommend the
use of such gasolines. If fuels containing MMT are used,
spark plug life may be reduced and your system
performance may be affected.
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help prevent
deposits from forming in your engine and fuel system,
allowing your emission control system to function properly.

MEFI 4
 Engine Controls Schematics (8.1L - Sensors) 6 - 30

MEFI 4
Engine
Control
Module
ECT Knock Knock (ECM)
5 Volt Sensor IAT Sensor Sensor 1 Sensor 2
Reference Signal Signal Signal Signal

2 7 21 J2 17 1 J1

TAN 472 DK BLU 496 LT BLU 1876

S100

YEL 410 A
GRY 416E Intake Air
GRY 416 Knock Knock
B Temperature(IAT)
Engine Controls - 8.1L

Sensor 1 Sensor 2
Engine Coolant Sensor (KS) (KS)
C Temperature (If Applicible)
Manifold (ECT) Sensor B
Absolute
Pressure A A
(MAP)
Sensor Throttle
B A Position(TP)
Sensor
BLK 814
B C BLK 814
BLK 813

S102 S101 Stepper Idle Air

Motor Control
LT GRN 432 DK BLU 417 Coil M Coil (IAC) Valve
B A

B A C D
BLK 814
GRN/WHT 443 BLU/BLK 442

LT
GRN/BLK 444 BLU/WHT 441
8 23 3 J2 30 15 31 16 J1

Map TP Sensor Sensor IAC IAC IAC IAC Engine

Sensor Signal Ground Coil B Coil B Coil A Coil A Control
Signal High Low Low High Module
(ECM)

MEFI401
5-17-00
Engine
 Engine Controls Schematics (8.1L - Ignition Coils 1 & 3)

Hot in Run And Start

Engine

From MEFI System Relay

To Injectors

PPL 902 To Fuel Pump Relay

Term. "86"
To Fuel Pump S103 C D S104
Relay Fuse
(Fuse Block term. "A") Fuse Block
INJ/ECM Fuse PNK 439
10A
PPL 902
19 J2
Ignition Feed Engine
Control
Module
(ECM)
Ignition Control A Ground 3 Ignition Control H

31 J2 13 J1 12 J2

PPL 2121 BRN 2129 LT BLU 2123

H G E F
C109

S107 PNK PNK

39 39
PPL 2121 LT BLU 2123 PNK 39
PNK 39
BRN S105 BRN
Ignition Coils 2129 2129 B C D
(cylinders #5 & #7) D C B
Ignition IC Signal Reference Reference IC Signal Ignition
Low Ignition Coils Low
Ignition Coil
Ignition Coil (cylinders #5 & #7) (cylinder #3)
(cylinder #1)

Ground Ground

A A
Spark Spark
Plug Plug
BLK 151 BLK 151
S106

BLK 151

Firing Order: 1-8-7-2-6-5-4-3

Engine Controls - 8.1L

Ignition Control: A - B - C - D - E - F - G - H
MEFI402
6-26-00

MEFI 4
6 - 31
 Engine Controls Schematics (8.1L - Ignition Coils 5 & 7)
6 - 32

Hot in Run And Start

MEFI 4
From MEFI System Relay
To Injectors

PPL 902 To Fuel Pump Relay

Term. "86"
To Fuel Pump S103 C D S104
Relay Fuse
(Fuse Block term. "A") Fuse Block
PNK 439
INJ/ECM Fuse
10A
PPL 902
19 J2
Ignition Feed Engine
Control
Module
(ECM)
Engine Controls - 8.1L

Ignition Control F Ground 3 Ignition Control C

13 J2 13 J1 30 J2

DK GRN 2125 BRN 2129 RED 2127

H C E B
C109

S107 PNK PNK

39 39
DK GRN 2125
PNK 39
PNK 39 RED 2127
Ignition Coils BRN S105 BRN
(cylinders #1 & #3) D C B 2129 2129 B C D

Ignition IC Signal Reference Reference IC Signal Ignition

Low Ignition Coils Low
Ignition Coil (cylinders #1 & #3) Ignition Coil
(cylinder #5) (cylinder #7)

Ground Ground

A A
Spark Spark
Plug Plug
BLK 151 BLK 151
S106

BLK 151

Firing Order: 1-8-7-2-6-5-4-3

Ignition Control: A - B - C - D - E - F - G - H

MEFI403
6-26-00
Engine
 Engine Controls Schematics (8.1L - Ignition Coils 2 & 4)
Hot in Run And Start
Engine

From MEFI System Relay

To Injectors

PPL 902 To Fuel Pump Relay

Term. "86"
To Fuel Pump S103 C D S104
Relay Fuse
(Fuse Block term. "A") Fuse Block
INJ/ECM Fuse PNK 439
10A
PPL 902
19 J2
Ignition Feed Engine
Control
Module
(ECM)
Ignition Control D Ground 3 Ignition Control G

14 J2 13 J1 28 J2

RED/WHT 2122 BRN 2129 DK GRN/WHT 2124

H B E C
C110

S107 PNK PNK

39 39
RED 2122 DK GRN 2124
Ignition Coils PNK 39 S105 PNK 39
BRN BRN
(cylinders #6 & #8) D C B 2129 2129 B C D

Ignition IC Signal Reference Reference IC Signal Ignition

Low Ignition Coils Low
Ignition Coil (cylinders #6 & #8) Ignition Coil
(cylinder #2) (cylinder #4)

Ground Ground

A A
Spark Spark
Plug Plug
BLK 151 BLK 151
S106

BLK 151

Firing Order: 1-8-7-2-6-5-4-3

Engine Controls - 8.1L

Ignition Control: A - B - C - D - E - F - G - H
MEFI404

MEFI 4
6-26-00
6 - 33
 Engine Controls Schematics (8.1l - Ignition Coils 6 & 8) 6 - 34

Hot in Run And Start

MEFI 4
From MEFI System Relay
To Injectors

PPL 902 To Fuel Pump Relay

Term. "86"
To Fuel Pump S103 C D S104
Relay Fuse
(Fuse Block term. "A") Fuse Block
INJ/ECM Fuse PNK 439
10A
PPL 902
19 J2
Ignition Feed Engine
Control
Module
(ECM)
Engine Controls - 8.1L

Ignition Control E Ground 3 Ignition Control B

29 J2 13 J1 15 J2

LT BLU/
WHT 2126 BRN 2129 PPL/WHT 2128
H F E G
C110

S107 PNK PNK

39 39
LT BLU 2126 PPL 2128

Ignition Coils PNK 39 BRN S105 BRN PNK 39

(cylinders #2 & #4) D C B 2129 2129 B C D

Ignition IC Signal Reference Reference IC Signal Ignition

Low Ignition Coils Low
Ignition Coil (cylinders #2 & #4) Ignition Coil
(cylinder #6) (cylinder #8)

Ground Ground

A A
Spark Spark
Plug Plug
BLK 151 BLK 151
S106

BLK 151

Firing Order: 1-8-7-2-6-5-4-3

Ignition Control: A - B - C - D - E - F - G - H
MEFI405
6-26-00
Engine
 Engine Controls Schematics (CMP & CKP Sensors)
Engine

Solid Camshaft
Crankshaft State Position
Solid Position (CMP)
State (CKP) Sensor
Sensor

A B C
C B A
RED
631 S108

S109
YEL/BLK
1868

YEL/BLK 1868 RED 631

DK BLU/WHT 1869 BRN/WHT 633

16 18 17 32 J2
CKP Sensor DepsLo Depspower CMP Sensor Engine
Signal Signal Control
Module
(ECM)

MEFI406
Engine Controls - 8.1L

5-17-00

MEFI 4
6 - 35
 Engine Controls Schematics (8.1L - DLC Connector) 6 - 36

MEFI 4
ORN 461 From S117

ORN 440
Twin Engine
In-Line
Connector F G H J K DLC
E D C B A
Connector
B A

S110
BLK
450
Engine Controls - 8.1L

ORN 461 BLK/

WHT 451

YEL 916 BRN/WHT 419

3 J1 10 J2 27 2 J1

Master/ Serial Malfunction Diagnostic Engine

Slave Data Indicator "Test" Terminal Control
Lamp (MIL) Module
(ECM)
ECM ECM ECM
Ground Ground Ground

29 28 13 J1

BLK 450 BLK 450 BLK 450

BLK
S111 450

MEFI407
5-17-00
Engine
 Engine Controls Schematics (8.1L - Fuel Injectors)
Hot in Run And Start
Engine

C Fuse Block
To ECM Term "J2-19"" To Fuel Pump
INJ/ECM Fuse
10A Relay Term. "86"
PNK 439 D PNK 439

S104

PNK 439

J K

S112 S112a

PNK 439 PNK 439 PNK 439 PNK 439 PNK 439 PNK 439 PNK 439
PNK 439

B B B B B B B B
Fuel Fuel Fuel Fuel Fuel Fuel Fuel Fuel
Injector Injector Injector Injector Injector Injector Injector Injector
Cylinder #1 Cylinder #4 Cylinder #6 Cylinder #7 Cylinder #2 Cylinder #3 Cylinder #5 Cylinder #8

A A A A A A A A

A C E G H D F B
S114 S113

DK BLU 467 DK GRN 468

26 11 J1

Fuel Fuel Engine

Injector Injector Control
Driver Driver Module
(ECM)
Engine Controls - 8.1L

MEFI408

MEFI 4
5-17-00
6 - 37
 Engine Controls Schematics (8.1L - MEFI System Relay & Fuel Pump) 6 - 38

MEFI 4
From Ignition
From B+ Tach Lead
To DLC GRY 120
Connector Term. F

S115 Not Used

GRY
To ECM Term. A
921
"J1-14" Fuel Pump
87A 87 85 Fuel Pump
PPL 903 M Relay
E Fuse Block RED 2
B
ECM/BAT
Fuse15A
ORN 440 30 86
F 30 86
Engine Controls - 8.1L

BLK 150
MEFI
Fuse Block
System PNK 339
A B
Relay
87A 87 85
Fuel Pump
Not Used BLK 150 Relay Fuse
S117 S116 15A
PPL 902 PPL 902
S103 To Ignition Coils BLK 150

C PNK 439
Fuse Block
INJ/ECM Fuse
15A
D
DK GRN/WHT 485
ORN 440
S104

To S113

PNK 439

1 19 J2 6 J1

Battery Feed Ignition Feed Fuel

Engine
Pump Control
Relay Module
Control (ECM)

MEFI409
4-20-00
Engine
 Engine Controls Schematics (8.1L - VSS Circuit)
Engine

Vehicle
Speed
Sensor
(VSS)
OR
Vehicle
Speed
Sensor A B C
From Ignition
(VSS)

BLK 814

A B PPL 401

PPL 401 YEL 400

26 2 3 25 J2

Vehicle 5 Volt Sensor Vehicle Engine

Speed Reference Ground Speed Control
Sensor (VSS) Sensor (VSS) Module
Signal Signal (ECM)

MEFI4012a
7-01-00
Engine Controls - 8.1L

MEFI 4
6 - 39
 Engine Controls Schematics (8.1L - HO2S & EGR Valve) 6 - 40

MEFI 4
Engine
Control
Module
5 Volt (ECM)
Reference
From Ignition
2 J2

From Fuel Pump

Relay Term. "87"

GRY 416
Engine Controls - 8.1L

D E

PNK 439 PNK 439

Exhaust
Gas
Recirculation
D D (EGR) Valve
B C A
Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2
*** Must be
B A C A B C connected
on system
GRY 1666 BLK 450 BLK 450 using
GRY 1666
BLK 1665 BLK 1665 EGR and/or
BRN 1456
TBI

WHT 257
GRY 1666
S101

6 3 22 5 J2 12 32 J1

HO2 Sensor 1 Sensor HO2 Sensor 2 EGR Valve EGR Solenoid FPR Sense Engine
Signal Ground Signal Position Control Control
Signal Module
(ECM)

MEFI4015
6-25-00
Engine
 Engine Controls Schematics (8.1L - Discrete Inputs & Outputs)

From Ignition
Engine

10 Amp
Fuse

24 23 22 9 8 J1

Oil General Warning General Warning Check Gauges / Buzzer

Level 2 Lamp / 1 Lamp / Governor
Lamp Troll Lamp / Trans / Overspeed
Engine
Canister Purge
Control
Governor
Module
(ECM)

Load 2 / Load 1 /
Twin Engine Sync / Lock Lo / General Warning 1 / Oil Emergency General Warning 2 /
Troll Mode Shift Interrupt FCal Level Stop Governor Mode

21 20 19 18 5 4 J1
Engine Controls - 8.1L

MEFI4014
5-17-00

MEFI 4
6 - 41
 Engine Controls Schematics (8.1L - Twin Engine) 6 - 42

MEFI 4
Engine
Control Port Engine
Module (Master ECM)
(ECM)
Serial CAN CAN
Data Hi Lo

10 24 9 J2

To DLC Connector
Term. "G"
Must be
twisted wire.
Engine Controls - 8.1L

To DLC Connector Must be

Term. "G" twisted wire.

10 24 9 J2

CAN CAN
Engine
Serial Starboard Engine
Hi Lo
Control
Data (Slave ECM)
Module
(ECM)
Master/
Slave

3 J1

MEFI4020
5-10-00
Engine
Engine Engine Controls - 8.1L 6 - 43

MEFI 4
6 - 44 Engine Controls - 8.1L Engine
Camshaft Sensor - 8.1L

656525

Legend
(1) Engine - 8.1L
(2) Camshaft Sensor
(3) Camshaft Sensor Connector

MEFI 4
Engine Engine Controls - 8.1L 6 - 45
Engine View - Upper Right (8.1L)

656520

Legend
(1) Engine Harness
(2) Manifold Absolute Pressure (MAP) Sensor
(3) Engine - 8.1L
(4) Engine Coil Harness Connector
(5) Engine Coil Connector

MEFI 4
6 - 46 Engine Controls - 8.1L Engine
Engine View - Lower Left (8.1L)

656528

Legend
(1) Engine - 8.1L (4) Engine Harness
(2) Engine Knock Sensor (5) Engine Harness Ground
(3) Engine Knock Sensor Connector

MEFI 4
Engine Engine Controls - 8.1L 6 - 47

MEFI 4
6 - 48 Engine Controls - 8.1L Engine
ECM Connector Identification (1 of 2)

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

J-1
ECM 32 WAY OUTPUT CONNECTOR
ECM PIN CKT(WIRE) CKT (WIRE)
CIRCUIT DESCRIPTION
NUMBER NUMBER COLOR
J1-1 468 LT GRN KNOCK SENSOR 2 SIGNAL (OPTIONAL)
J1-2 451 BLK/WHT DIAGNOSTIC “TEST” TERMINAL
J1-3 916 YEL MASTER/SLAVE
J1-4 GENERAL WARNING 2 / GOVERNOR MODE
J1-5 EMERGENCY STOP
J1-6 485 DK GRN/WHT FUEL PUMP RELAY CONTROL
J1-7 RPM CHANGE STATE
J1-8 BUZZER
J1-9 CHECK GAUGES / GOVERNOR OVERSPEED LAMP
J1-10
J1-11 468 DK GRN FUEL INJECTOR B DRIVER
J1-12 EXHAUST GAS RECIRCULATION (EGR) VALVE
J1-13 450 BLK ECM GROUND
J1-14 TACHOMETER OUTPUT
J1-15 444 GRN/BLK IDLE AIR CONTROL (IAC) COIL “B” LOW
J1-16 441 BLU/WHT IDLE AIR CONTROL (IAC) COIL “A” HIGH
J1-17 467 DK BLU KNOCK SENSOR 1 SIGNAL
J1-18 OIL LEVEL
J1-19 GENERAL WARNING 1 / FCAL
J1-20 LOAD 1 / LOCK LO / SHIFT INTERRUPT
J1-21 LOAD 2 / TWIN ENGINE SYNC / TROLL MODE
J1-22 GENERAL WARNING 1 LAMP / TRANS LAMP / CANISTER
PURGE
J1-23 GENERAL WARNING 2 LAMP / TROLL LAMP / GOVERNOR
J1-24 OIL LEVEL LAMP
J1-25
J1-26 467 DK BLU FUEL INJECTOR A DRIVER
J1-27 444 GRN/BLK IDLE AIR CONTROL (IAC) COIL “B” LOW
J1-28 450 BLK ECM GROUND
J1-29 450 BLK ECM GROUND
J1-30 443 GRN/WHT IDLE AIR CONTROL (IAC) COIL “B” HIGH
J1-31 442 BLU/BLK IDLE AIR CONTROL (IAC) COIL “A” LOW
J1-32 FUEL PRESSURE RELAY SENSE

MEFI 4
Engine Engine Controls - 8.1L 6 - 49
ECM Connector Identification (2 of 2)

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

J-2
ECM 32 WAY OUTPUT CONNECTOR
ECM PIN CKT(WIRE) CKT (WIRE)
CIRCUIT DESCRIPTION
NUMBER NUMBER COLOR
J2-1 440 ORN BATTERY FEED
J2-2 416 GRY 5 VOLT REFERENCE
J2-3 814 BLK SENSOR GROUND
J2-4 FUEL PRESSURE SENSOR SIGNAL
J2-5 EXHAUST GAS RECIRCULATION (EGR) VALVE FEEDBACK
J2-6 HEATED OXYGEN (HO2) SENSOR “1” SIGNAL
J2-7 410 YEL ECT SENSOR SIGNAL
J2-8 432 LT GRN MAP SENSOR SIGNAL
J2-9
J2-10 461 ORN SERIAL DATA
J2-11 410 YEL TAC SERIAL DATA 2
J2-12 2123 LT BLU IGNITION CONTROL H
J2-13 2125 DK GRN IGNITION CONTROL F
J2-14 2122 PPL/WHT IGNITION CONTROL D
J2-15 2128 RED/WHT IGNITION CONTROL B / BYPASS (DISTRIBUTOR APP.)
J2-16 634 DK BLU/WHT CRANK SENSOR SIGNAL
J2-17 631 RED DEPSPOWER
J2-18 632 YEL/BLK DEPSLO
J2-19 439 PNK IGNITION FEED
J2-20 OIL PRESSURE INPUT
J2-21 472 TAN IAT SENSOR SIGNAL
J2-22 HEATED OXYGEN (HO2) SENSOR “2” SIGNAL
J2-23 417 DK BLU TP SENSOR SIGNAL
J2-24
J2-25 SPEED SENSOR SIGNAL (VF)
J2-26 SPEED SENSOR SIGNAL (AN) / FUEL TEMPERATURE
J2-27 1061 ORN/BLK TAC SERIAL DATA 1
J2-28 2124 LT BLU/WHT IGNITION CONTROL G
J2-29 2126 GRN/WHT IGNITION CONTROL E
J2-30 2127 RED IGNITION CONTROL C
J2-31 2121 PPL IGNITION CONTROL A
J2-32 633 BRN/WHT CAM SENSOR SIGNAL

MEFI 4
6 - 50 Engine Controls - 8.1L Engine

Camshaft Position (CMP) Sensor (8.1L) Crankshaft Position (CKP) Sensor (8.1L)

684840 366117
Connector Part • 12129946 Connector Part • 15324165
Information • 3-Way F Metri-Pack Information • 3-Way F Metri-Pack
150 Series Sealed 150 Series Sealed
Wire Circuit Wire Circuit
Pin Color No. Function Pin Color No. Function
A RED 631 DEPSPOWER (12V Ref) A RED 631 DEPSPOWER (12V Ref)
B YEL/BLK 1868 DEPSLO (Low Ref) B YEL/BLK 1868 DEPSLO (Low Ref)
C BRN/WHT 633 CMP Sensor Signal C DK BLU/WHT 1869 CMP Sensor Signal

Exhaust Gas Recirculation (EGR) Valve (8.1L) Fuel Injector #1 (8.1L)

684863 684833
Connector Part • 15324589 Connector Part • 12129140
Information • 3-Way F Metri-Pack Information • 2-Way F Metri-Pack 280.1
150 Series Sealed P2S (BLK)
Wire Circuit Wire Circuit
Pin Color No. Function Pin Color No. Function
A WHT 257 EGR Solenoid Control A DK BLU 467 Fuel Injector 1 Control
B GRY 1666 Sensor Ground B PNK 439 Ignition Voltage
EGR Valve Position
C BRN 1456
Signal
D GRY 416 5 Volt Reference
EGR Valve Supply
E RED 1676
Voltage

MEFI 4
Engine Engine Controls - 8.1L 6 - 51

Fuel Injector #2 (8.1L) Fuel Injector #4 (8.1L)

684833 684833
Connector Part • 12129140 Connector Part • 12129140
Information • 2-Way F Metri-Pack 280.1 Information • 2-Way F Metri-Pack 280.1
P2S (BLK) P2S (BLK)
Wire Circuit Wire Circuit
Pin Color No. Function Pin Color No. Function
A DK GRN 468 Fuel Injector 2 Control A DK BLU 467 Fuel Injector 4 Control
B PNK 439 Ignition Voltage B PNK 439 Ignition Voltage

Fuel Injector #3 (8.1L) Fuel Injector #5 (8.1L)

684833 684833
Connector Part • 12129140 Connector Part • 12129140
Information • 2-Way F Metri-Pack 280.1 Information • 2-Way F Metri-Pack 280.1
P2S (BLK) P2S (BLK)
Wire Circuit Wire Circuit
Pin Color No. Function Pin Color No. Function
A DK GRN 468 Fuel Injector 3 Control A DK GRN 468 Fuel Injector 5 Control
B PNK 439 Ignition Voltage B PNK 439 Ignition Voltage

MEFI 4
6 - 52 Engine Controls - 8.1L Engine
Fuel Injector #6 (8.1L) Fuel Injector #8 (8.1L)

684833 684833
Connector Part • 12129140 Connector Part • 12129140
Information • 2-Way F Metri-Pack 280.1 Information • 2-Way F Metri-Pack 280.1
P2S (BLK) P2S (BLK)
Wire Circuit Wire Circuit
Pin Color No. Function Pin Color No. Function
A DK BLU 467 Fuel Injector 6 Control A DK GRN 468 Fuel Injector 8 Control
B PNK 439 Ignition Voltage B PNK 439 Ignition Voltage

Fuel Injector #7 (8.1L) Ignition Coil/Driver - Cylinder #1 (8.1L)

684833 684854
Connector Part • 12129140 Connector Part • 12162144
Information • 2-Way F Metri-Pack 280.1 Information • 4-Way F Metri-Pack
P2S (BLK) 150 Series Sealed (BLK)
Wire Circuit Wire Circuit
Pin Color No. Function Pin Color No. Function
A DK BLU 467 Fuel Injector 7 Control A BLK 151 Ground
B PNK 439 Ignition Voltage B BRN 2129 Low Reference
C PPL 2121 IC 1 Control
D PNK 39 Ignition Voltage

MEFI 4
Engine Engine Controls - 8.1L 6 - 53
Ignition Coil/Driver - Cylinder #3 (8.1L) Ignition Coil/Driver - Cylinder #7 (8.1L)

684854 684854
Connector Part • 12162144 Connector Part • 12162144
Information • 4-Way F Metri-Pack Information • 4-Way F Metri-Pack
150 Series Sealed (BLK) 150 Series Sealed (BLK)
Wire Circuit Wire Circuit
Pin Color No. Function Pin Color No. Function
A BLK 151 Ground A BLK 151 Ground
B BRN 2129 Low Reference B BRN 2129 Low Reference
C LT BLU 2123 IC 3 Control C RED 2127 IC 7 Control
D PNK 39 Ignition Voltage D PNK 39 Ignition Voltage

Ignition Coil/Driver - Cylinder #5 (8.1L) Ignition Coil/Driver - Cylinder #2 (8.1L)

684854 684854
Connector Part • 12162144 Connector Part • 12162144
Information • 4-Way F Metri-Pack Information • 4-Way F Metri-Pack
150 Series Sealed (BLK) 150 Series Sealed (BLK)
Wire Circuit Wire Circuit
Pin Color No. Function Pin Color No. Function
A BLK 151 Ground A BLK 151 Ground
B BRN 2129 Low Reference B BRN 2130 Low Reference
C DK GRN 2125 IC 5 Control C RED 2122 IC 2 Control
D PNK 39 Ignition Voltage D PNK 39 Ignition Voltage

MEFI 4
6 - 54 Engine Controls - 8.1L Engine
Ignition Coil/Driver - Cylinder #4 (8.1L) Ignition Coil/Driver - Cylinder #8 (8.1L)

684854 684854
Connector Part • 12162144 Connector Part • 12162144
Information • 4-Way F Metri-Pack Information • 4-Way F Metri-Pack
150 Series Sealed (BLK) 150 Series Sealed (BLK)
Wire Circuit Wire Circuit
Pin Color No. Function Pin Color No. Function
A BLK 151 Ground A BLK 151 Ground
B BRN 2130 Low Reference B BRN 2130 Low Reference
C DK GRN 2124 IC 4 Control C PPL 2128 IC 8 Control
D PNK 39 Ignition Voltage D PNK 39 Ignition Voltage

Ignition Coil/Driver - Cylinder #6 (8.1L) Ignition Coils - 1,3,5,7 (Inline Connector-8.1L)

684854 684790
Connector Part • 12162144 Connector Part • 12047938
Information • 4-Way F Metri-Pack Information • 7-Way F Metri-Pack
150 Series Sealed (BLK) 150 Series Sealed (LT GRY)
Wire Circuit Wire Circuit
Pin Color No. Function Pin Color No. Function
A BLK 151 Ground A BLK 151 Ground
B BRN 2130 Low Reference B RED 2127 IC 7 Control
C LT BLU 2126 IC 6 Control C DK GRN 2125 IC 5 Control
D PNK 39 Ignition Voltage E BRN 2129 Low Reference
F LT BLU 2123 IC 3 Control
G PPL 2121 IC 1 Control
H PNK 39 Ignition Voltage

MEFI 4
Engine Engine Controls - 8.1L 6 - 55
Ignition Coils - 2,4,6,8 (Inline Connector-8.1L) Knock Sensor, LH - Odd (8.1L)

684790 35437
Connector Part • 12047938 Connector Part • 15355362
Information • 7-Way F Metri-Pack Information • 1-Way F Metri-Pack
150 Series Sealed (LT GRY) 150 Series Sealed (NAT)
Wire Circuit Wire Circuit
Pin Color No. Function Pin Color No. Function
A BLK 151 Ground A DK BLU 496 KS 1 Signal
B RED/WHT 2122 IC 2 Control
C DK GRN/WHT 2124 IC 4 Control
E BRN/WHT 2130 Low Reference
F LT BLU/WHT 2126 IC 6 Control
G PPL/WHT 2128 IC 8 Control
H PNK 39 Ignition Voltage

Manifold Absolute Pressure (MAP) Sensor

(8.1L) Knock Sensor, RH - Even (8.1L)

684840 35437
Connector Part • 12129946 Connector Part • 15355362
Information • 3-Way F Metri-Pack Information • 1-Way F Metri-Pack
150 Series Sealed (GRY) 150 Series Sealed (NAT)
Wire Circuit Wire Circuit
Pin Color No. Function Pin Color No. Function
A BLK 814 Low Reference A LT BLU 1876 KS 2 Signal
B LT GRN 432 MAP Sensor Signal
C GRY 416E 5 Volt Reference

MEFI 4
6 - 56 Engine Controls - 8.1L Engine

Diagnostic Information and the electronic engine control system. The Diagnostic
System Check must be the starting point for any
Procedures driveability concern. The Diagnostic System Check directs
the service technician to the next logical step in order to
A Diagnostic Starting Point - Engine Controls diagnose the concern. Understanding, and correctly using
Begin the system diagnosis with A Diagnostic System Check- the diagnostic table reduces diagnostic time, and prevents
Engine Controls. The Diagnostic System Check will provide the replacement of good parts.
the following information: Test Description
• The ability of the control module to communicate Number(s) below refer to the Step number(s) on the
through the serial data circuit. Diagnostic Table:
• The identification of any stored Diagnostic Trouble 1. The MIL should be “ON” steady with the ignition “ON,”
Codes (DTCs) and Logged Warnings. engine “OFF.” If not, Table A-1 should be used to isolate
The use of the Diagnostic System Check will identify the the malfunction.
correct procedure for diagnosing the system. 3. Checks the serial data circuit and ensures that the ECM
is able to transmit serial data.
A Diagnostic System Check - Engine 5. If the engine will not start, Table A-3 should be used to
Controls diagnose the condition.
Description 8. A scan tool parameter which is not within the typical
range may help to isolate the area which is causing the
The Diagnostic System Check is an organized approach
problem.
to identifying a condition that is created by a malfunction in

MEFI 4
Engine Engine Controls - 8.1L 6 - 57
On-Board Diagnostic (OBD) System Check - Scan
Step Action Value Yes No
Important:
• Do not perform thsi diagnostic if there is not a
driveability concern, unless another procedure directs
you to this diagnostic.
• Before you proceed with diagnosis, search for
applicable service bulletins.
• Unless a diagnostic procedure instructs you, DO NOT
clear the DTC’s.
1
• If there is a condition with the starting system, repair
that first.
• Ensure the battery has a full charge.
• Ensure the battery cables are clean and tight.
• Ensure the ECM grounds are clean, tight and in the
correct location. Go to Data
Install a scan tool. Link Connector
Does the scan tool turn ON? — Go to Step 2 Diagnosis

Go to Engine
2 Attempt to start the engine. Cranks but
Does the engine start and idle? — Go to Step 3 Does Not Run

Select the DTC display function on the scan tool. Go to Applicable

3 Does the scan tool display DTCs? — DTC Table Go to Step 4

1. Review the following symptoms.

2. Refer to the applicable symptom diagnostic table.
• Hard Start
• Surges/Chuggles
• Lack of Power, Sluggishness or Sponginess
• Detonation/Spark Knock
4 • Hesitation, Sag or Stumble
• Cuts Out, Misses
• Poor Fuel Economy
• Rough, Unstable or Incorrect Idle and Stalling
• Dieseling, Run-On Go to
• Backfire Intermittent
Did you find and correct the condition? — System OK Conditions

MEFI 4
6 - 58 Engine Controls - 8.1L Engine

E Fuse Block
ECM/BAT From S117
ORN 461
Fuse15A
ORN 440
F
Twin Engine
To DLC In-Line
Connector
S117 Connector
F G H J K DLC
Term. "F" E D C B A
Connector
B A

C
Fuse Block
S110
INJ/ECM Fuse BLK
15A 450
D

To Fuel
ORN 440 Pump Relay
S104 Term. "86"
ORN 461 BLK/
WHT 451
To S113
YEL 916 BRN/WHT 419

PNK 439

19 J2 10 J2 27
1 3 J1 2 J1

Master/ Serial Malfunction Diagnostic Engine

Slave Data Indicator "Test" Terminal Control
Lamp (MIL) Module
(ECM)
ECM ECM ECM
Ground Ground Ground

29 28 13 J1

BLK 450 BLK 450 BLK 450

BLK
S111 450

MEFI4302
Data Link Connector Diagnosis 4-20-00
Circuit Description 9. A no start condition occurs when the fuse(s) for the
Use a properly functioning scan tool with the diagnostic battery or ignition feed circuits is open. The MIL is
tables in this section. DO NOT clear the DTC’s unless inoperative when the battery and ignition feed circuit
directed by a diagnostic procedure. Clearing the DTC’s fuses open. Inspect the circuits for being grounded
may also clear valuable diagnostic information. when either of these fuses open.
Test Description 12. The scan tool does not communicate when the
serial data circuit from the ECM to the DLC is open.
Number(s) below refer to the step number(s) on the
diagnostic table: 14. If the test lamp not illuminate for a circuit, inspect the
fuse for being open. If the fuse is open, inspect the
3. An engine that just cranks and does not attempt to circuit for a short to ground.
start indicates that the ECM is not powered-up.
15. Inspect for an open ground circuit.
5. This step is checking for a B+ supply to the Data
Link Connector (DLC). 16. Inspect for an open fuse that supplies the DLC. If the
fuse is open, repair the grounded circuit.
6. A ground must be available for the scan tool to
function properly.

MEFI 4
Engine Engine Controls - 8.1L 6 - 59

Data Link Connector Diagnosis

Step Action Value Yes No
Did you perfom the On-Board Diagnostic (OBD) System Go to OBD
1
Check? — Go to Step 2 System Check

Important: This table assumes that the scan tool you are
using is functional.
1. Turn ON the ignition leaving the engine OFF.
2 2. Connect the scan tool to the Data Link Connector
(DLC).
Does the scan tool power-up? — Go to Step 3 Go to Step 5
3 Does the engine start and continue to operate? — Go to Step 6 Go to Step 4
4 Does the engine start and stall? — Go to Step 12 Go to Step 9

1. Disconnect the scan tool from the DLC.

2. Turn ON the ignition leaving the engine OFF.
5 3. Probe the DLC terminal F using a test lamp
J 34142-B connected to the battery ground.
Is the test lamp illuminated? — Go to Step 6 Go to Step 16

Probe the DLC terminal A using a test lamp J 34142-B

6 connected to B+.
Is the test lamp illuminated? — Go to Step 7 Go to Step 8
Inspect the scan tool connections at the DLC. Also inspect
7 the terminals for proper terminal tension at the DLC. Go to OBD
Did you find and repair the condition? — System Check Go to Step 12

Repair the open ground circuit to the DLC terminal A. Go to OBD

8
Is the action complete? — System Check —

1. Turn OFF the ignition.

2. Disconnect the ECM connector J2.
3. Turn ON the ignition leaving the engine OFF.
4. Probe the ECM battery and the ECM ignition feed
9 circuits (J2-1 and J2-19) in the ECM harness
connector using a test lamp J 34142-B connected to
a battery ground.
Does the test lamp illuminate for each circuit? — Go to Step 10 Go to Step 14
1. Turn OFF the ignition.
2. Disconnect the ECM connector J1.
3. Measure the resistance between the battery ground
10 and the ECM ground circuits (J1-13, J1-28 and J1-29)
in the ECM harness connectors using a DMM J 39200.
Does the DMM display between the specified range on
each circuit? 0-2 ohms Go to Step 11 Go to Step 15
Inspect the ECM for proper connections. Go to OBD
11
Did you find and correct the condition? — System Check Go to Step 13

Inspect the serial data circuit for being open, shorted or a

12 poor connection at the ECM. Go to OBD
Did you find and repair the condition? — System Check Go to Step 13

MEFI 4
6 - 60 Engine Controls - 8.1L Engine

Data Link Connector Diagnosis (cont’d)

Step Action Value Yes No
Replace the ECM. Go to OBD
13
Is action complete? — System Check —

Repair the circuit that did not illuminate the test lamp. Go to OBD
14 Is action complete? — System Check —

Repair the faulty ECM ground circuit(s). Go to OBD

15 Is action complete? — System Check —

Repair the faulty B+ supply circuit. Go to OBD

16
Is action complete? — System Check —

MEFI 4
Engine Engine Controls - 8.1L 6 - 61

MEFI 4
6 - 62 Engine Controls - 8.1L Engine

Solid Camshaft
Crankshaft State Position
Solid Position
State (CMP)
(CKP) Sensor
Sensor

A B C
C B A
RED
631 S108
YEL/BLK 632

YEL/BLK
S109 1868
BRN/WHT 633

RED 631

YEL/BLK 1868
DK BLU/WHT 1869

16 18 17 32 J2

DepsLo Depspower CMP Sensor Engine

CKP Sensor Control
Signal Signal
Module
(ECM)

MEFI4301
5-17-00
Engine Cranks but Does Not Run
Circuit Description 6. The Crankshaft Position sensor is located at the left
The Engine Cranks but Does Not Run diagnostic table rear of the engine.
assumes that battery condition and engine cranking speed 7. The Camshaft Position sensor is located in the front
are OK. If the battery condition and the cranking speed are engine cover.
not OK, refer to those conditions first. Make sure that there 8. The ignition feed circuit for the Camshaft and
is adequate fuel in the fuel tank(s). Crankshaft Position sensors is internally connected
Test Description within the ECM. A short to ground on either circuit
will cause a no start condition.
Number(s) below refer to the step number(s) on the
diagnostic table: 10. You may need to get close to the fuel pump in order
to hear if the fuel pump is operating.
4. It may be necessary to connect a battery charger to
the battery for this step. If the battery state of charge 12. At this point, the engine should start. Refer to Hard
is low, the scan tool may reset during the cranking Start Symptom for further diagnosis.
test.
5. This step tests the system relay for proper operation.
The system relay supplies voltage to the injectors
and the ignition coils. When the system relay is not
operating properly, a no start condition occurs. If the
test lamp does not illuminate, this indicates the
system relay is not supplying a voltage to the fuses.

MEFI 4
Engine Engine Controls - 8.1L 6 - 63

Engine Cranks but Does Not Run

Step Action Value Yes No
Did you perfom the On-Board Diagnostic (OBD) System Go to OBD
1
Check? — Go to Step 2 System Check

Important: Refer to the applicable DTC table if any of the

following DTC’s are set: 41 or 81.
2 Monitor the engine speed while cranking the engine.
Is engine RPM indicated on the scan tool? — Go to Step 3 Go to Step 4
1. Turn ON the ignition leaving the engine OFF.
2. Probe both sides of the fuses listed below using a test
test lamp J 34142-B connected to ground.
3 • INJ A
• INJ B
• ECM Go to System
Does the test lamp illuminate on both sides of the fuses? — Go to Step 7 Relay Diagnosis
1. Disconnect the Crankshaft Position (CKP) sensor
electrical connector.
4 2. Measure the voltage at the ignition feed circuit at the
CKP electrical connector using a DMM J 39200.
Does the DMM display near the specified voltage? B+ Go to Step 11 Go to Step 5

1. Disconnect the Camshaft Position (CMP) sensor

electrical connector.
5 2. Measure the voltage at the ignition feed circuit at the
CMP electrical connector using a DMM J 39200.
Does the DMM display near the specified voltage? B+ Go to Step 12 Go to Step 6

Inspect the Camshaft and Crankshaft Position sensor

6 ignition feed circuits for a short to ground.
Did you find and correct the condition? — Go to Step 14 Go to Step 13
Monitor the engine coolant temperature using the scan Go to DTC 15
tool. Engine Coolant
7
Is the engine coolant temperature on the scan tool close Temperature
to the actual engine temperature? (ECT) Sensor
Circuit High
— Go to Step 8 Voltage

Enable the fuel pump using the scan tool. Go to Fuel Pump
8
Does the fuel pump operate? — Go to Step 9 Relay Diagnosis

1. Turn OFF the ignition.

2. Install a fuel pressure gauge.
Important: The fuel pump operates for about 2 seconds
when the ignition is turned ON. The fuel pressure must be
9 observed when the fuel pump is operating.
3. Turn ON the ignition leaving the engine OFF.
4. Observe the fuel pressure while the fuel pump is Go to Fuel
operating. 379-427 kPa System
Is the fuel pressure within the specified range? (55-62 psi) Go to Step 10 Diagnosis

MEFI 4
6 - 64 Engine Controls - 8.1L Engine
Engine Cranks but Does Not Run (cont’d)
Step Action Value Yes No
Perform the following additional inspections:
• Inspect that the throttle angle is at 0% at a closed
throttle. If the throttle angle is not at 0%, refer to
DTC 21 Throttle Position (TP) Sensor Circuit High
Voltage or DTC 22 Throttle Position (TP) Sensor
Circuit Low Voltage.
• Inspect the spark plugs for being gas fouled. If the
10 spark plugs are gas fouled, determine what caused the
rich condition.
• Inspect for an engine mechanical failure that causes
an engine not to start (i.e. timing chain, low
compression). Refer to Engine Compression Test in
Engine Mechanical.
• Compare MAP/BARO parameters to another vehicle. Go to Hard Start
The parameter values should be close to each other. — Go to Step 14 for diagnosis

Replace the CKP sensor. Refer to Crankshaft Position

11 Sensor Replacement.
Is the action complete? — Go to Step 14 —
Replace the CMP sensor. Refer to Camshaft Position
12 Sensor Replacement.
Is the action complete? — Go to Step 14 —
Replace the ECM.
13
Is the action complete? — Go to Step 14 —

1. Select the Diagnostic Trouble Codes (DTC) option

and the Clear DTC option using the scan tool.
14
2. Attempt to start the engine.
Does the engine start and continue to run? — Go to Step 15 Go to Step 2

1. Idle the engine at the normal operating temperature.

2. Select the Diagnostic Trouble Codes (DTC) option Go to the
15 using the scan tool. applicable
Are any DTCs displayed? — DTC table System OK

MEFI 4
Engine Engine Controls - 8.1L 6 - 65

From Ignition
From B+
Tach Lead
To DLC
Connector Term. F

S115
GRY
To ECM Term.
921
"J1-14"
PPL 903
E Fuse Block RED 2

ECM/BAT
Fuse15A
ORN 440 30 86
F
MEFI
System
Relay
87A 87 85

Not Used BLK 150

S117 S116
PPL 902

S103 To Ignition Coils

C
Fuse Block To Fuel
INJ/ECM Fuse Pump Relay
15A Fuse
D

ORN 440 To Fuel

S104 Pump Relay
Term. "86"
To S113

PNK 439

1 19 J2
Engine
Battery Feed Ignition Feed Control
Module
(ECM)

MEFI4303
4-20-00

System Relay Diagnosis

Circuit Description • Broken wire inside the insulation
The system relay powers the following components: Test Description
• Injectors Number(s) below refer to the step number(s) on the
• Ignition Coils diagnostic table:
2. Refer to Thumbnail Schematic for proper relay
Diagnostic Aids terminal identification.
The following may cause an intermittent: 4. This step is testing the relay ground circuit.
• Poor connections. Check for adequate terminal 5. This step isolates the circuit from the system relay.
tension. All of the circuits are good if the test lamp
• Corrosion illuminates.
• Mis-routed harness 9. The open circuit will be between the splice and the
system relay.
• Rubbed through wire insulation

MEFI 4
6 - 66 Engine Controls - 8.1L Engine
System Relay Diagnosis
Step Action Value Yes No
Did you perfom the On-Board Diagnostic (OBD) System Go to OBD
1
Check? — Go to Step 2 System Check

1. Turn OFF the ignition.

2. Disconnect the system relay electrical connector.
3. Probe the system relay B+ feed circuit (switch side of
2 the relay) using a test lamp J 34142-B connected to a
ground.
Does the test lamp illuminate? — Go to Step 3 Go to Step 8
1. Turn ON the ignition leaving the engine OFF.
2. Probe the system relay ignition feed circuit using a test
3 lamp J 34142-B connected to a ground.
Does the test lamp illuminate? — Go to Step 4 Go to Step 9
1. Turn OFF the ignition.
2. Meausure the resistance of the system relay ground
4 circuit using a DMM J 39200 connected to the battery
ground.
Is the resistance less than the specified value? 0-5 ohms Go to Step 5 Go to Step 10

1. Turn OFF the ignition.

2. Jumper the system relay B+ feed circuit and the
system relay load circuit together using a fused jumper
wire.
5 3. Probe the fuses for the following components with a
test lamp J 34142-B connected to a ground.
• Injectors
• Ignition coils
Does the test lamp illuminate? — Go to Step 6 Go to Step 11

Inspect for poor terminal contact at the system relay

6 connector.
Did you find and correct the condition? — System OK Go to Step 7
Replace the system relay.
7
Is the action complete? — System OK —

Repair the open B+ supply to the system relay.

8
Is the action complete? — System OK —

Repair the ignition feed circuit to the system relay.

9 Is the action complete? — System OK —
Repair the system relay ground circuit.
10 Is the action complete? — System OK —
Repair the system relay load circuit.
11
Is the action complete? — System OK —

MEFI 4
Engine Engine Controls - 8.1L 6 - 67

GRY 120

Not Used
A
Fuel Pump 85 Fuel Pump
87A 87
M Relay
B

30 86
BLK 150
Fuse Block
A B PNK 339

Fuel Pump
Relay Fuse PNK 439
S116 15A
PPL 902
DK GRN/WHT 485
BLK 150

From System
Relay
From
INJ/ECM
Fuse 6 J1

Fuel
Engine
Pump Control
Relay Module
Control (ECM)

MEFI4304
4-20-00
Fuel Pump Relay Circuit Diagnosis
Circuit Description Diagnostic Aids
When the ignition switch is ON, the ECM activates the The following conditions may have caused the fuel pump
electric fuel pump. The fuel pump remains ON as long as fuse to open:
the ECM receives reference pulses from the ignition • The fuse is faulty
system. If there are no reference pulses, the ECM turns
the fuel pump OFF after about 2 seconds. The pump • There is an intermittent short in the fuel pump power
delivers fuel to the fuel rail and injectors, then to the feed circuit.
pressure regulator, where the system pressure remains at • The fuel pump has an intermittent internal problem.
379-427 kPa (55-62 psi) while the fuel pump is running. For an intermittent condition, refer to Symptoms.
Excess fuel returns to the fuel tank. When the engine is
stopped, a scan tool in the output controls function can Test Description
turn ON the fuel pump. Number(s) below refer to the step number(s) on the
Improper fuel system pressure results in one or many of diagnostic table:
the following symptoms: 3. Refer to Thumbnail Schematic for proper terminal
• Cranks but will not run identification.
• Cuts out, may feel like an ignition problem 5. The test lamp only illuminates for two seconds even
through the scan tool commanded position is ON.
• Poor fuel economy You will have to command the fuel pump OFF then
• Loss of power ON to re-enable the ECM fuel pump control.
12. Inspect the fuel pump fuse for an open. If the fuse is
• Hesitation
open, inspect the circuit for a short to ground.
• DTCs 20. Inspect the fuel pump fuse for an open. If the fuse is
open, inspect the circuit for a short to ground.

MEFI 4
6 - 68 Engine Controls - 8.1L Engine
Fuel Pump Relay Circuit Diagnosis
Step Action Value Yes No
Did you perfom the On-Board Diagnostic (OBD) System Go to OBD
1
Check? — Go to Step 2 System Check

Check the fuel pump fuse.

2 Is the fuse open? — Go to Step 9 Go to Step 3
1. Install a scan tool.
2. Disconnect the fuel pump relay harness connector.
3. Turn ON the ignition leaving the engine OFF.
3 4. Probe the fuel pump relay battery feed circuit at the
harness connector with a test lamp J 34142-B
connected to ground.
Does the test lamp illuminate? — Go to Step 4 Go to Step 12
Probe the fuel pump relay ground circuit at the harness
connector with a test lamp J 34142-B connected to B+.
4 Refer to the thumbnail wiring schematic for the proper
terminal identification.
Does the test lamp illuminate? — Go to Step 5 Go to Step 13

1. Probe the fuel pump control circuit at the harness

connector with a test lamp J 34142-B connected to
ground. Refer to the thumbnail wiring schematic for the
5
proper terminal identification.
2. Enable the fuel pump using the scan tool.
Does the test lamp illuminate? — Go to Step 6 Go to Step 11

Important: Ignition must be ON before performing this

step.
Jumper the fuel pump relay battery feed circuit to the fuel
6 pump load circuit at the harness connector using a fused
jumper wire.
Does the fuel pump operate? — Go to Step 18 Go to Step 7
1. Leave the fused jumper wire connected.
2. Disconnect the fuel pump harness connector at the
fuel pump.
7 3. Probe the power feed circuit in the fuel pump harness
connector with a test lamp J 34142-B connected to
ground.
Does the test lamp illuminate? — Go to Step 8 Go to Step 14

1. Leave the fused jumper wire connected.

2. Connect the test lamp J 34142-B between the battery
8 feed circuit and the ground circuit in the fuel pump
harness connector.
Does the test lamp illuminate? — Go to Step 25 Go to Step 15

1. Turn OFF the ignition.

2. Remove the fuel pump fuse.
9 3. Disconnect the fuel pump harness connector at the
fuel pump.

MEFI 4
Engine Engine Controls - 8.1L 6 - 69
Fuel Pump Relay Circuit Diagnosis (cont’d)
Step Action Value Yes No
4. Probe the load circuit for the fuel pump relay at the
harness connector with a test lamp J 34142-B
9
connected to B+.
Does the test lamp illuminate? — Go to Step 16 Go to Step 10

Probe the battery feed circuit for the fuel pump relay at the
harness connector with a test lamp J 34142-B connected
10 to B+.
Does the test lamp illuminate? — Go to Step 20 Go to Step 21
1. Turn OFF the ignition.
2. Disconnect the ECM connector J1.
3. Measure the continuity of the fuel pump relay control
11 circuit from the fuel pump relay harness connector to
the ECM connector using the DMM J 39200.
Does the DMM display the specified value or lower? 5 ohms Go to Step 22 Go to Step 17
Repair the open or grounded battery feed circuit to the
12 relay. Replace the fuel pump fuse if the fuse is open.
Is the action complete? — Go to Step 26 —

Repair the open fuel pump relay ground circuit.

13
Is the action complete? — Go to Step 26 —

Repair the open circuit between the fuel pump relay and
14 the fuel pump.
Is the action complete? — Go to Step 26 —
Repair the open fuel pump ground circuit.
15
Is the action complete? — Go to Step 26 —

Repair the short to ground in the fuel pump relay load

16 circuit between the relay and the fuel pump.
Is the action complete? — Go to Step 26 —

Repair the fuel pump relay control circuit.

17 Is the action complete? — Go to Step 26 —
Inspect for poor connections at the relay harness
18 connector.
Did you find and correct the condition? — Go to Step 26 Go to Step 19
Replace the relay. Refer to Fuel Pump Relay Replacement.
19
Is the action complete? — Go to Step 26 —

Repair the short to ground in the battery feed circuit to the

20 fuel pump relay.
Is the action complete? — Go to Step 26 —
1. Turn OFF the ignition.
2. Re-install the fuel pump relay.
3. Install a new fuse.
21 4. Connect the fuel pump harness to the fuel pump.
5. Turn ON the ignition leaving the engine OFF.
6. Command the fuel pump relay ON using a scan tool. Go to
Is the fuel pump fuse open? — Go to Step 24 Diagnostic Aids

MEFI 4
6 - 70 Engine Controls - 8.1L Engine
Fuel Pump Relay Circuit Diagnosis (cont’d)
Step Action Value Yes No
Inspect for a poor connection at the ECM.
22
Did you find and correct the condition? — Go to Step 26 Go to Step 23

Replace the ECM.

23 Is the action complete? — Go to Step 26 —
1. Inspect the fuel pump harness for a short to ground.
24 2. If you find a short, repair the circuit as necessary.
Did you find and correct the condition? — Go to Step 26 Go to Step 25
Important: Inspect for poor electrical connections at the
fuel pump harness before replacing the fuel pump.
25
Replace the fuel pump.
Is the action complete? — Go to Step 26 —

1. Select the Diagnostic Trouble Code (DTC) option

and the Clear DTC Information option using the scan
26 tool.
2. Attempt to start the engine.
Does the engine start and continue to operate? — Go to Step 27 Go to Step 2

1. Idle the engine until the normal operating temperature

is reached. Go to the
27 2. Select the Diagnostic Trouble Code (DTC) option. applicable
Are any DTCs displayed? — DTC table System OK

MEFI 4
Engine Engine Controls - 8.1L 6 - 71

WATER
SEPERATOR

FUEL
FUEL
TANK
PUMP

FUEL
FILTER PRESSURE
REGULATOR

FUEL RAIL ASSEMBLY

ENGINE
CONTROL
MODULE
(ECM)

ENGINE

NETWORK
OF
ENGINE
SENSORS

MEFI 4305
Fuel System Diagnosis 4-20-00

Circuit Description • The fuel pump check valve.

When the ignition switch is ON, the ECM activates the • The fuel pump flex pipe.
electric fuel pump. The fuel pump remains ON as long as
the ECM receives reference pulses from the ignition • The valve or valve seat within the fuel pressure
system. If there are no reference pulses, the ECM turns regulator.
the fuel pump OFF after about 2 seconds. • The fuel injector(s).
The electric pump delivers fuel through an in-pipe fuel filter 4. A fuel system that drops more than 14 kPa (2 psi) in
to the fuel rail assembly. The fuel pump provides fuel at a 10 minutes after being relieved to 69 kPa (10 psi)
pressure above the pressure needed by the fuel injectors. indicates a leaking fuel pump check valve.
A fuel pressure regulator, attached to the fuel rail, keeps 5. Fuel pressure that drops off during acceleration,
the fuel available to the fuel injectors at a regulated cruise or hard cornering may cause a lean condition.
pressure. Unused fuel returns to the fuel tank by a A lean condition can cause a loss of power, surging
seperate fuel return pipe. or misfire.
Test Description 8. When the engine is at idle, the manifold pressure is
Number(s) below refer to the step number(s) on the low (high vacuum). This low pressure (high vacuum)
diagnostic table: is applied to the fuel pressure regulator diaphragm.
The low pressure (high vacuum) will offset the
2. When the ignition switch is ON and the fuel pump is
pressure being applied to the fuel pressure regulator
running, the fuel pressure indicated by the fuel
diaphragm by the spring inside the fuel pressure
pressure gauge should read 379-427 kPa (55-62
regulator. When this happens, the result is lower fuel
psi). The spring pressure inside the fuel pressure
pressure. The fuel pressure at idle will vary slightly
regulator controls the fuel pressure.
as the barometric pressure changes, but the fuel
3. A fuel system that drops more than 14 kPa (2 psi) in pressure at idle should always be less than the fuel
10 minutes has a leak in one or more of the pressure noted in step 2 with the engine OFF.
following areas:

MEFI 4
6 - 72 Engine Controls - 8.1L Engine

12. A rich condition may result from the fuel pressure determine if that particular fuel injector is leaking. If
being above 427 kPa (62 psi). Driveability conditions checking the spark plug associated with a particular
associated with rich conditions can include hard fuel injector for fouling or saturation does not
starting followed by black smoke and a strong sulfur determine that a particular fuel injector is leaking,
smell in the exhaust. use the following procedure.
13. This test determines if the high fuel pressure is due 1. Remove the fuel rail. Refer to Fuel Rail
to a restricted fuel return pipe or if the high fuel Assembly Replacement.
pressure is due to a faulty fuel pressure regulator. 2. Reinstall the crossover pipe to the right fuel rail.
15. A lean condition may result from the fuel pressure Refer to Fuel Rail Assembly Replacement.
being below 379 kPa (55 psi). Driveability conditions 3. Connect the fuel feed pipe and the fuel return
associated with lean conditions can include hard pipe to the fuel rail. Refer to Fuel Rail Assembly
starting (when the engine is cold), hesitation, poor Replacement.
driveability, lack of power, surging and misfiring. 4. Lift the fuel rail just enough to leave the fuel
Notice: Do not allow the fuel pressure to exceed 517 kPa injector nozzles in the fuel injector ports.
(75 psi). Excessive pressure may damage the fuel Caution: In order to reduce the risk of fire and
pressure regulator. personal injury that may result from fuel spraying on
16. Restricting the fuel return pipe with the J 37287 fuel the engine, verify that the fuel rail is positioned over
pipe shut-off adapter causes the fuel pressure to the fuel injector ports. Also verify that the fuel injector
rise above the regulated pressure. Using a scan tool retaining clips ar intact.
to pressurize the fuel system, the fuel pressure 5. Pressurize the fuel system by using the scan
should rise above 427 kPa (62 psi) as the valve on tool fuel pump enable.
the fuel pipe shut-off adapter connected to the fuel
6. Visually and physically inspect the fuel injector
return pipe becomes partially closed.
nozzles for leaks.
22. Check the spark plug associated with a particular
fuel injector for fouling or saturation in order to

Fuel System Diagnosis

Step Action Value Yes No
Did you perfom the On-Board Diagnostic (OBD) System Go to OBD
1
Check? — Go to Step 2 System Check

1. Turn OFF the ignition.

Caution: Wrap a shop towel around the fuel pressure
connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage
that occurs during the connection of the fuel pressure
gauge. Place the towel in an approved container when
the connection of the fuel pressure gauge is complete.
2. Install the J 34730-1A fuel pressure gauge.
3. Place the bleed hose of the fuel pressure gauge into
2 an approved gasoline container.
4. Turn the ignition ON leaving the engine OFF.
5. Bleed the air out of the fuel pressure gauge.
6. Turn the ignition OFF for 10 seconds.
7. Turn the ignition ON leaving the engine OFF.
Important: The fuel pump will run for approximately
2 seconds. Cycle the ignition as necessary in order to
achieve the highest possible fuel pressure.
8. Observe the fuel pressure with the fuel pump running. 379-427 kPa
Is the fuel pressure within the specified limits? (55-62 psi) Go to Step 3 Go to Step 12

MEFI 4
Engine Engine Controls - 8.1L 6 - 73

Fuel System Diagnosis (cont’d)

Step Action Value Yes No
Important: The fuel pressure may vary slightly when the
fuel pump stops running. After the fuel pump stops
running, the fuel pressure should stabilize and remain
3 constant.
Does the fuel pressure drop more than the specified
value in 10 minutes? — Go to Step 10 Go to Step 4
Relieve the fuel pressure to the first specified value.
4 Does the fuel pressure drop more than the second 69 kPa (10 psi)
specified value in 10 minutes? 14 kPa (2 psi) Go to Step 19 Go to Step 5
Do you suspect the fuel pressure of dropping-off during
5 acceleration, cruise or hard cornering? — Go to Step 6 Go to Step 8
Visually and physically inspect the following items for a
restriction:
6 • The fuel filter
• The fuel feed pipe
Did you find a restriction? — Go to Step 24 Go to Step 7

1. Remove the fuel sender assembly.

2. Visually and physically inspect the following items:
• The fuel strainer/check valve for a restriction.
7 • The fuel pump pipe for leaks.
• Verify the fuel pump is the correct fuel pump for this
vehicle.
Did you find a problem in any of these areas? — Go to Step 24 Go to Step 19

1. Start the engine.

2. Allow the engine to idle at normal operating
8 temperature. 21-69 kPa Go to
Does the fuel pressure drop by the amount specified? (3-10 psi) Symptoms Go to Step 9
1. Disconnect the vacuum hose from the fuel pressure
regulator.
9 2. With the engine idling, apply 12-14 inches of vacuum
to the fuel pressure regulator. 21-69 kPa
Does the fuel pressure drop by the amount specified? (3-10 psi) Go to Step 20 Go to Step 21

1. Relieve the fuel pressure. Refer to Fuel Pressure

Relief Procedure.
2. Disconnect the fuel feed pipe and the fuel return pipe
from the fuel rail.
3. Install the J 37287 fuel pipe shut-off adapters between
10 the fuel feed pipe and the fuel return pipe and the fuel
rail.
4. Open the valves on the fuel pipe shut-off adapters.
5. Turn the ignition ON.
6. Pressurize the fuel system using a scan tool.
7. Place the bleed hose of the fuel pressure gauge into

MEFI 4
6 - 74 Engine Controls - 8.1L Engine
Fuel System Diagnosis (cont’d)
Step Action Value Yes No
an approved gasoline container.
8. Bleed the air out of the fuel pressure gauge.
9. Wait for the fuel pressure to build.
10
10. Close the valve in the fuel pipe shut-off adapter that is
connected to the fuel return pipe.
Does the fuel pressure remain constant? — Go to Step 19 Go to Step 11

1. Open the valve in the fuel pipe shut-off adapter that is

connected to the fuel feed pipe.
2. Pressurize the fuel system using a scan tool.
11 3. Wait for the fuel pressure to build.
4. Close the valve in the fuel pipe shut-off adapter that is
connected to the fuel return pipe.
Does the fuel pressure remain constant? — Go to Step 21 Go to Step 22
Is the fuel pressure above the specified limit? 427 kPa
12 (62 psi) Go to Step 13 Go to Step 15
1. Relieve the fuel pressure. Refer to the Fuel Pressure
Relief Procedure.
2. Disconnect the fuel return pipe from the fuel rail.
3. Attach a length of flexible fuel hose to the fuel rail outlet
passage.
13 4. Place the open end of the flexible fuel hose into an
approved gasoline container.
5. Turn the ignition OFF for 10 seconds.
6. Turn the ignition ON.
7. Observe the fuel pressure with the fuel pump running. 379-427 kPa
Is the fuel pressure within the specified limits? (55-62 psi) Go to Step 23 Go to Step 14

Visually and physically inspect the fuel rail outlet passages

14 for a restriction.
Was a restriction found? — Go to Step 24 Go to Step 21

15 Is the fuel pressure above the specified value? 0 kPa (0 psi) Go to Step 16 Go to Step 17
1. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure.
2. Disconnect the fuel return pipe from the fuel rail.
3. Install the J 37287 fuel pipe shut-off adapter between
the fuel return pipe and the fuel rail.
4. Open the valve on the fuel pipe shut-off adapter.
16 5. Turn the ignition ON.
6. Pressurize the fuel system using a scan tool.
7. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container.
8. Bleed the air out of the fuel pressure gauge.
Notice: Do not allow the fuel pressure to exceed 517 kPa
(75 psi). Excessive pressure may damage the fuel

MEFI 4
Engine Engine Controls - 8.1L 6 - 75
Fuel System Diagnosis (cont’d)
Step Action Value Yes No
pressure regulator.
9. Slowly close the valve in the fuel pipe shut-off adapter
16
that is connected to the fuel return pipe. 427 kPa
Does the fuel pressure rise above the specified value? (62 psi) Go to Step 21 Go to Step 7

Turn ON the fuel pump using a scan tool. Go to Fuel

17 Does the fuel pump run? Pump Relay
— Go to Step 18 Circuit Diagnosis

Visually and physically inspect the following items:

• The fuel filter for obstructions.
• The fuel feed pipe for a restriction.
18 • The fuel strainer for obstructions.
• The fuel pump pipe for leaks.
Did you find a problem in any of these areas? — Go to Step 24 Go to Step 19
Replace the fuel pump.
19
Is the action complete? — System OK —

Locate and repair the loss of vacuum to the fuel pressure

20 regulator.
Is the action complete? — System OK —

Replace the fuel pressure regulator.

21 Is the action complete? — System OK —
Locate and replace any leaking fuel injector(s).
22 Is the action complete? — System OK —
Locate and repair the restriction in the fuel return pipe.
23 Is the action complete? — System OK —
Repair the problem as necessary.
24 Is the action complete? — System OK —

MEFI 4
6 - 76 Engine Controls - 8.1L Engine
Fuel Injector Coil Test - Engine Coolant Temperature (ECT) Between 10-35 Degrees C (50-95
Degrees F)

Test Description
2. The engine coolant temperature affects the ability of the Resistance Voltage Specification at 10-35
fuel injector tester to detect a faulty fuel injector. If the
Ohms Degrees C (50-95 Degrees F)
engine coolant temperature is NOT between 10-35
degrees C (50-95 degrees F), use Fuel Injector Test - 11.8-12.6 5.7-6.6 V
Engine Coolant Temperature (ECT) Outside 10-35 Fuel Injector
Degrees C (50-95 Degrees F) table. Number Voltage Reading Pass/Fail
3. The first second of the voltage displayed by the DMM 1 6.3 P
may be inaccurate due to the initial current surge. 2 5.9 P
Therefore, record the lowest voltage displayed by the
DMM after the first second of the test. The voltage 3 6.2 P
displayed by the DMM should be within the specified 4 6.1 P
range. Refer to the Example. The voltage displayed by 5 4.8 F
the DMM may increase throughout the test as the fuel 6 6.0 P
injector windings warm and the resistance of the fuel
injector windings changes. An erratic voltage reading with 7 5.0 P
large fluctuations in voltage that do not stabilize, indicates 8 5.3 P
an intermittent connection with the fuel injector.

Fuel Injector Coil Test - Engine Coolant Temperature (ECT) Between 10-35 Degrees C (50-95
Degrees F)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Connect the scan tool. Go to Fuel

2. Check the engine coolant temperature. Injector Coil
2 Is the engine coolant temperature within the specified Test-ECT
limits? 10°C-35°C Outside 10-35°C
(50°F-95°F) Go to Step 3 (50-95°F)

1. Turn the ignition OFF.

Notice: Be careful not to flood a single cylinder.
2. Relieve the fuel pressure per manufacturers
recommendation.
3. Access the fuel injector electrical connectors as
required.
4. Connect the J 39021 fuel injector tester to B+ and
ground.
3 5. Set the amperage supply selector switch on the fuel
injector tester to the Coil Test 0.5 amp position.
6. Connect the leads from the DMM to the fuel injector
tester.
7. Set the DMM to the tenths scale (0.0).
8. Connect the fuel injector tester to a fuel injector using
the J 39021-380 injector test adapter.
Important: Check the engine coolant temperature again in
order to ensure that the correct chart is being used.

MEFI 4
Engine Engine Controls - 8.1L 6 - 77
Fuel Injector Coil Test - Engine Coolant Temperature (ECT) Between 10-35 Degrees C (50-95
Degrees F) (cont’d)
Step Action Value Yes No
9. Press the Push to Start Test button on the fuel injector
tester.
Important: The voltage reading may rise during the test.
10. Observe the voltage reading on the DMM.
11. Record the lowest voltage observed after the first
3 second of the test.
12. Repeat steps 8 through 11 for each fuel injector. Go to Fuel
Did any fuel injector have an erratic voltage reading with Injector Balance
large fluctuations in voltage that do not stabilize, or a Test with
voltage reading outside the specified limits? 5.7-6.6 V Go to Step 4 Special Tool
Replace the faulty fuel injectors. Refer to Fuel Injector Go to Fuel
Replacement. Injector Balance
4
Is the action complete? Test with
— Special Tool —

Fuel Injector Coil Test - Engine Coolant Temperature (ECT) Outside 10-35 Degrees C (50-95
Degrees F)

Test Description
2. The engine coolant temperature affects the ability of the Acceptable Subtracted
fuel injector tester to detect a faulty fuel injector. If the
Value Above/Below 10-
engine coolant temperature is between 10-35 degrees
C (50-95 degrees F), use Fuel Injector Test - Engine Highest Voltage Reading 35°C (50-95°F)
Coolant Temperature (ECT) Between 10-35 Degrees C 7.1 V 0.6 V
(50-95 Degrees F) table. Injector Subtracted
3. The first second of the voltage displayed by the DMM Number Voltage Value Pass/Fail
may be inaccurate due to the initial current surge. 1 9.8 — F
Therefore, record the lowest voltage displayed by the
DMM after the first second of the test. The voltage 2 6.6 0.5 P
displayed by the DMM may increase throughout the test 3 6.9 0.2 P
as the fuel injector windings warm and the resistance of 4 5.8 1.3 F
the fuel injector windings changes. An erratic voltage 5 7.0 0.1 P
reading with large fluctuations in voltage that do not
stabilize, indicates an intermittent connection with the 6 7.1 0.0 P
fuel injector. From the voltages recorded, identify the 7 9.6 — F
highest voltage, excluding any voltages above 9.5 volts. 8 6.0 1.1 F
Subtract each voltage that is not above 9.5 volts from
the highest voltage. Record each subtracted value. Refer
to the Example. The subtracted value that is more than
0.6 volt is faulty. Replace the fuel injector. A fuel injector
with a recorded voltage above 9.5 volts is also faulty.
Replace the fuel injector.

MEFI 4
6 - 78 Engine Controls - 8.1L Engine
Fuel Injector Coil Test - Engine Coolant Temperature (ECT) Outside 10-35 Degrees C (50-95
Degrees F)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Connect the scan tool. Go to Fuel

2. Check the engine coolant temperature. Injector Coil
2 Is the engine coolant temperature within the specified Test-ECT
limits? 10°C-35°C Between10-35°C
(50°F-95°F) Go to Step 3 (50-95°F)

1. Turn the ignition OFF.

Notice: Be careful not to flood a single cylinder.
2. Relieve the fuel pressure per manufacturers
recommendation.
3. Access the fuel injector electrical connectors as
required.
4. Connect the J 39021 fuel injector tester to B+ and
ground.
3 5. Set the amperage supply selector switch on the fuel
injector tester to the Coil Test 0.5 amp position.
6. Connect the leads from the DMM to the fuel injector
tester.
7. Set the DMM to the tenths scale (0.0).
8. Connect the fuel injector tester to a fuel injector using
the J 39021-380 injector test adapter.
Important: Check the engine coolant temperature again in
order to ensure that the correct chart is being used.
9. Press the Push to Start Test button on the fuel injector
tester.
Important: The voltage reading may rise during the test.
10. Observe the voltage reading on the DMM.
11. Record the lowest voltage observed after the first
second of the test.
12. Repeat steps 8 through 11 for each fuel injector.
13. Identify the highest voltage reading recorded other
than those above 9.5 volts.
14. Subtract any other voltage readings recorded from the
highest voltage reading recorded. Go to Fuel
15. Repeat step 14 for all the remaining fuel injectors. Injector Balance
Is any value that resulted from subtraction more than the Test with
specified value? 0.6 V Go to Step 4 Special Tool
Replace any fuel injector that had any of the following:
• A subtracted value exceeding 0.6 volts
• An initial reading above 9.5 volts Go to Fuel
4
• An erratic reading Injector Balance
Refer to Fuel Injector Replacement. Test with
Is the action complete? — Special Tool —

MEFI 4
Engine Engine Controls - 8.1L 6 - 79
Fuel Injector Balance Test with Special Tool
Test Description 7. If the fuel pressure drop value for each injector is within
4. The engine coolant temperature must be below the 10 Kpa (1.5 psi) of the average pressure drop value, the
operating temperature in order to avoid irregular fuel fuel injectors are flowing properly. Calculate the pressure
pressure readings due to Hot Soak fuel boiling. drop value for each fuel injector by subtracting the second
5. The fuel pressure should be within the specified range. pressure reading from the first pressure reading.
6. The fuel pressure should reach a steady value.

Fuel Injector Balance Test with Special Tool

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Did you perform the Fuel Injector Coil Test Procedure? Go to Fuel
Injector Coil
Test-ECT
2
Between
10-35°C
— Go to Step 3 (50-95°F)

Is the engine coolant temperature above the specified

3
value? 94°C(201°F) Go to Step 4 Go to Step 5
Allow the engine to cool below the specified value.
4 Is the engine coolant temperature below the specified
value? 94°C(201°F) Go to Step 5 —

1. Turn the ignition OFF.

2. Connect the J 34730-1A fuel pressure gauge to the
fuel pressure test port.
3. Turn ON the ignitiion leaving the engine OFF.
4. Install the scan tool.
5. Energize the fuel pump using the scan tool.
6. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container.
5 7. Bleed the air out of the fuel pressure gauge.
8. Again energize the fuel pump using the scan tool.
Important: The fuel pump will run for approximately 2
seconds. Repeat step 8 as necessary in order to achieve
the highest possible fuel pressure.
9. Wait for the fuel pressure to build.
10. Observe the reading on the fuel pressure gauge Go to Fuel
while the fuel pump is running. 379-427 kPa System
Is the fuel pressure within the specified limits? (55-62 psi) Go to Step 6 Diagnosis

After the fuel pump stops, the fuel pressure may vary
slightly, then should hold steady. Go to Fuel
6
Does the fuel pressure remain constant within the 379-427 kPa System
specified value? (55-62 psi) Go to Step 7 Diagnosis

MEFI 4
6 - 80 Engine Controls - 8.1L Engine
Fuel Injector Balance Test with Special Tool (cont’d)
Step Action Value Yes No
1. Connect the J 39021 fuel injector tester to a fuel
injector using the J 39021-380 injector test adapter.
2. Set the amperage supply selector switch on the fuel
injector tester to the balance test 0.5-2.5 amp position.
3. Energize the fuel pump using the scan tool in order to
pressurize the fuel system.
4. Record the fuel pressure indicated by the fuel pressure
gauge after the fuel pressure stabilizes. This is the 1st
pressure reading.
5. Energize the fuel injector by depressing the Push to
Start Test button on the fuel injector tester.
6. Record the fuel pressure indicated by the fuel pressure
gauge after the fuel pressure gauge needle has
7 stopped moving. This is the 2nd pressure reading.
7. Repeat steps 1 through 6 for each fuel injector.
8. Subtract the 2nd pressure reading from the 1st
pressure reading for one fuel injector. The result is the
pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10. Add all of the individual pressure drop values. This is
the total pressure drop.
11. Divide the total pressure drop by the number of fuel
injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that is
either higher than the average pressure drop or lower than Go to
the average pressure drop by the specified value? 10 kPa (1.5 psi) Go to Step 8 Symptoms
Notice: Do Not repeat any portion of this test before
running the engine in order to prevent the engine from
flooding.
Retest any fuel injector that does not meet the
8
specification. Refer to the procedure in step 7.
Does any fuel injector still have a pressure drop value that
is either higher than the average pressure drop or lower Go to
than the average pressure drop by the specified value? 10 kPa (1.5 psi) Go to Step 9 Symptoms

Replace the faulty fuel injectors. Refer to Fuel Injector

9 Replacement.
Is the action complete? — System OK —

MEFI 4
Engine Engine Controls - 8.1L 6 - 81

MEFI 4
6 - 82 Engine Controls - 8.1L Engine

Stepper Idle Air

Motor Control
Coil M Coil (IAC) Valve
B A

B A C D

BLU/BLK 442
GRN/WHT 443
LT
GRN/BLK 444 BLU/WHT 441
30 15 31 16 J1
IAC IAC IAC IAC Engine
Coil B Coil B Coil A Coil A Control
High Low Low High Module
(ECM)

MEFI 4306
Idle Air Control Functional Test 4-20-00

Circuit Description • Check for poor connections, opens or short to grounds

The ECM controls idle speed to a calibrated “desired” RPM in CKT’s 441, 442, 443 and 444. This may result in
based on sensor inputs and actual engine RPM. The ECM improper idle control.
uses four (4) circuits to move the Idle Air Control (IAC) valve. • An IAC valve which is “frozen” and will not respond to
The movement of the IAC valve varies the amount of air flow the ECM, a throttle stop screw which has been tampered
bypassing the throttle plates. The ECM controls idle speed with, or a damaged throttle body or linkage may cause
by determining the position of the IAC valve. improper idle.

Diagnostic Aids Test Description

An intermittent may be caused by a poor connection, rubbed 2. This step determines if the IAC valve is functioning
through wire insulation or a wire broken inside the insulation. properly.
Check for the following items: 4. This step determines if the circuitry or the IAC valve is
• Poor connection or damaged harness. Inspect the ECM faulty.
harness and connectors for improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wire connection and damaged harness.
• Check for vacuum leaks, disconnected or brittle vacuum
hoses, cuts, etc. Examine manifold and throttle body
gaskets for proper seal. Check for cracked intake
manifold.

MEFI 4
Engine Engine Controls - 8.1L 6 - 83

Idle Air Control Functional Test

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Engine should be at normal operating temperature.

2. Start engine and allow idle to stabilize.
3. Record RPM.
2 4. Ignition “OFF” for 10 seconds.
5. Disconnect IAC harness connector.
6. Restart engine and record RPM.
Is RPM higher than the first recorded RPM by more than
the specified value? 200 RPM Go to Step 3 Go to Step 4

1. Reinstall IAC harness connector.

2. Idle speed should gradually return within 75 RPM of
3 the original recorded RPM within 30 seconds.
Does RPM return to original recorded RPM? — Go to Step 5 Go to Step 4

1. Ignition “OFF” for 10 seconds.

2. Disconnect IAC harness connector.
3. Restart engine.
4
4. Using a test lamp J 34142-B connected to ground,
probe each one of the four IAC harness terminals.
Does the test lamp blink on all four terminals? — Go to Step 7 Go to Step 6

5 IAC circuit is functioning properly. — — —

Locate and repair poor connection, open, or short to

ground in the IAC circuit that did not blink. If a problem
6 was found, repair as necessary. Go to OBD
Was a problem found? — System Check Go to Step 8

Check for poor IAC connections or replace the faulty

7 IAC valve. Go to OBD
Is action complete? — System Check —

Repair faulty ECM connections or replace faulty ECM. Go to OBD

8
Is action complete? — System Check —

MEFI 4
6 - 84 Engine Controls - 8.1L Engine

From Ignition

PNK 439 PNK 439

D D

Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2

B A C A B C

GRY 1666 BLK 450 GRY 1666 BLK 450

BLK 1665 BLK 1665

S101

6 3 22 J2
Engine
HO2 Sensor 1 Sensor HO2 Sensor 2 Control
Signal Ground Signal Module
(ECM)

MEFI4313
4-26-00

DTC 13 - Heated Oxygen (HO2) Sensor 1 Circuit Inactive (Non-Scan Diagnostics)

Circuit Description Never solder the HO2 wires. For proper wire and connection
The Heated Oxygen (HO2) Sensor(s) varies voltage within repairs, refer to “Wiring Repair.”
a range from about 1.0 volt if the exhaust is rich, down to After repairs, clear DTC’s following “Clear DTC’s Procedure.”
about 0.1 volt if the exhaust is lean. Failure to do so may result in DTC’s not properly being
The sensor is like an open circuit and produces no voltage cleared.
when it is below 360° C (600° F). An open oxygen sensor
circuit or cold oxygen sensor causes an Open Loop operation. Test Description
The heater provides for a faster sensor warm-up. This allows 2. Probing terminal ”D” of the HO2 sensor harness
the sensor(s) to become active in a shorter period of time connector verifies if the voltage is available to the HO2
and remain active during a long extended idle. sensor heater.
DTC 13 determines if the heated oxygen sensor circuit(s) 3. Verifies a good ground circuit for the HO2 sensor heater
has developed an open. With an active DTC 13 set, the circuit.
system operates in an Open Loop mode and the Malfunction 4. Checks for ignition “ON” bias voltage on the HO2 sensor
Indicator Lamp (MIL) is turned on. signal circuit. This should be between 0.423 and 0.487
volts with the ignition “ON”.
Diagnostic Aids
5. Checks for a good ground for the HO2 sensor circuit.
Check for the following conditions:
• Poor connection in harness. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
terminal to wire connection.

MEFI 4
Engine Engine Controls - 8.1L 6 - 85
DTC 13 - Heated Oxygen (HO2) Sensor 1 Circuit Inactive (Non-Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Disconnect the HO2 sensor 1 electrical connector.

2. Ignition turned ON.
2 3. With a test light connected to a known good ground,
probe terminal “D” of the ECM harness connector.
Does the test light illuminate brightly? — Go to Step 3 Go to Step 6

Connect test light between terminals “C” and “D” of the

3 ECM harness connector.
Does the test light illuminate brightly? — Go to Step 4 Go to Step 7

1. Ignition turned ON.

2. Using DVOM J 39200 connected to a known good
4 ground, probe terminal “B” of the ECM harness 0.423 -
connector. 0.487
Is the voltage within the specified value? volt Go to Step 5 Go to Step 8

1. Ignition turned ON.

5 2. Using DVOM J 39200, check voltage between terminals 0.423 -
“A” and “B” of the ECM harness connector. 0.487
Is the voltage within the specified value? volt Go to Step 10 Go to Step 9
Locate and repair open or short to ground in the
6 ignition feed circuit for the HO2 heater.
Is action complete? — Verify Repair —
Locate and repair open in the ground circuit for the HO2
7 heater.
Is action complete? — Verify Repair —

Locate and repair open in the HO2 sensor 1 signal circuit.

8 If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 11
Locate and repair open in the HO2 sensor 1 ground circuit.
9 If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 11
Check for faulty HO2 sensor 1 connections.
10 If OK, replace HO2 sensor 1.
Is action complete? — Verify Repair —
Repair faulty ECM connections or replace faulty ECM.
11 Is action complete? — Verify Repair —

MEFI 4
6 - 86 Engine Controls - 8.1L Engine

From Ignition

PNK 439 PNK 439

D D

Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2

B A C A B C

GRY 1666 BLK 450 GRY 1666 BLK 450

BLK 1665 BLK 1665

S101

6 3 22 J2
Engine
HO2 Sensor 1 Sensor HO2 Sensor 2 Control
Signal Ground Signal Module
(ECM)

MEFI4313
4-26-00

DTC 13 - Heated Oxygen (HO2) Sensor 2 Circuit Inactive (Non-Scan Diagnostics)

Circuit Description Never solder the HO2 wires. For proper wire and connection
The Heated Oxygen (HO2) Sensor(s) varies voltage within repairs, refer to “Wiring Repair.”
a range from about 1.0 volt if the exhaust is rich, down to After repairs, clear DTC’s following “Clear DTC’s Procedure.”
about 0.1 volt if the exhaust is lean. Failure to do so may result in DTC’s not properly being
The sensor is like an open circuit and produces no voltage cleared.
when it is below 360° C (600° F). An open oxygen sensor
circuit or cold oxygen sensor causes an Open Loop operation. Test Description
The heater provides for a faster sensor warm-up. This allows 2. Probing terminal ”D” of the HO2 sensor harness
the sensor(s) to become active in a shorter period of time connector verifies if the voltage is available to the HO2
and remain active during a long extended idle. sensor heater.
DTC 13 determines if the heated oxygen sensor circuit(s) 3. Verifies a good ground circuit for the HO2 sensor heater
has developed an open. With an active DTC 13 set, the circuit.
system operates in an Open Loop mode and the Malfunction 4. Checks for ignition “ON” bias voltage on the HO2 sensor
Indicator Lamp (MIL) is turned on. signal circuit. This should be between 0.423 and 0.487
volts with the ignition “ON”.
Diagnostic Aids
5. Checks for a good ground for the HO2 sensor circuit.
Check for the following conditions:
• Poor connection in harness. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
terminal to wire connection.

MEFI 4
Engine Engine Controls - 8.1L 6 - 87
DTC 13 - Heated Oxygen (HO2) Sensor 2 Circuit Inactive (Non-Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Disconnect the HO2 sensor 2 electrical connector.

2. Ignition turned ON.
2 3. With a test light connected to a known good ground,
probe terminal “D” of the ECM harness connector.
Does the test light illuminate brightly? — Go to Step 3 Go to Step 6

Connect test light between terminals “C” and “D” of the

3 ECM harness connector.
Does the test light illuminate brightly? — Go to Step 4 Go to Step 7

1. Ignition turned ON.

2. Using DVOM J 39200 connected to a known good
4 ground, probe terminal “B” of the ECM harness 0.423 -
connector. 0.487
Is the voltage within the specified value? volt Go to Step 5 Go to Step 8

1. Ignition turned ON.

5 2. Using DVOM J 39200, check voltage between terminals 0.423 -
“A” and “B” of the ECM harness connector. 0.487
Is the voltage within the specified value? volt Go to Step 10 Go to Step 9
Locate and repair open or short to ground in the
6 ignition feed circuit for the HO2 heater.
Is action complete? — Verify Repair —
Locate and repair open in the ground circuit for the HO2
7 heater.
Is action complete? — Verify Repair —

Locate and repair open in the HO2 sensor 2 signal circuit.

8 If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 11
Locate and repair open in the HO2 sensor 2 ground circuit.
9 If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 11
Check for faulty HO2 sensor 2 connections.
10 If OK, replace HO2 sensor 2.
Is action complete? — Verify Repair —
Repair faulty ECM connections or replace faulty ECM.
11 Is action complete? — Verify Repair —

MEFI 4
6 - 88 Engine Controls - 8.1L Engine

Engine
ECT Control
Sensor Module
Signal (ECM)
7 J2
YEL 410
B
Engine Coolant
Temperature
(ECT) Sensor
A
T0 BLK 814
MAP/TP/ S110
IAT Sensors
BLK 814
3 J2

Sensor Engine
Ground Control
Module
(ECM)

MEFI 4307
4-20-00

DTC 14 - Engine Coolant Temperature (ECT) Sensor Circuit - Low Temp Indicated
(Non-Scan Diagnostics)

Circuit Description Test Description

The Engine Coolant Temperature (ECT) sensor uses a 2. This step checks if there is a problem with the ECM and
thermistor to control the signal voltage to the ECM. The ECM wiring or if the problem is the ECT sensor.
applies 5 volts on CKT 410 to the sensor. When the engine 3. This step will isolate the problem to CKT 410 (5 volt
coolant is cold, the sensor (thermistor) resistance is high. As reference) or to CKT 814 (sensor ground).
the engine coolant warms up, the sensor resistance becomes 4. Check the harness terminals thoroughly for loose
less. See engine coolant temperature sensor table under connections. If the resistance of the ECT sensor is
“Diagnostic Aids.” At normal operating temperature (85°C - monitored, the resistance should steadily decrease as
95°C or 185°F - 203°F), the voltage will measure about 1.5- the engine coolant warms up. The resistance reading
2.0 volts. should stabilize when the thermostat opens.
Diagnostic Aids
Check for the following conditions: Engine Coolant Temperature Sensor Table
• Poor connection at ECM. Inspect harness connectors °C °F OHMS
for backed out terminals, improper mating, broken locks,
Temperature vs Resistance Values (Approximate)
improperly formed or damaged terminals and poor
terminal to wire connection. 100 212 177
• Damaged harness. Inspect the wiring harness for 80 176 332
damage. If the harness appears to be OK, observe the 60 140 667
ECT display on the scan tool while moving connectors 45 113 1188
and wiring harnesses related to the ECT sensor. A
35 95 1802
change in the ECT display will indicate the location of
the fault. 25 77 2796
• If DTC 33 is also set, check for open ground CKT 814. 15 59 4450
After repairs, clear DTC’s following “Clear DTC’s Procedure” 5 41 7280
in the General Information section. Failure to do so may result -5 23 12300
in DTC’s not properly being cleared. -15 5 21450
-30 -22 52700
-40 -40 100700

MEFI 4
Engine Engine Controls - 8.1L 6 - 89

DTC 14 - Engine Coolant Temperature (ECT) Sensor Circuit - Low Temp Indicated (Non-Scan
Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Ignition “OFF.”
2. Disconnect ECT sensor harness connector.
3. Ignition “ON,” engine “OFF.”
2
4. Connect DVOM across the coolant sensor harness
terminals.
Is voltage above the specified value? 4 volts Go to Step 4 Go to Step 3

1. Connect positive DVOM lead to harness terminal “B”

CKT 410 (5 volt reference).
3
2. Connect negative DVOM lead to a known good ground.
Is voltage above the specified value? 4 volts Go to Step 6 Go to Step 5

Locate and repair intermittent faulty connections. If OK,

4 replace faulty ECT sensor.
Is action complete? — Verify Repair —

Locate and repair open CKT 410. If a problem is found,

5 repair as necessary.
Was a problem found? — Verify Repair Go to Step 7

Locate and repair open ground CKT 814. If a problem is

6 found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 7

Repair faulty ECM connections or replace faulty ECM.

7
Is action complete? — Verify Repair —

MEFI 4
6 - 90 Engine Controls - 8.1L Engine

Engine
ECT Control
Sensor Module
Signal (ECM)
7 J2
YEL 410
B
Engine Coolant
Temperature
(ECT) Sensor
A
T0 BLK 814
MAP/TP/ S110
IAT Sensors
BLK 814
3 J2

Sensor Engine
Ground Control
Module
(ECM)

MEFI 4307
4-20-00

DTC 15 - Engine Coolant Temperature (ECT) Sensor Circuit - High Temp Indicated
(Non-Scan Diagnostics)

Circuit Description Test Description

The Engine Coolant Temperature (ECT) sensor uses a 2. This step checks if there is a problem with the ECM and
thermistor to control the signal voltage to the ECM. The ECM wiring or if the problem is the ECT sensor.
applies 5 volts on CKT 410 to the sensor. When the engine 3. Check the harness terminals thoroughly for loose
coolant is cold, the sensor (thermistor) resistance is high. As connections. If the resistance of the ECT sensor is
the engine coolant warms up, the sensor resistance becomes monitored, the resistance should steadily decrease as
less. See engine coolant temperature sensor table under the engine coolant warms up. The resistance reading
“Diagnostic Aids.” At normal operating temperature (85°C - should stabilize when the thermostat opens.
95°C or 185°F - 203°F), the voltage will measure about 1.5-
2.0 volts.
Diagnostic Aids
Check for the following conditions: Engine Coolant Temperature Sensor Table
• Poor connection at ECM. Inspect harness connectors °C °F OHMS
for backed out terminals, improper mating, broken locks,
Temperature vs Resistance Values (Approximate)
improperly formed or damaged terminals and poor
terminal to wire connection. 100 212 177
• Damaged harness. Inspect the wiring harness for 80 176 332
damage. If the harness appears to be OK, observe the 60 140 667
ECT display on the scan tool while moving connectors 45 113 1188
and wiring harnesses related to the ECT sensor. A
35 95 1802
change in the ECT display will indicate the location of
the fault. 25 77 2796
• Check harness routing for a potential short to ground in 15 59 4450
CKT 410. 5 41 7280
After repairs, clear DTC’s following “Clear DTC’s Procedure” -5 23 12300
in the General Information section. Failure to do so may result -15 5 21450
in DTC’s not properly being cleared.
-30 -22 52700
-40 -40 100700

MEFI 4
Engine Engine Controls - 8.1L 6 - 91

DTC 15 - Engine Coolant Temperature (ECT) Sensor Circuit - High Temp Indicated
(Non-Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Ignition “OFF.”
2. Disconnect ECT sensor harness connector.
3. Ignition “ON,” engine “OFF.”
2
4. Connect DVOM across the coolant sensor harness
terminals.
Is voltage above the specified value? 4 volts Go to Step 3 Go to Step 4

Locate and repair intermittent faulty connections. If OK,

3 replace faulty ECT sensor.
Is action complete? — Verify Repair —

Locate and repair short to ground in CKT 410. If a problem

4 is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 5

Repair faulty ECM connections or replace faulty ECM.

5
Is action complete? — Verify Repair —

MEFI 4
6 - 92 Engine Controls - 8.1L Engine

Engine
Control
Module A
(ECM) Throttle
5 Volt
Reference GRY 416 Position(TP)
Sensor
2 J2
C B
BLK 813
To MAP/ECT/
IAT Sensors
DK BLU 417

23 3 J2

TP Sensor Sensor Engine

Signal Ground Control
To MAP Module
Sensor (ECM)
Term. "B"

MEFI4308
4-20-00

DTC 21 - Throttle Position (TP) Sensor Circuit - Signal Voltage High (Non-Scan Diagnostics)

Circuit Description Test Description

The Throttle Position (TP) sensor is a potentiometer that 2. This step simulates a DTC 22. If the ECM recognizes
provides a voltage signal that changes relative to the throttle the low signal voltage and sets DTC 22, the ECM and
blade. Signal voltage should vary from about .7 volt at idle to wiring are OK.
about 4.8 volts at Wide Open Throttle (WOT). 3. This step checks to see if CKT 813 is open.
The TP sensor signal is one of the most important inputs
used by the ECM for fuel control and for IAC control.
The ECM supplies a 5 volt signal to the sensor through CKT
416. CKT 813 is the TP sensor ground circuit. The TP sensor
will send a voltage signal back to the ECM, through CKT
417, according to where the throttle blades are positioned.
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
terminal to wire connection.
• Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK, observe the
TP sensor display on the scan tool while moving
connectors and wiring harnesses related to the TP
sensor. A change in the TP sensor display will indicate
the location of the fault.
• If a TP sensor circuit failure is present, the MAP sensor
default value will be used along with the TP sensor default
value.
After repairs, clear DTC’s following “Clear DTC’s
Procedure” in the General Information section. Failure
to do so may result in DTC’s not properly being cleared.

MEFI 4
Engine Engine Controls - 8.1L 6 - 93
DTC 21 - Throttle Position (TP) Sensor Circuit - Signal Voltage High (Non-Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Diagnostic Trouble Code (DTC) tool switched

to “normal mode,” or “OFF.”
2. Ignition “OFF.”
3. Disconnect TP sensor harness connector.
2 4. Start engine and idle for 2 minutes or until DTC tool
indicates a stored DTC.
5. Ignition “ON,” engine “OFF.”
6. Switch DTC tool to “service mode,” or “ON” and note
DTC.
Is DTC 22 present? — Go to Step 4 Go to Step 3

1. TP sensor harness connector disconnected.

2. Ignition “ON,” engine “OFF.”
3 3. Connect DVOM from harness terminal “B” (CKT 813) to
harness terminal “A” (CKT 416).
Is voltage reading above the specified value? 4 volts Go to Step 6 Go to Step 5

Locate and repair intermittent faulty connections. If OK,

4 replace faulty TP sensor.
Is action complete? — Verify Repair —

Locate and repair open in CKT 813. If a problem is found,

5 repair as necessary.
Was a problem found? — Verify Repair Go to Step 7

Locate and repair short to voltage in CKT 417. If a problem

6 is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 7

Repair faulty ECM connections or replace faulty ECM.

7
Is action complete? — Verify Repair —

MEFI 4
6 - 94 Engine Controls - 8.1L Engine

Engine
Control
Module A
(ECM) Throttle
5 Volt
Reference GRY 416 Position(TP)
Sensor
2 J2
C B
BLK 813
To MAP/ECT/
IAT Sensors
DK BLU 417

23 3 J2

TP Sensor Sensor Engine

Signal Ground Control
To MAP Module
Sensor (ECM)
Term. "B"

MEFI4308
4-20-00

DTC 22 - Throttle Position (TP) Sensor Circuit - Signal Voltage Low (Non-Scan Diagnostics)
Circuit Description Test Description
The Throttle Position (TP) sensor is a potentiometer that 2. This step simulates a DTC 21. If the ECM recognizes
provides a voltage signal that changes relative to the throttle the high signal voltage and sets a DTC 21, the ECM and
blade. Signal voltage should vary from about .7 volt at idle to wiring are OK.
about 4.8 volts at Wide Open Throttle (WOT).
3. This step checks CKT 416 for the 5 volt reference.
The TP sensor signal is one of the most important inputs
used by the ECM for fuel control and for IAC control.
The ECM supplies a 5 volt signal to the sensor through CKT
416. CKT 813 is the TP sensor ground circuit. The TP sensor
will send a voltage signal back to the ECM, through CKT
417, according to where the throttle blades are positioned.
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
terminal to wire connection.
• Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK, observe the
TP sensor display on the scan tool while moving
connectors and wiring harnesses related to the TP
sensor. A change in the TP sensor display will indicate
the location of the fault.
• If DTC 34 is also set, check for a short to ground in CKT
416 or CKT 416E.
• If a TP sensor circuit failure is present, the MAP sensor
default value will be used along with the TP sensor default
value.
After repairs, clear DTC’s following “Clear DTC’s Procedure”
in the General Information section. Failure to do so may result
in DTC’s not properly being cleared.

MEFI 4
Engine Engine Controls - 8.1L 6 - 95

DTC 22 - Throttle Position (TP) Sensor Circuit - Signal Voltage Low (Non-Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Diagnostic Trouble Code (DTC) tool switched

to “normal mode,” or “OFF.”
2. Ignition “OFF.”
3. Disconnect TP sensor harness connector.
4. Connect a jumper wire from harness terminal “A”
2 (CKT 416) to harness terminal “C” (CKT 417).
5. Start engine and idle for 2 minutes or until DTC tool
indicates a stored DTC.
6. Ignition “ON,” engine “OFF.”
7. Switch DTC tool to “service mode,” or “ON” and note
DTC.
Is DTC 21 present? — Go to Step 4 Go to Step 3

1. Remove jumper wire from CKT 416 and 417.

2. Connect DVOM from harness terminal “A” (CKT 416)
3 to harness terminal “B” (CKT 813).
Is voltage reading above the specified value? 4 volts Go to Step 5 Go to Step 6

Locate and repair intermittent faulty connections. If OK,

4 replace faulty TP sensor.
Is action complete? — Verify repair —

Locate and repair open or short to ground in CKT 417.

5 If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 7

Locate and repair open or short to ground in CKT 416.

Also check CKT 416E to the MAP sensor for a short to
6 ground. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 7

Repair faulty ECM connections or replace faulty ECM.

7 Is action complete? — Verify Repair —

MEFI 4
6 - 96 Engine Controls - 8.1L Engine

Engine
IAT Control
Sensor Module
Signal (ECM)
21 J2
TAN 472
A
Intake Air
Temperature
(IAT) Sensor
B
T0 BLK 814
MAP/TP/ S101
ECT Sensors
BLK 814
3 J2

Sensor Engine
Ground Control
Module
(ECM)

MEFI 4322
6-11-00

DTC 23 - Intake Air Temperature (IAT) Sensor Circuit - Low Temp Indicated
(Non-Scan Diagnostics)

Circuit Description wiring or if the problem is the IAT sensor.

The Intake Air Temperature (IAT) sensor uses a thermistor 3. This step will isolate the problem to CKT 472 (5 volt
to control the signal voltage to the ECM. The ECM applies 5 reference) or to CKT 814 (sensor ground).
volts on CKT 472 to the sensor. When the intake air 4. Check the harness terminals thoroughly for loose
temperature is cold, the sensor (thermistor) resistance is high. connections. If the resistance of the IAT sensor is
As the intake air temperature warms up, the sensor resistance monitored, the resistance should steadily decrease as
becomes less. See intake air temperature sensor table under the intake air temperature warms up.
“Diagnostic Aids.”
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors
for backed out terminals, improper mating, broken locks, Intake Air Temperature Sensor Table
improperly formed or damaged terminals and poor °C °F OHMS
terminal to wire connection.
Temperature vs Resistance Values (Approximate)
• Damaged harness. Inspect the wiring harness for 100 212 177
damage. If the harness appears to be OK, observe the
IAT display on the scan tool while moving connectors 80 176 332
and wiring harnesses related to the IAT sensor. A change 60 140 667
in the IAT display will indicate the location of the fault. 45 113 1188
• If DTC 33 is also set, check for open ground CKT 814. 35 95 1802
After repairs, clear DTC’s following “Clear DTC’s Procedure” 25 77 2796
in the General Information section. Failure to do so may result
15 59 4450
in DTC’s not properly being cleared.
5 41 7280
Test Description -5 23 12300
2. This step checks if there is a problem with the ECM and
-15 5 21450
-30 -22 52700
-40 -40 100700

MEFI 4
Engine Engine Controls - 8.1L 6 - 97

DTC 23 - Intake Air Temperature (IAT) Sensor Circuit - Low Temp Indicated (Non-Scan
Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Ignition “OFF.”
2. Disconnect IAT sensor harness connector.
3. Ignition “ON,” engine “OFF.”
2
4. Connect DVOM across the intake air temperature
sensor harness terminals.
Is voltage above the specified value? 4 volts Go to Step 4 Go to Step 3

1. Connect positive DVOM lead to harness terminal “A”

CKT 472 (5 volt reference).
3
2. Connect negative DVOM lead to a known good ground.
Is voltage above the specified value? 4 volts Go to Step 6 Go to Step 5

Locate and repair intermittent faulty connections. If OK,

4 replace faulty IAT sensor.
Is action complete? — Verify Repair —

Locate and repair open CKT 472. If a problem is found,

5 repair as necessary.
Was a problem found? — Verify Repair Go to Step 7

Locate and repair open ground CKT 814. If a problem is

6 found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 7

Repair faulty ECM connections or replace faulty ECM.

7
Is action complete? — Verify Repair —

MEFI 4
6 - 98 Engine Controls - 8.1L Engine

Vehicle
Speed
Sensor
(VSS)

A B C
From Ignition

BLK 814

PPL 401

3 25 J2
Engine
Control
Module
(ECM)

MEFI4314
4-26-00

DTC 24 - Vehicle Speed Sensor (VSS) Circuit (Non-Scan Diagnostics)

Circuit Description Check VSS circuits for proper connections and the harness
The vehicle speed is provided to the ECM by means of the is routed properly.
Vehicle Speed Sensor (VSS). The sensor may be mounted After repairs, clear DTC’s following “Clear DTC’s Procedure.”
in the transmission, but the actual location depends on the Failure to do so may result in DTC’s not properly being
application. The sensor produces a 12 volt digital signal cleared.
whenever the vehicle is moving. The number of pulses
increases with vehicle speed. The ECM converts this signal Test Description
into MPH, which can be monitored with a scan tool. This 2. This step determines if the VSS is receiving ignition
information may be used by the ECM for several reasons voltage.
such as governing the vehicle speed to a maximum 3. This step checks for a good ground circuit.
road speed.
The sensor is a three-wire sensor. Terminal “A” of the sensor
is provided a ground on CKT 814 through the ECM. Terminal
“C” of the sensor is provided ignition voltage. Terminal “B” of
the sensor is the signal to the ECM through CKT 400.
Diagnostic Aids
Check for the following conditions:
• Poor connection in harness. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
terminal to wire connection.

MEFI 4
Engine Engine Controls - 8.1L 6 - 99

DTC 24 - Vehicle Speed Sensor (VSS) Circuit (Non-Scan Diagnostics)

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Disconnect the vehicle speed sensor electrical

connector.
2. Ignition turned ON.
2 3. Using a test light connected to a known good ground,
probe ECM harness terminal “C”.
Does the test light illuminate brightly? — Go to Step 3 Go to Step 7

1. Ignition turned ON.

2. Using a test light connected to B+, probe ECM
3 harness terminal “A”.
Does the test light illuminate brightly? — Go to Step 4 Go to Step 8

1. Ignition OFF.
2. Reconnect VSS electrical connector.
3. Ignition turned ON.
4. Raise and support the vehicle drive wheel(s) per
manufacturer’s recommendations.
4 5. Using DVOM J 39200 connected to a known good
ground, back probe ECM harness connector terminal
“J2-25”.
6. While observing the DVOM, slowly rotate the drive
wheel(s).
Does the DVOM indicate a voltage changing as the
wheels are rotated? — Go to Step 9 Go to Step 5

Locate and repair open or short to ground on CKT 400.

5 If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 6

Replace faulty VSS.

6 — Verify repair —
Is action complete?

Locate and repair open or short to ground in the ignition

7 circuit to the VSS.
Is action complete? — Verify Repair —
Locate and repair open in the ground circuit to the VSS.
8
Is action complete? — Verify Repair —
DTC 24 may be intermittent. Clear DTC and drive
the vehicle. If DTC 24 returns, repair faulty ECM
9 connections or replace faulty ECM.
Is action complete? — Verify Repair —

MEFI 4
6 - 100 Engine Controls - 8.1L Engine

Engine
IAT Control
Sensor Module
Signal (ECM)
21 J2
TAN 472
A
Intake Air
Temperature
(IAT) Sensor
B
T0 BLK 814
MAP/TP/ S101
ECT Sensors
BLK 814
3 J2

Sensor Engine
Ground Control
Module
(ECM)

MEFI 4322
6-11-00

DTC 25 - Intake Air Temperature (IAT) Sensor Circuit - High Temp Indicated
(Non-Scan Diagnostics)

Circuit Description wiring or if the problem is the IAT sensor.

The Intake Air Temperature (IAT) sensor uses a thermistor 3. Check the harness terminals thoroughly for loose
to control the signal voltage to the ECM. The ECM applies 5 connections. If the resistance of the IAT sensor is
volts on CKT 472 to the sensor. When the intake air monitored, the resistance should steadily decrease as
temperature is cold, the sensor (thermistor) resistance is high. the intake air temperature warms up.
As the intake air temperature warms up, the sensor resistance
becomes less. See intake air temperature sensor table under
“Diagnostic Aids.”
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors
for backed out terminals, improper mating, broken locks, Intake Air Temperature Sensor Table
improperly formed or damaged terminals and poor °C °F OHMS
terminal to wire connection.
Temperature vs Resistance Values (Approximate)
• Damaged harness. Inspect the wiring harness for 100 212 177
damage. If the harness appears to be OK, observe the
IAT display on the scan tool while moving connectors 80 176 332
and wiring harnesses related to the IAT sensor. A change 60 140 667
in the IAT display will indicate the location of the fault. 45 113 1188
• Check harness routing for a potential short to ground in 35 95 1802
CKT 814.
25 77 2796
After repairs, clear DTC’s following “Clear DTC’s Procedure”
15 59 4450
in the General Information section. Failure to do so may result
in DTC’s not properly being cleared. 5 41 7280
-5 23 12300
Test Description
-15 5 21450
2. This step checks if there is a problem with the ECM and
-30 -22 52700
-40 -40 100700

MEFI 4
Engine Engine Controls - 8.1L 6 - 101

DTC 25 - Intake Air Temperature (IAT) Sensor Circuit - High Temp Indicated
(Non-Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Ignition “OFF.”
2. Disconnect IAT sensor harness connector.
3. Ignition “ON,” engine “OFF.”
2
4. Connect DVOM across the IAT sensor harness
terminals.
Is voltage above the specified value? 4 volts Go to Step 3 Go to Step 4

Locate and repair intermittent faulty connections. If OK,

3 replace faulty IAT sensor.
Is action complete? — Verify Repair —

Locate and repair short to ground in CKT 472. If a problem

4 is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 5

Repair faulty ECM connections or replace faulty ECM.

5
Is action complete? — Verify Repair —

MEFI 4
6 - 102 Engine Controls - 8.1L Engine

Engine
Control
Module C
(ECM) Manifold
5 Volt Absolute
Reference Pressure To ECT/IAT/
2 J2
(MAP) TP Sensors
B A Sensor
GRY 416E BLK 814 BLK 814

LT GRN 432
BLK 814
8 3 J2
S100
Map Sensor Engine
Sensor Ground Control
Signal Module
(ECM)
To TP Sensor

MEFI4309
4-20-00

DTC 33 - Manifold Absolute Pressure (MAP) Sensor Circuit - Signal Voltage High
(Non-Scan Diagnostics)
Circuit Description • If the idle is rough or unstable, refer to Symptoms section
The Manifold Absolute Pressure (MAP) sensor responds to for items which may cause an unstable idle.
changes in manifold pressure (vacuum). The ECM receives • With the ignition “ON,” engine “OFF,” the manifold
this information as a signal voltage that will vary from about pressure is equal to atmospheric pressure and the signal
1.0-1.5 volts at idle to about 4.0-4.5 volts at Wide Open voltage will be high. This information is used by the ECM
Throttle (WOT). as an indication of altitude and is referred to as BARO.
If the MAP sensor fails, the ECM will substitute a default • If DTC 14 is also set, check for open in ground CKT 814.
MAP value that will vary with RPM. • If a MAP sensor circuit failure is present, the TP sensor
The MAP sensor voltage of 5 volts is delivered to the MAP default value will be used along with the MAP sensor
sensor through CKT 416E. CKT 814 is the ground circuit for default value.
the MAP sensor. The MAP signal CKT 432 will send a voltage After repairs, clear DTC’s following “Clear DTC’s Procedure”
signal back to the ECM according to what the manifold in the General Information section. Failure to do so may result
pressure is. in DTC’s not properly being cleared.
Diagnostic Aids Test Description
Check for the following conditions: 2. This step will determine if there is an adequate vacuum
• Poor connection at ECM. Inspect harness connectors supply to the MAP sensor. If the vacuum gauge reading
for backed out terminals, improper mating, broken locks, is erratic, refer to the “Rough or Unstable Idle” symptom.
improperly formed or damaged terminals and poor 3. This step simulates a DTC 34. If the ECM recognizes
terminal to wire connection. the low signal voltage and sets a DTC 34, the ECM and
• Damaged harness. Inspect the wiring harness for wiring are OK.
damage. If the harness appears to be OK, observe the 4. This step checks to see if CKT 814 is open.
MAP sensor display on the scan tool while moving 5. Low manifold vacuum may result from a restriction in
connectors and wiring harnesses related to the MAP the MAP sensor hose or from vacuum leaks in the engine
sensor. A change in the MAP sensor display will indicate induction system.
the location of the fault.

MEFI 4
Engine Engine Controls - 8.1L 6 - 103

DTC 33 - Manifold Absolute Pressure (MAP) Sensor Circuit - Signal Voltage High
(Non-Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Ignition “OFF.”
2. Install a vacuum gauge to a manifold vacuum source.
3. Start engine and raise to about 1000 RPM in neutral.
2
4. The vacuum reading should be steady.
Is the vacuum gauge reading steady and above the 14” Hg
specified value? (45.5 kPa) Go to Step 3 Go to Step 5

1. Diagnostic Trouble Code (DTC) tool switched

to “normal mode,” or “OFF.”
2. Ignition “OFF.”
3. Disconnect MAP sensor harness connector.
4. Start engine and idle for 2 minutes or until DTC tool
3 indicates a stored DTC.
5. Ignition “ON,” engine “OFF.”
6. Switch DTC tool to “service mode,” or “ON” and note
DTC.
Is DTC 34 present? — Go to Step 6 Go to Step 4

1. MAP sensor harness connector disconnected.

2. Ignition “ON,” engine “OFF.”
4 3. Connect DVOM from harness terminal “A” (CKT 814) to
harness terminal “C” (CKT 416E).
Is voltage reading above the specified value? 4 volts Go to Step 7 Go to Step 8

Repair low or unsteady vacuum problem.

5 Is action complete? — Verify Repair —

Check for plugged or leaking sensor vacuum fitting. Also

locate and repair intermittent faulty connections. If OK,
6 replace faulty MAP sensor.
Is action complete? — Verify Repair —

Locate and repair short to voltage in CKT 432. If a problem

7 is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 9

Locate and repair open in CKT 814. If a problem is found,

8 repair as necessary.
Was a problem found? — Verify Repair Go to Step 9

Repair faulty ECM connections or replace faulty ECM.

9
Is action complete? — Verify Repair —

MEFI 4
6 - 104 Engine Controls - 8.1L Engine

Engine
Control
Module C
(ECM) Manifold
5 Volt Absolute
Reference Pressure To ECT/IAT/
2 J2
(MAP) TP Sensors
B A Sensor
GRY 416E BLK 814 BLK 814

LT GRN 432
BLK 814
8 3 J2
S100
Map Sensor Engine
Sensor Ground Control
Signal Module
(ECM)
To TP Sensor

MEFI4309
4-20-00

DTC 34 - Manifold Absolute Pressure (MAP) Sensor Circuit - Signal Voltage Low
(Non-Scan Diagnostics)
Circuit Description • If the idle is rough or unstable, refer to Symptoms section
The Manifold Absolute Pressure (MAP) sensor responds to for items which may cause an unstable idle.
changes in manifold pressure (vacuum). The ECM receives • With the ignition “ON,” engine “OFF,” the manifold
this information as a signal voltage that will vary from about pressure is equal to atmospheric pressure and the signal
1.0-1.5 volts at idle to about 4.0-4.5 volts at Wide Open voltage will be high. This information is used by the ECM
Throttle (WOT). as an indication of altitude and is referred to as BARO.
If the MAP sensor fails, the ECM will substitute a default • a MAP sensor circuit failure is present, the TP sensor
If
MAP value that will vary with RPM. default value will be used along with the MAP sensor
The MAP sensor voltage of 5 volts is delivered to the MAP default value.
sensor through CKT 416E. CKT 814 is the ground circuit for After repairs, clear DTC’s following “Clear DTC’s Procedure”
the MAP sensor. The MAP signal CKT 432 will send a voltage in the General Information section. Failure to do so may result
signal back to the ECM according to what the manifold in DTC’s not properly being cleared.
pressure is.
Test Description
Diagnostic Aids 2. This step simulates a DTC 33. If the ECM recognizes
Check for the following conditions: the high signal voltage and sets a DTC 33, the ECM and
• Poor connection at ECM. Inspect harness connectors wiring are OK.
for backed out terminals, improper mating, broken locks, 3. This step checks CKT 416E for the 5 volt reference.
improperly formed or damaged terminals and poor
terminal to wire connection.
• Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK, observe the
MAP sensor display on the scan tool while moving
connectors and wiring harnesses related to the MAP
sensor. A change in the MAP sensor display will indicate
the location of the fault.

MEFI 4
Engine Engine Controls - 8.1L 6 - 105

DTC 34 - Manifold Absolute Pressure (MAP) Sensor Circuit - Signal Voltage Low
(Non-Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Marine Diagnostic Trouble Code (MDTC) tool switched

to “normal mode,” or “OFF.”
2. Ignition “OFF.”
3. Disconnect MAP sensor harness connector.
4. Connect a jumper wire from harness terminal “B”
2 (CKT 432) to harness terminal “C” (CKT 416E).
5. Start engine and idle for 2 minutes or until MDTC tool
indicates a stored DTC.
6. Ignition “ON,” engine “OFF.”
7. Switch MDTC tool to “service mode,” or “ON” and note
DTC.
Is DTC 33 present? — Go to Step 4 Go to Step 3

1. Remove jumper wire from CKT 416E and 432.

2. Connect DVOM from harness terminal “A” (CKT 814)
3 to harness terminal “C” (CKT 416E).
Is voltage reading above the specified value? 4 volts Go to Step 5 Go to Step 6

Locate and repair intermittent faulty connections. If OK,

4 replace faulty MAP sensor.
Is action complete? — Verify repair —

Locate and repair open or short to ground in CKT 432. If a

5 problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 7

Locate and repair open or short to ground in CKT 416E.

Also check CKT 416 to the TP sensor for a short to ground.
6 If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 7

Repair faulty ECM connections or replace faulty ECM.

7
Is action complete? — Verify Repair —

MEFI 4
6 - 106 Engine Controls - 8.1L Engine

Engine
Control
Module
Knock Knock (ECM)
Sensor 1 Sensor 2
Signal Signal

17 1 J1

DK BLU 496 LT BLU 1876

Knock Knock
Sensor 1 Sensor 2
(KS) (KS)

MEFI4310
6-28-00

DTC 44 - Knock Sensor (KS) 1 System Inactive (Non-Scan Diagnostics)

Circuit Description Test Description

The ECM uses the Knock Sensors in order to detect engine 4. This step ensures the knock sensors are secured
detonation. This detection allows the ECM to retard spark properly in the engine block.
timing based on the KS signal coming into the ECM. 5. Checks to see that each knock sensor circuit is within
DTC 44 will set only if the ECM does not see any activity on specifications. Some engines use two knock sensors,
the KS signal circuits. so both circuits need to be checked individually.
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
terminal to wire connection.
• Damaged harness. Inspect the wiring harness for
damage.
• Loose Knock Sensors in engine block.
• Poor connection at the Knock Sensors.
After repairs, clear DTC’s following “Clear DTC’s Procedure”
in the General Information section. Failure to do so may result
in DTC’s not properly being cleared.
If CKT 496 or CKT497 are routed too close to secondary
ignition wires, the ECM may see the interference as a knock
signal, resulting in false timing retard.

MEFI 4
Engine Engine Controls - 8.1L 6 - 107

DTC 44 - Knock Sensor (KS) 1 System Inactive (Non-Scan Diagnostics)

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Important: If you can hear the engine knock, repair the

engine mechanical problem before proceeding with this
diagnostic table.
2 Check the KS signal circuits for incorrect routing near the
secondary wires. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 3

Check the KS signal circuits for any terminals not being

fully seated or for incorrect installation. If a problem is
3 found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 4

Checks knock sensors for being loose in the engine

4 block. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 5
1. Ignition “OFF.”
2. Disconnect “J1” harness connector.
5 3. Connect DVOM from “J1-17” (CKT 496 - Knock Signal 1)
to a known good ground near knock sensor. 100,000
Is resistance between the specified value for each circuit? ohms Go to Step 8 Go to Step 6

Locate and repair open or short to ground in the circuit(s)

that were out of range. If a problem is found, repair
6 as necessary.
Was a problem found? — Verify Repair Go to Step 7

Inspect knock sensor terminal contacts. If OK, replace

7 faulty knock sensor(s).
Is action complete? — Verify Repair —

Replace faulty ECM connections or replace faulty ECM.

8 Is action complete? — Verify Repair —

MEFI 4
6 - 108 Engine Controls - 8.1L Engine

Engine
Control
Module
Knock Knock (ECM)
Sensor 1 Sensor 2
Signal Signal

17 1 J1

DK BLU 496 LT BLU 1876

Knock Knock
Sensor 1 Sensor 2
(KS) (KS)

MEFI4310
6-28-00

DTC 44 - Knock Sensor (KS) 2 System Inactive (Non-Scan Diagnostics)

Circuit Description Test Description

The ECM uses the Knock Sensors in order to detect engine 4. This step ensures the knock sensors are secured
detonation. This detection allows the ECM to retard spark properly in the engine block.
timing based on the KS signal coming into the ECM. 5. Checks to see that each knock sensor circuit is within
DTC 44 will set only if the ECM does not see any activity on specifications. Some engines use two knock sensors,
the KS signal circuits. so both circuits need to be checked individually.
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
terminal to wire connection.
• Damaged harness. Inspect the wiring harness for
damage.
• Loose Knock Sensors in engine block.
• Poor connection at the Knock Sensors.
After repairs, clear DTC’s following “Clear DTC’s Procedure”
in the General Information section. Failure to do so may result
in DTC’s not properly being cleared.
If CKT 496 or CKT497 are routed too close to secondary
ignition wires, the ECM may see the interference as a knock
signal, resulting in false timing retard.

MEFI 4
Engine Engine Controls - 8.1L 6 - 109

DTC 44 - Knock Sensor (KS) 2 System Inactive (Non-Scan Diagnostics)

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Important: If you can hear the engine knock, repair the

engine mechanical problem before proceeding with this
diagnostic table.
2 Check the KS signal circuits for incorrect routing near the
secondary wires. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 3

Check the KS signal circuits for any terminals not being

fully seated or for incorrect installation. If a problem is
3 found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 4

Checks knock sensors for being loose in the engine

4 block. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 5
1. Ignition “OFF.”
2. Disconnect “J1” harness connector.
5 3. Connect DVOM from “J1-1” (CKT 497 - Knock Signal 2)
to a known good ground near knock sensor. ?
Is resistance between the specified value for each circuit? ohms Go to Step 8 Go to Step 6

Locate and repair open or short to ground in the circuit(s)

that were out of range. If a problem is found, repair
6 as necessary.
Was a problem found? — Verify Repair Go to Step 7

Inspect knock sensor terminal contacts. If OK, replace

7 faulty knock sensor(s).
Is action complete? — Verify Repair —

Replace faulty ECM connections or replace faulty ECM.

8 Is action complete? — Verify Repair —

MEFI 4
6 - 110 Engine Controls - 8.1L Engine

J1 J2

MEFI3004
DTC 51 - Calibration Checksum Failure (Non-Scan Diagnostics)

Circuit Description Diagnostic Aids

This test allows the ECM to check for a calibration failure by If DTC 51 failed more than once, but is intermittent, replace
comparing the calibration value to a known value stored in the ECM.
the EEPROM.
Test Description
This test is also used as a security measure to prevent
improper use of calibration or changes to these calibrations 2. This step checks to see if the fault is present during
that may alter the designed function of MEFI. diagnosis. If present, the ECM is not functioning properly
and must be replaced or reprogrammed.

DTC 51 - Calibration Checksum Failure (Non-Scan Diagnostics)

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Install Diagnostic Trouble Code (DTC) tool.

2. Using “Clear DTC Procedure,” clear DTC 51.
2 3. Ignition “ON.”
4. Switch DTC tool to “service mode,” or “ON.” Refer to
Does DTC 51 reset? — Go to Step 3 Diagnostic Aids

Replace or reprogram faulty ECM and verify DTC does

3 not reset.
Is action complete? — Verify Repair —

MEFI 4
Engine Engine Controls - 8.1L 6 - 111

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MEFI 4
6 - 112 Engine Controls - 8.1L Engine

From Ignition

PNK 439 PNK 439

D D

Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2

B A C A B C

GRY 1666 BLK 450 GRY 1666 BLK 450

BLK 1665 BLK 1665

S101

6 3 22 J2
Engine
HO2 Sensor 1 Sensor HO2 Sensor 2 Control
Signal Ground Signal Module
(ECM)

MEFI4313
4-26-00

DTC 54 - Heated Oxygen (HO2) Sensor 1 Circuit Low Voltage - Lean Exhaust Indicated
(Non-Scan Diagnostics)
Circuit Description loads.
The Heated Oxygen (HO2) Sensor(s) varies voltage within • Exhaust Leaks: If there is an exhaust leak, the engine
a range from about 1.0 volt if the exhaust is rich, down to may pull the outside air into the exhaust and past the
about 0.1 volt if the exhaust is lean. sensor.
The sensor is like an open circuit and produces no voltage • Vacuum leaks can cause a lean condition or high idle.
when it is below 360° C (600° F). An open oxygen sensor Never solder the HO2 wires. For proper wire and connection
circuit or cold oxygen sensor causes an Open Loop operation. .mj,,l;h x’kgsbgg repairs, refer to “Wiring Repair.”
Diagnostic Aids After repairs, clear DTC’s following “Clear DTC’s Procedure.”
Failure to do so may result in DTC’s not properly being
Check for the following conditions:
cleared.
• Poor connection in harness. Inspect harness connectors
for backed out terminals, improper mating, broken locks, Test Description
improperly formed or damaged terminals and poor 2. Running the engine at 1200 RPM keeps the HO2 sensor
terminal to wire connection. hot in order to ensure the oxygen sensor remains active
• An intermittent short to ground in the HO2 sensor signal and can indicate the exhaust oxygen content accurately.
circuit. 3. Opening the heated oxygen sensor circuit should result
• Fuel contamination: Water, even in small amounts in a displayed voltage between 0.423 volt and 0.487 volt.
delivered to the injectors can cause a lean condition. If the display is fixed below 0.100 volt, the fault is a short
to ground in HO2 sensor signal circuit or a faulty ECM.
• Fuel Pressure: If the fuel pressure is too low, the system
will be lean. In order to confirm, monitor a fuel pressure
gauge while driving the vehicle at various speeds and

MEFI 4
Engine Engine Controls - 8.1L 6 - 113
DTC 54 - Heated Oxygen (HO2) Sensor 1 Circuit Low Voltage - Lean Exhaust Indicated
(Non-Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Disconnect HO2 sensor 1 electrical connector.

2. Install jumper wires between the two harness
connectors.
3. Run the engine at the normal operaing temperature.
2 4. Place the vehicle in park or neutral. 1200
5. Increase the engine speed to the specified value. RPM
6. Using DVOM J 39200, check the voltage between
CKT 1665 and CKT 1666. 0.100
Is the voltage displayed fixed less than the specified value? volt Go to Step 3 Go to Step 4

1. Disconnect the HO2 sensor electrical connector.

2. Using a jumper wire, connect the HO2 sensor 1 Low
3 circuit to a known good ground. Refer to
3. Ignition turned ON. 0.423- Diagnostic
Is the voltage displayed within the specified value? 0.487 volt Aids Go to Step 5

DTC 54 is intermittent. If no additional DTC’s are stored, Go to

4 refer to the Diagnostic Aids. If any additional DTC’s are Applicable
stored, refer to those table(s) first. — DTC Table —

Locate and repair short to ground in the HO2 sensor 1

5 signal circuit. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 6

Repair faulty ECM connections or replace faulty ECM.

6 Is action complete? — Verify Repair —

MEFI 4
6 - 114 Engine Controls - 8.1L Engine

From Ignition

PNK 439 PNK 439

D D

Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2

B A C A B C

GRY 1666 BLK 450 GRY 1666 BLK 450

BLK 1665 BLK 1665

S101

6 3 22 J2
Engine
HO2 Sensor 1 Sensor HO2 Sensor 2 Control
Signal Ground Signal Module
(ECM)

MEFI4313
4-26-00

DTC 54 - Heated Oxygen (HO2) Sensor 2 Circuit Low Voltage - Lean Exhaust Indicated
(Non-Scan Diagnostics)
Circuit Description loads.
The Heated Oxygen (HO2) Sensor(s) varies voltage within • Exhaust Leaks: If there is an exhaust leak, the engine
a range from about 1.0 volt if the exhaust is rich, down to may pull the outside air into the exhaust and past the
about 0.1 volt if the exhaust is lean. sensor.
The sensor is like an open circuit and produces no voltage • Vacuum leaks can cause a lean condition or high idle.
when it is below 360° C (600° F). An open oxygen sensor Never solder the HO2 wires. For proper wire and connection
circuit or cold oxygen sensor causes an Open Loop operation. repairs, refer to “Wiring Repair.”
Diagnostic Aids After repairs, clear DTC’s following “Clear DTC’s Procedure.”
Failure to do so may result in DTC’s not properly being
Check for the following conditions:
cleared.
• Poor connection in harness. Inspect harness connectors
for backed out terminals, improper mating, broken locks, Test Description
improperly formed or damaged terminals and poor 2. Running the engine at 1200 RPM keeps the HO2 sensor
terminal to wire connection. hot in order to ensure the oxygen sensor remains active
• An intermittent short to ground in the HO2 sensor signal and can indicate the exhaust oxygen content accurately.
circuit. 3. Opening the heated oxygen sensor circuit should result
• Fuel contamination: Water, even in small amounts in a displayed voltage between 0.423 volt and 0.487 volt.
delivered to the injectors can cause a lean condition. If the display is fixed below 0.100 volt, the fault is a short
to ground in HO2 sensor signal circuit or a faulty ECM.
• Fuel Pressure: If the fuel pressure is too low, the system
will be lean. In order to confirm, monitor a fuel pressure
gauge while driving the vehicle at various speeds and

MEFI 4
Engine Engine Controls - 8.1L 6 - 115
DTC 54 - Heated Oxygen (HO2) Sensor 2 Circuit Low Voltage - Lean Exhaust Indicated
(Non-Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Disconnect HO2 sensor 2 electrical connector.

2. Install jumper wires between the two harness
connectors.
3. Run the engine at the normal operaing temperature.
2 4. Place the vehicle in park or neutral. 1200
5. Increase the engine speed to the specified value. RPM
6. Using DVOM J 39200, check the voltage between
CKT 1665 and CKT 1666. 0.100
Is the voltage displayed fixed less than the specified value? volt Go to Step 3 Go to Step 4

1. Disconnect the HO2 sensor electrical connector.

2. Using a jumper wire, connect the HO2 sensor 2 Low
3 circuit to a known good ground. Refer to
3. Ignition turned ON. 0.423- Diagnostic
Is the voltage displayed within the specified value? 0.487 volt Aids Go to Step 5

DTC 54 is intermittent. If no additional DTC’s are stored, Go to

4 refer to the Diagnostic Aids. If any additional DTC’s are Applicable
stored, refer to those table(s) first. — DTC Table —

Locate and repair short to ground in the HO2 sensor 2

5 signal circuit. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 6

Repair faulty ECM connections or replace faulty ECM.

6 Is action complete? — Verify Repair —

MEFI 4
6 - 116 Engine Controls - 8.1L Engine

From Ignition

PNK 439 PNK 439

D D

Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2

B A C A B C

GRY 1666 BLK 450 GRY 1666 BLK 450

BLK 1665 BLK 1665

S101

6 3 22 J2
Engine
HO2 Sensor 1 Sensor HO2 Sensor 2 Control
Signal Ground Signal Module
(ECM)

MEFI4313
4-26-00

DTC 55 - Heated Oxygen (HO2) Sensor 1 Circuit High Voltage - Rich Exhaust Indicated
(Non-Scan Diagnostics)
Circuit Description vacuum line to regulator.
The Heated Oxygen (HO2) Sensor varies voltage within a • The TP sensor: An intermittent TP sensor output can
range from about 1.0 volt if the exhaust is rich, down to about cause the system to run rich due to a false indication of
0.1 volt if the exhaust is lean. the throttle moving.
The sensor is like an open circuit and produces no voltage • False rich indication due to silicon contamination of the
when it is below 360° C (600° F). An open oxygen sensor HO2 sensor. A DTC 55 accompanied by lean drivability
circuit or cold oxygen sensor causes an Open Loop operation. conditions and a powdery white deposit on the sensor
indicates a false rich condition.
Diagnostic Aids
Check for the following conditions:
• Faulty HO2 sensor: The HO2 sensor is internally shorted,
the HO2 sensor voltage displayed will be over 1.0 volt.
• Poor connection in harness. Inspect harness connectors Never solder the HO2 wires. For proper wire and connection
for backed out terminals, improper mating, broken locks, repairs, refer to “Wiring Repair.”
improperly formed or damaged terminals and poor
terminal to wire connection. After repairs, clear DTC’s following “Clear DTC’s Procedure.”
Failure to do so may result in DTC’s not properly being
• A leaking injector. cleared.
• Fuel contaminated oil.
Test Description
• Fuel Pressure: If the fuel pressure is too high, the system
will be rich. In order to confirm, monitor a fuel pressure 2. This test determines if the conditions exist in order to set
gauge while driving the vehicle at various speeds and DTC 55.
loads.
• Leaking fuel pressure regulator. Check for fuel in the

MEFI 4
Engine Engine Controls - 8.1L 6 - 117

DTC 55 - Heated Oxygen (HO2) Sensor 1 Circuit High Voltage - Rich Exhaust Indicated
(Non-Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Disconnect HO2 sensor 1 electrical connector.

2. Install jumper wires between the two harness
connectors.
3. Run the engine at the normal operaing temperature.
4. Place the vehicle in park or neutral. 1200
2 5. Increase the engine speed to the specified value. RPM
6. Using a DVOM, check the voltage between CKT 1665
and CKT 1666. 0.900
Is the voltage displayed fixed above the specified value? volt Go to Step 3 Go to Step 5
Ignition turned ON. 0.900 Refer to
3 Is the voltage displayed fixed above the specified value? volt Go to Step 4 Diagnostic Aids
1. Disconnect the HO2 sensor 1 electrical connector.
4 2. Ignition turned ON. 0.900
Is the voltage displayed fixed above the specified value? volt Go to Step 7 Go to Step 6

DTC 55 is intermittent. If no additional DTC’s are stored, Go to

5 refer to the Diagnostic Aids. If any additional DTC’s are Applicable
stored, refer to those table(s) first. — DTC Table —
Replace HO2 sensor 1.
6 Is action complete? — Verify Repair —
Locate and repair short to voltage in the HO2 sensor 1
7 signal circuit. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 8
Repair faulty ECM connections or replace faulty ECM.
8 Is action complete? — Verify Repair —

MEFI 4
6 - 118 Engine Controls - 8.1L Engine

From Ignition

PNK 439 PNK 439

D D

Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2

B A C A B C

GRY 1666 BLK 450 GRY 1666 BLK 450

BLK 1665 BLK 1665

S101

6 3 22 J2
Engine
HO2 Sensor 1 Sensor HO2 Sensor 2 Control
Signal Ground Signal Module
(ECM)

MEFI4313
4-26-00

DTC 55 - Heated Oxygen (HO2) Sensor 2 Circuit High Voltage - Rich Exhaust Indicated
(Non-Scan Diagnostics)
Circuit Description vacuum line to regulator.
The Heated Oxygen (HO2) Sensor varies voltage within a • The TP sensor: An intermittent TP sensor output can
range from about 1.0 volt if the exhaust is rich, down to about cause the system to run rich due to a false indication of
0.1 volt if the exhaust is lean. the throttle moving.
The sensor is like an open circuit and produces no voltage • False rich indication due to silicon contamination of the
when it is below 360° C (600° F). An open oxygen sensor HO2 sensor. A DTC 55 accompanied by lean drivability
circuit or cold oxygen sensor causes an Open Loop operation. conditions and a powdery white deposit on the sensor
indicates a false rich condition.
Diagnostic Aids
Check for the following conditions:
• Faulty HO2 sensor: The HO2 sensor is internally shorted,
the HO2 sensor voltage displayed will be over 1.0 volt.
• Poor connection in harness. Inspect harness connectors Never solder the HO2 wires. For proper wire and connection
for backed out terminals, improper mating, broken locks, repairs, refer to “Wiring Repair.”
improperly formed or damaged terminals and poor
terminal to wire connection. After repairs, clear DTC’s following “Clear DTC’s Procedure.”
Failure to do so may result in DTC’s not properly being
• A leaking injector. cleared.
• Fuel contaminated oil.
Test Description
• Fuel Pressure: If the fuel pressure is too high, the system
will be rich. In order to confirm, monitor a fuel pressure 2. This test determines if the conditions exist in order to set
gauge while driving the vehicle at various speeds and DTC 55.
loads.
• Leaking fuel pressure regulator. Check for fuel in the

MEFI 4
Engine Engine Controls - 8.1L 6 - 119

DTC 55 - Heated Oxygen (HO2) Sensor 2 Circuit High Voltage - Rich Exhaust Indicated
(Non-Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Disconnect HO2 sensor 2 electrical connector.

2. Install jumper wires between the two harness
connectors.
3. Run the engine at the normal operaing temperature.
4. Place the vehicle in park or neutral. 1200
2 5. Increase the engine speed to the specified value. RPM
6. Using a DVOM, check the voltage between CKT 1665
and CKT 1666. 0.900
Is the voltage displayed fixed above the specified value? volt Go to Step 3 Go to Step 5
Ignition turned ON. 0.900 Refer to
3 Is the voltage displayed fixed above the specified value? volt Go to Step 4 Diagnostic Aids
1. Disconnect the HO2 sensor 2 electrical connector.
4 2. Ignition turned ON. 0.900
Is the voltage displayed fixed above the specified value? volt Go to Step 7 Go to Step 6

DTC 55 is intermittent. If no additional DTC’s are stored, Go to

5 refer to the Diagnostic Aids. If any additional DTC’s are Applicable
stored, refer to those table(s) first. — DTC Table —
Replace HO2 sensor 2.
6 Is action complete? — Verify Repair —
Locate and repair short to voltage in the HO2 sensor 2
7 signal circuit. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 8
Repair faulty ECM connections or replace faulty ECM.
8 Is action complete? — Verify Repair —

MEFI 4
6 - 120 Engine Controls - 8.1L Engine

MEFI4323
DTC 81 -Non-Scan Diagnostics 6-12-00

Diagnostic Aids
When a DTC 81 is flashed out using a Diagnostic Trouble Code (DTC) tool, a scan tool MUST be used for further diagnostics.
DTC 81 has multiple failures, and are only distinguished using a scan tool.

MEFI 4
Engine Engine Controls - 8.1L 6 - 121

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MEFI 4
6 - 122 Engine Controls - 8.1L Engine

From Ignition

PNK 439 PNK 439

D D

Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2

B A C A B C

GRY 1666 BLK 450 GRY 1666 BLK 450

BLK 1665 BLK 1665

S101

6 3 22 J2
Engine
HO2 Sensor 1 Sensor HO2 Sensor 2 Control
Signal Ground Signal Module
(ECM)

MEFI4313
4-26-00
DTC 13 - Heated Oxygen (HO2) Sensor 1 Circuit Inactive (Scan Diagnostics)
Circuit Description sensor connector and connect a test light between
The Heated Oxygen (HO2) Sensor varies voltage within a harness terminals “C” and “D.” If the test light does not
range from about 1.0 volt if the exhaust is rich, down to about illuminate brightly, repair the open in the ignition feed or
0.1 volt if the exhaust is lean. ground for the HO2 heater circuit. If the test light
The sensor is like an open circuit and produces no voltage illuminates brightly, replace the HO2 sensor.
when it is below 360° C (600° F). An open oxygen sensor Never solder the HO2 wires. For proper wire and connection
circuit or cold oxygen sensor causes an Open Loop operation. repairs, refer to “Wiring Repair.”
The heater provides for a faster sensor warm-up. This allows After repairs, clear DTC’s following “Clear DTC’s Procedure.”
the sensor to become active in a shorter period of time and Failure to do so may result in DTC’s not properly being
remain active during a long extended idle. cleared.
DTC 13 determines if the heated oxygen sensor circuit has
Test Description
developed an open. With an active DTC 13 set, the system
operates in an Open Loop mode and the Malfunction Indicator 2. With ignition “ON”, engine “OFF”, the HO2 Sensor
Lamp (MIL) is turned on. Voltage displayed on the scan tool should gradually
decrease down to approximately 0.150 volt, indicating
Diagnostic Aids that the heater is working properly. The HO2 voltage may
Check for the following conditions: rise as high as 0.975 volt before it toggles back down.
The main thing to look for is a change.
• Poor connection in harness. Inspect harness connectors
for backed out terminals, improper mating, broken locks, 3. Probing terminal ”D” of the HO2 sensor harness
improperly formed or damaged terminals and poor connector verifies if the voltage is available to the HO2
terminal to wire connection. sensor heater.
• A faulty HO2 heater or heater circuit. With ignition “ON,” 5. If conditions for setting DTC 13 exist, the system will not
engine “OFF,” the HO2 voltage displayed on the scan go into Closed Loop Fuel.
tool should gradually drop to below 0.150 volt, indicating 7. This test checks the continuity of the HO2 signal circuit.
that the heater works properly. If not, disconnect the HO2

MEFI 4
Engine Engine Controls - 8.1L 6 - 123

DTC 13 - Heated Oxygen (HO2) Sensor 1 Circuit Inactive (Scan Diagnostics)

Step Action Value Yes No
Was the “On-Board Diagnostics”(OBD) System Check Go to OBD
1 performed? — Go to Step 2 System Check

1. Connect scan tool.

2. Ignition turned ON.
2 3. Monitor the HO2 Sensor 1 Voltage.
Does the voltage displayed gradually decrease down to 0.150
approximately the specified value? volt Go to Step 5 Go to Step 3

1. Disconnect the HO2 sensor 1 electrical connector.

2. Using a test light connected to a known good ground,
3 probe terminal “D” of the ECM harness connector.
Does the test light illuminate brightly? — Go to Step 4 Go to Step 9

Connect test light between terminals “C” and “D” of the

4 HO2 sensor 1 harness connector.
Does the test light illuminate brightly? — Go to Step 5 Go to Step 10

1. Reconnect HO2 sensor 1 electrical connector.

2. Connect scan tool.
3. Run the engine at the normal operating temperature.
5 4. Run the engine above the specified value for 2
minutes. 1200
Does the scan tool indicate Closed Loop Fuel control? RPM Go to Step 8 Go to Step 6
1. Disconnect the Heated Oxygen (HO2) sensor 1
electrical connector.
2. Install a jumper between the HO2 sensor 1 signal and
6 ground circuit on the ECM harness side.
3. Ignition turned ON.
Does the scan tool HO2 Sensor 1 Voltage display indicate
a voltage less than the specified value? 0.100 volt Go to Step 13 Go to Step 7
1. Turn ignition OFF.
2. Remove the jumpers.
7 3. Using a test light connected to B+, probe the HO2
sensor 1 ground circuit on the ECM harness side.
Does the test light illuminate brightly? — Go to Step 11 Go to Step 12

DTC 13 is intermittent. If no additional DTC’s are stored, Go to

8 refer to the Diagnostic Aids. If any additional DTC’s are Applicable
stored, refer to those table(s) first. — DTC Table —

Locate and repair open or short to ground in the ignition

9 feed circuit for the HO2 heater.
Is action complete? — Verify Repair —

Locate and repair open in the ground circuit for the

10 HO2 heater.
Is action complete? — Verify Repair —

MEFI 4
6 - 124 Engine Controls - 8.1L Engine

DTC 13 - Heated Oxygen (HO2) Sensor 1 Circuit Inactive (Scan Diagnostics)

Step Action Value Yes No
Locate and repair open in the HO2 sensor 1 signal circuit.
11 If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 14

Locate and repair open in the HO2 sensor 1 ground circuit.

12 If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 14

Check for faulty HO2 sensor 1 connections.

13 If OK, replace HO2 sensor.
Is action complete? — Verify Repair —

Repair faulty ECM connections or replace faulty ECM.

14 Is action complete? — Verify Repair —

MEFI 4
Engine Engine Controls - 8.1L 6 - 125

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MEFI 4
6 - 126 Engine Controls - 8.1L Engine
From Ignition

PNK 439 PNK 439

D D

Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2

B A C A B C

GRY 1666 BLK 450 GRY 1666 BLK 450

BLK 1665 BLK 1665

S101

6 3 22 J2
Engine
HO2 Sensor 1 Sensor HO2 Sensor 2 Control
Signal Ground Signal Module
(ECM)

MEFI4313
4-26-00
DTC 13 - Heated Oxygen (HO2) Sensor 2 Circuit Inactive (Scan Diagnostics)
Circuit Description sensor connector and connect a test light between
The Heated Oxygen (HO2) Sensor varies voltage within a harness terminals “C” and “D.” If the test light does not
range from about 1.0 volt if the exhaust is rich, down to about illuminate brightly, repair the open in the ignition feed or
0.1 volt if the exhaust is lean. ground for the HO2 heater circuit. If the test light
The sensor is like an open circuit and produces no voltage illuminates brightly, replace the HO2 sensor.
when it is below 360° C (600° F). An open oxygen sensor Never solder the HO2 wires. For proper wire and connection
circuit or cold oxygen sensor causes an Open Loop operation. repairs, refer to “Wiring Repair.”
The heater provides for a faster sensor warm-up. This allows After repairs, clear DTC’s following “Clear DTC’s Procedure.”
the sensor to become active in a shorter period of time and Failure to do so may result in DTC’s not properly being
remain active during a long extended idle. cleared.
DTC 13 determines if the heated oxygen sensor circuit has
Test Description
developed an open. With an active DTC 13 set, the system
operates in an Open Loop mode and the Malfunction Indicator 2. With ignition “ON”, engine “OFF”, the HO2 Sensor
Lamp (MIL) is turned on. Voltage displayed on the scan tool should gradually
decrease down to approximately 0.150 volt, indicating
Diagnostic Aids that the heater is working properly. The HO2 voltage may
Check for the following conditions: rise as high as 0.975 volt before it toggles back down.
The main thing to look for is a change.
• Poor connection in harness. Inspect harness connectors
for backed out terminals, improper mating, broken locks, 3. Probing terminal ”D” of the HO 2 sensor harness
improperly formed or damaged terminals and poor connector verifies if the voltage is available to the HO2
terminal to wire connection. sensor heater.
• A faulty HO2 heater or heater circuit. With ignition “ON,” 5. If conditions for setting DTC 13 exist, the system will not
engine “OFF,” the HO2 voltage displayed on the scan go into Closed Loop Fuel.
tool should gradually drop to below 0.150 volt, indicating 7. This test checks the continuity of the HO2 signal circuit.
that the heater works properly. If not, disconnect the HO2

MEFI 4
Engine Engine Controls - 8.1L 6 - 127

DTC 13 - Heated Oxygen (HO2) Sensor 2 Circuit Inactive (Scan Diagnostics)

Step Action Value Yes No
Was the “On-Board Diagnostics”(OBD) System Check Go to OBD
1 performed? — Go to Step 2 System Check

1. Connect scan tool.

2. Ignition turned ON.
2 3. Monitor the HO2 Sensor 2 Voltage.
Does the voltage displayed gradually decrease down to 0.150
approximately the specified value? volt Go to Step 5 Go to Step 3

1. Disconnect the HO2 sensor 2 electrical connector.

2. Using a test light connected to a known good ground,
3 probe terminal “D” of the ECM harness connector.
Does the test light illuminate brightly? — Go to Step 4 Go to Step 9

Connect test light between terminals “C” and “D” of the

4 HO2 sensor 1 harness connector.
Does the test light illuminate brightly? — Go to Step 5 Go to Step 10

1. Reconnect HO2 sensor 2 electrical connector.

2. Connect scan tool.
3. Run the engine at the normal operating temperature.
5 4. Run the engine above the specified value for 2
minutes. 1200
Does the scan tool indicate Closed Loop Fuel control? RPM Go to Step 8 Go to Step 6
1. Disconnect the Heated Oxygen (HO2) sensor 2
electrical connector.
2. Install a jumper between the HO2 sensor 2 signal and
6 ground circuit on the ECM harness side.
3. Ignition turned ON.
Does the scan tool HO2 Sensor 2 Voltage display indicate
a voltage less than the specified value? 0.100 volt Go to Step 13 Go to Step 7
1. Turn ignition OFF.
2. Remove the jumpers.
7 3. Using a test light connected to B+, probe the HO2
sensor 2 ground circuit on the ECM harness side.
Does the test light illuminate brightly? — Go to Step 11 Go to Step 12

DTC 13 is intermittent. If no additional DTC’s are stored, Go to

8 refer to the Diagnostic Aids. If any additional DTC’s are Applicable
stored, refer to those table(s) first. — DTC Table —

Locate and repair open or short to ground in the ignition

9 feed circuit for the HO2 heater.
Is action complete? — Verify Repair —

Locate and repair open in the ground circuit for the

10 HO2 heater.
Is action complete? — Verify Repair —

MEFI 4
6 - 128 Engine Controls - 8.1L Engine

DTC 13 - Heated Oxygen (HO2) Sensor 2 Circuit Inactive (Scan Diagnostics)

Step Action Value Yes No
Locate and repair open in the HO2 sensor 2 signal circuit.
11 If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 14

Locate and repair open in the HO2 sensor 2 ground circuit.

12 If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 14

Check for faulty HO2 sensor 2 connections.

13 If OK, replace HO2 sensor.
Is action complete? — Verify Repair —

Repair faulty ECM connections or replace faulty ECM.

14 Is action complete? — Verify Repair —

MEFI 4
Engine Engine Controls - 8.1L 6 - 129

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MEFI 4
6 - 130 Engine Controls - 8.1L Engine

Engine
ECT Control
Sensor Module
Signal (ECM)
7 J2
YEL 410
B
Engine Coolant
Temperature
(ECT) Sensor
A
T0 BLK 814
MAP/TP/ S110
IAT Sensors
BLK 814
3 J2

Sensor Engine
Ground Control
Module
(ECM)

MEFI 4307
4-20-00

DTC 14 - Engine Coolant Temperature (ECT) Sensor Circuit - Low Temp Indicated
(Scan Diagnostics)
Circuit Description After repairs, clear DTC’s following “Clear DTC’s Procedure.”
The Engine Coolant Temperature (ECT) sensor uses a Failure to do so may result in DTC’s not properly being
thermistor to control the signal voltage to the ECM. The ECM cleared.
applies 5 volts on CKT 410 to the sensor. When the engine
Test Description
coolant is cold, the sensor (thermistor) resistance is high. As
the engine coolant warms up, the sensor resistance becomes 2. DTC 14 will set if signal voltage indicates a coolant
less. See engine coolant temperature sensor table under temperature below -30°C (-22°F).
“Diagnostic Aids.” At normal operating temperature (85°C - 3. This test simulates a DTC 15. If the ECM recognizes the
95°C or 185°F - 203°F), the voltage will measure about 1.5- low voltage signal and displays a high temperature, the
2.0 volts. ECM and wiring are OK.
Diagnostic Aids
Check for the following conditions: Engine Coolant Temperature Sensor Table
• Poor connection at ECM. Inspect harness connectors °C °F OHMS
for backed out terminals, improper mating, broken locks, Temperature vs Resistance Values (Approximate)
improperly formed or damaged terminals and poor
100 212 177
terminal to wire connection.
80 176 332
• Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK, observe the 60 140 667
ECT display on the scan tool while moving connectors 45 113 1188
and wiring harnesses related to the ECT sensor. A 35 95 1802
change in the ECT display will indicate the location of
25 77 2796
the fault.
15 59 4450
• The scan tool displays engine coolant temperature in
5 41 7280
degrees celsius and fahrenheit. If the engine is cold (not
running within 8 hours), the scan tool should display a -5 23 12300
ECT sensor value within a few degrees of outside air -15 5 21450
temperature. This may help aid in diagnosing a “shifted” -30 -22 52700
coolant sensor. After engine is started, the temperature
should rise steadily and then stabilize at operating -40 -40 100700
temperature when the thermostat opens.
• If DTC 33 is also set, check for open ground CKT 814.

MEFI 4
Engine Engine Controls - 8.1L 6 - 131
DTC 14 - Engine Coolant Temperature (ECT) Sensor Circuit - Low Temp Indicated
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Turn ignition ON, leaving engine OFF.

2 Does scan tool display a coolant temperature less than
the specified value? -30°C (-22°F) Go to Step 3 Go to Step 4

1. Turn ignition OFF.

2. Disconnect the ECT sensor harness connector.
3. Connect a jumper wire from harness terminal “A”
3 (CKT 814) to harness terminal “B” (CKT 410).
4. Turn ignition ON, leaving engine OFF.
Does scan tool display a coolant temperature above the
specified value? 130°C (266°F) Go to Step 6 Go to Step 5

DTC 14 is intermittent. Locate and repair intermittent

4 faulty connections.
• Refer to “Diagnostic Aids.” — Verify Repair —

Locate and repair open in CKT 410 or CKT 814. If a

5 problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 7

Repair faulty ECT sensor.

6
Is action complete? — Verify Repair —

Repair faulty ECM connections or replace faulty ECM.

7
Is action complete? — Verify Repair —

MEFI 4
6 - 132 Engine Controls - 8.1L Engine

Engine
ECT Control
Sensor Module
Signal (ECM)
7 J2
YEL 410
B
Engine Coolant
Temperature
(ECT) Sensor
A
T0 BLK 814
MAP/TP/ S110
IAT Sensors
BLK 814
3 J2

Sensor Engine
Ground Control
Module
(ECM)

MEFI 4307
4-20-00

DTC 15 - Engine Coolant Temperature (ECT) Sensor Circuit - High Temp Indicated
(Scan Diagnostics)

Circuit Description • Check harness routing for a potential short to ground in

CKT 410.
The Engine Coolant Temperature (ECT) sensor uses a
thermistor to control the signal voltage to the ECM. The ECM After repairs, clear DTC’s following “Clear DTC’s Procedure.”
applies 5 volts on CKT 410 to the sensor. When the engine Failure to do so may result in DTC’s not properly being
coolant is cold, the sensor (thermistor) resistance is high. As cleared.
the engine coolant warms up, the sensor resistance becomes Test Description
less. See engine coolant temperature sensor table under
2. DTC 15 will set if signal voltage indicates a coolant
“Diagnostic Aids.” At normal operating temperature (85°C -
temperature above 130°C or 266°F.
95°C or 185°F - 203°F), the voltage will measure about 1.5-
2.0 volts. 3. This test simulates a DTC 14. If the ECM recognizes the
high voltage signal and displays a low temperature, the
Diagnostic Aids ECM and wiring are OK.
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
Engine Coolant Temperature Sensor Table
terminal to wire connection. °C °F OHMS
• Damaged harness. Inspect the wiring harness for Temperature vs Resistance Values (Approximate)
damage. If the harness appears to be OK, observe the 100 212 177
ECT display on the scan tool while moving connectors
80 176 332
and wiring harnesses related to the ECT sensor. A
change in the ECT display will indicate the location of 60 140 667
the fault. 45 113 1188
• The scan tool displays engine coolant temperature in 35 95 1802
degrees celsius and fahrenheit. If the engine is cold (not 25 77 2796
running within 8 hours), the scan tool should display a
15 59 4450
ECT sensor value within a few degrees of outside air
temperature. This may help aid in diagnosing a “shifted” 5 41 7280
coolant sensor. After engine is started, the temperature -5 23 12300
should rise steadily and then stabilize at operating -15 5 21450
temperature when the thermostat opens.
-30 -22 52700
-40 -40 100700

MEFI 4
Engine Engine Controls - 8.1L 6 - 133
DTC 15 - Engine Coolant Temperature (ECT) Sensor Circuit - High Temp Indicated
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Turn ignition ON, leaving engine OFF.

2 Does scan tool display a coolant temperature greater than
the specified value? 130°C (266°F) Go to Step 3 Go to Step 4

1. Turn ignition OFF.

2. Disconnect ECT sensor harness connector.
3 3. Turn ignition ON, leaving engine OFF.
Does scan tool display a coolant temperature below the
specified value? -30°C (-22°F) Go to Step 6 Go to Step 5

DTC 15 is intermittent. Locate and repair intermittent faulty

4 connections.
• Refer to “Diagnostic Aids.” — Verify Repair —

Locate and repair short to ground in CKT 410. If a problem

5 is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 7

Repair faulty ECT sensor.

6
Is action complete? — Verify Repair —

Repair faulty ECM connections or replace faulty ECM.

7
Is action complete? — Verify Repair —

MEFI 4
6 - 134 Engine Controls - 8.1L Engine

Engine
Control
Module A
(ECM) Throttle
5 Volt
Reference GRY 416 Position(TP)
Sensor
2 J2
C B
BLK 813
To MAP/ECT/
IAT Sensors
DK BLU 417

23 3 J2

TP Sensor Sensor Engine

Signal Ground Control
To MAP Module
Sensor (ECM)
Term. "B"

MEFI4308
4-20-00

DTC 21 - Throttle Position (TP) Sensor Circuit - Signal Voltage High (Scan Diagnostics)

Circuit Description Failure to do so may result in DTC’s not properly being

cleared.
The Throttle Position (TP) sensor is a potentiometer that
provides a voltage signal that changes relative to the throttle Test Description
blade. Signal voltage should vary from about .7 volt at idle to 2. With the throttle closed, the TP sensor voltage should
about 4.8 volts at Wide Open Throttle (WOT). read 0.3-0.9 volt. If it does not, check the throttle cable
The TP sensor signal is one of the most important inputs adjustment or for bent or binding linkage.
used by the ECM for fuel control and for IAC control. 3. This test simulates a DTC 22. If the ECM recognizes the
The ECM supplies a 5 volt signal to the sensor through CKT low voltage signal, the ECM and wiring are OK.
416. CKT 813 is the TP sensor ground circuit. The TP sensor 4. Using DVOM from harness terminal “A” (CKT 416)
will send a voltage signal back to the ECM, through CKT harness terminal “B” (CKT 813) checks the sensor
417, according to where the throttle blades are positioned. ground circuit. A faulty sensor ground CKT 813 will cause
Diagnostic Aids a DTC 21.
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
terminal to wire connection.
• Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK, observe the
TP sensor display on the scan tool while moving
connectors and wiring harnesses related to the TP
sensor. A change in the TP sensor display will indicate
the location of the fault.
• The scan tool reads throttle position in voltage and
percentage relative to the throttle blade opening. With
ignition “ON,” engine “OFF,” throttle blades closed (idle),
the voltage should be 0.3-0.9 volts. The voltage should
steadily increase as the throttle is moved toward Wide
Open Throttle (WOT).
• If a TP sensor circuit failure is present, the MAP sensor
default value will be used along with the TP sensor default
value.
After repairs, clear DTC’s following “Clear DTC’s Procedure.”

MEFI 4
Engine Engine Controls - 8.1L 6 - 135
DTC 21 - Throttle Position (TP) Sensor Circuit - Signal Voltage High (Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Throttle closed.
2. Turn ignition ON, leaving engine OFF.
2
Does scan tool indicate TP sensor voltage greater than
the specified value? 4 volts Go to Step 3 Go to Step 5

1. Turn ignition OFF.

2. Disconnect TP sensor harness connector.
3 3. Turn ignition ON, leaving engine OFF.
Does DVOM indicate a voltage less than the
specified value? .36 volt Go to Step 4 Go to Step 6

Connect DVOM from harness terminal “A” (CKT 416) to

harness terminal “B” (CKT 813).
4
Does DVOM indicate a voltage greater than
the specified value? 4 volts Go to Step 8 Go to Step 7

DTC 21 is intermittent. Locate and repair intermittent faulty

5 connections.
• Refer to “Diagnostic Aids.” — — —

Locate and repair short to voltage in CKT 417.

6 If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 9

Locate and repair open in ground CKT 813. If a problem is

7 found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 9

Replace faulty TP sensor.

8
Is action complete? — Verify Repair —

Repair faulty ECM connections or replace faulty ECM.

9
Is action complete? — Verify Repair —

MEFI 4
6 - 136 Engine Controls - 8.1L Engine

Engine
Control
Module A
(ECM) Throttle
5 Volt
Reference GRY 416 Position(TP)
Sensor
2 J2
C B
BLK 813
To MAP/ECT/
IAT Sensors
DK BLU 417

23 3 J2

TP Sensor Sensor Engine

Signal Ground Control
To MAP Module
Sensor (ECM)
Term. "B"

MEFI4308
4-20-00

DTC 22 - Throttle Position (TP) Sensor Circuit - Signal Voltage Low (Scan Diagnostics)

Circuit Description • The scan tool reads throttle position in voltage and
percentage relative to the throttle blade opening. With
The Throttle Position (TP) sensor is a potentiometer that
ignition “ON,” engine “OFF,” throttle blades closed (idle),
provides a voltage signal that changes relative to the throttle
the voltage should be 0.3-0.9 volts. The voltage should
blade. Signal voltage should vary from about .7 volt at idle to
steadily increase as the throttle is moved toward Wide
about 4.8 volts at Wide Open Throttle (WOT).
Open Throttle (WOT).
The TP sensor signal is one of the most important inputs
used by the ECM for fuel control and for IAC control. • If DTC 34 is also set, check for a short to ground in CKT
416 or CKT 416E.
The ECM supplies a 5 volt signal to the sensor through CKT
416. CKT 813 is the TP sensor ground circuit. The TP sensor • If a TP sensor circuit failure is present, the MAP sensor
default value will be used along with the TP sensor default
will send a voltage signal back to the ECM, through CKT
value.
417, according to where the throttle blades are positioned.
After repairs, clear DTC’s following “Clear DTC’s Procedure.”
Diagnostic Aids Failure to do so may result in DTC’s not properly being
Check for the following conditions: cleared.
• Poor connection at ECM. Inspect harness connectors Test Description
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor 2. With the throttle closed, the TP sensor voltage should
terminal to wire connection. read 0.3-0.9 volt. If it does not, check the throttle cable
adjustment or for bent or binding linkage.
• Damaged harness. Inspect the wiring harness for 3. This test simulates a DTC 21. If the ECM recognizes the
damage. If the harness appears to be OK, observe the
high signal voltage, the ECM and wiring are OK.
TP sensor display on the scan tool while moving
connectors and wiring harnesses related to the TP 4. This test checks for the 5 volt reference on CKT 416.
sensor. A change in the TP sensor display will indicate
the location of the fault.

MEFI 4
Engine Engine Controls - 8.1L 6 - 137
DTC 22 - Throttle Position (TP) Sensor Circuit - Signal Voltage Low (Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Throttle closed.
2. Turn ignition ON, leaving engine OFF.
2
Does scan tool indicate TP sensor voltage less than the
specified value? .36 volt Go to Step 3 Go to Step 5

1. Turn ignition OFF.

2. Disconnect TP sensor harness connector.
3. Connect a jumper wire from harness terminal “A”
3 (CKT 416) to harness terminal “C” (CKT 417).
4. Turn ignition ON, leaving engine OFF.
Does scan tool indicate TP sensor voltage greater than the
specified value? 4 volts Go to Step 8 Go to Step 4

1. Turn ignition OFF.

2. Connect DVOM from harness terminal “A” (CKT 416)
to a known good ground.
4
3. Turn ignition ON, leaving engine OFF.
Does DVOM indicate a voltage greater than
the specified value? 4 volts Go to Step 7 Go to Step 6

DTC 22 is intermittent. Locate and repair intermittent

5 faulty connections.
• Refer to “Diagnostic Aids.” — — —

Locate and repair open or short to ground in CKT 416.

Also check CKT 416E to the MAP sensor for a short to
6 ground. If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9

Locate and repair open or short to ground in CKT 417. If a

7 problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9

8 Replace faulty TP sensor. Is action complete? — Verify repair —

Repair faulty ECM connections or replace faulty ECM.

9
Is action complete? — Verify repair —

MEFI 4
6 - 138 Engine Controls - 8.1L Engine

Engine
IAT Control
Sensor Module
Signal (ECM)
21 J2
TAN 472
A
Intake Air
Temperature
(IAT) Sensor
B
T0 BLK 814
MAP/TP/ S101
ECT Sensors
BLK 814
3 J2

Sensor Engine
Ground Control
Module
(ECM)

MEFI 4322
6-11-00

DTC 23 - Intake Air Temperature (IAT) Sensor Circuit - Low Temp Indicated
(Scan Diagnostics)
Circuit Description temperature below -30°C (-22°F).
The Intake Air Temperature (IAT) sensor uses a thermistor 3. This test simulates a DTC 25. If the ECM recognizes the
to control the signal voltage to the ECM. The ECM applies 5 low voltage signal and displays a high temperature, the
volts on CKT 472 to the sensor. When the intake air ECM and wiring are OK.
temperature is cold, the sensor (thermistor) resistance is high.
As the intake air temperature warms up, the sensor resistance
becomes less. See intake air temperature sensor table under
“Diagnostic Aids.”
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors Intake Air Temperature Sensor Table
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor °C °F OHMS
terminal to wire connection. Temperature vs Resistance Values (Approximate)
• Damaged harness. Inspect the wiring harness for 100 212 177
damage. If the harness appears to be OK, observe the
80 176 332
IAT display on the scan tool while moving connectors
and wiring harnesses related to the IAT sensor. A change 60 140 667
in the IAT display will indicate the location of the fault. 45 113 1188
• The scan tool displays intake air temperature in degrees 35 95 1802
celsius and fahrenheit. If the engine is cold (not running 25 77 2796
within 8 hours), the scan tool should display a IAT sensor
15 59 4450
value within a few degrees of outside air temperature.
This may help aid in diagnosing a “shifted” IAT sensor. 5 41 7280
-5 23 12300
• If DTC 33 is also set, check for open ground CKT 814.
After repairs, clear DTC’s following “Clear DTC’s Procedure.” -15 5 21450
Failure to do so may result in DTC’s not properly being -30 -22 52700
cleared. -40 -40 100700
Test Description
2. DTC 23 will set if signal voltage indicates a intake air

MEFI 4
Engine Engine Controls - 8.1L 6 - 139
DTC 23 - Intake Air Temperature (IAT) Sensor Circuit - Low Temp Indicated
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Turn ignition ON, leaving engine OFF.

2 Does scan tool display an intake air temperature less than
the specified value? -30°C (-22°F) Go to Step 3 Go to Step 4

1. Turn ignition OFF.

2. Disconnect IAT sensor harness connector.
3. Connect a jumper wire from harness terminal “A”
3 (CKT 472) to harness terminal “B” (CKT 814).
4. Turn ignition ON, leaving engine OFF.
Does scan tool display a coolant temperature above the
specified value? 130°C (266°F) Go to Step 6 Go to Step 5

DTC 23 is intermittent. Locate and repair intermittent

4 faulty connections.
• Refer to “Diagnostic Aids.” — Verify Repair —

Locate and repair open in CKT 472 or CKT 814. If a

5 problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 7

Repair faulty IAT sensor.

6
Is action complete? — Verify Repair —

Repair faulty ECM connections or replace faulty ECM.

7
Is action complete? — Verify Repair —

MEFI 4
6 - 140 Engine Controls - 8.1L Engine

Vehicle
Speed
Sensor
(VSS)

A B C
From Ignition

BLK 814

PPL 401

3 25 J2

Sensor Vehicle
Engine
Ground Speed Control
Sensor (VSS) Module
Signal (ECM)

MEFI4314
6-30-00

DTC 24 - Vehicle Speed Sensor (VSS) Circuit (Scan Diagnostics)

Circuit Description Check VSS circuits for proper connections and the harness
The vehicle speed is provided to the ECM by means of the is routed properly.
Vehicle Speed Sensor (VSS). The sensor may be mounted After repairs, clear DTC’s following “Clear DTC’s Procedure.”
in the transmission, but the actual location depends on the Failure to do so may result in DTC’s not properly being
application. The sensor produces a 12 volt digital signal cleared.
whenever the vehicle is moving. The number of pulses
increases with vehicle speed. The ECM converts this signal Test Description
into MPH, which can be monitored with a scan tool. This 2. This step determines if the VSS is receiving ignition
information may be used by the ECM for several reasons voltage.
such as governing the vehicle speed to a maximum 3. This step checks for a good ground circuit.
road speed.
The sensor is a three-wire sensor. Terminal “A” of the sensor
is provided a ground on CKT 814 through the ECM. Terminal
“C” of the sensor is provided ignition voltage. Terminal “B” of
the sensor is the signal to the ECM through CKT 401.
Diagnostic Aids
Check for the following conditions:
• Poor connection in harness. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
terminal to wire connection.

MEFI 4
Engine Engine Controls - 8.1L 6 - 141
DTC 24 - Vehicle Speed Sensor (VSS) Circuit (Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Disconnect the vehicle speed sensor harness

connector.
2. Turn ignition ON, leaving engine OFF.
2 3. Using a test light connected to a known good ground,
probe ECM harness terminal “C”.
Does the test light illuminate brightly? — Go to Step 3 Go to Step 7

1. Turn ignition ON, leaving engine OFF.

2. Using a test light connected to B+, probe ECM
3 harness terminal “A”.
Does the test light illuminate brightly? — Go to Step 4 Go to Step 8

1. Turn ignition OFF.

2. Reconnect VSS harness connector.
3. Turn ignition ON, leaving engine OFF.
4. Raise and support the vehicle drive wheel(s) per
manufacturer’s recommendations.
4 5. Using a DMM connected to a known good ground,
back probe ECM harness connector terminal “J2-25”.
6. While observing the DMM, slowly rotate the drive
wheel(s).
Does the DMM indicate a voltage changing as the
wheels are rotated? — Go to Step 9 Go to Step 5

Locate and repair open or short to ground on CKT 401.

5 If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 6

Replace faulty VSS.

6 — Verify repair —
Is action complete?

Locate and repair open or short to ground in the ignition

7 circuit to the VSS.
Is action complete? — Verify Repair —
Locate and repair open in the ground circuit to the VSS.
8
Is action complete? — Verify Repair —
DTC 24 may be intermittent. Clear DTC and drive
the vehicle. If DTC 24 returns, repair faulty ECM
9 connections or replace faulty ECM.
Is action complete? — Verify Repair —

MEFI 4
6 - 142 Engine Controls - 8.1L Engine

Engine
IAT Control
Sensor Module
Signal (ECM)
21 J2
TAN 472
A
Intake Air
Temperature
(IAT) Sensor
B
T0 BLK 814
MAP/TP/ S101
ECT Sensors
BLK 814
3 J2

Sensor Engine
Ground Control
Module
(ECM)

MEFI 4322
6-11-00

DTC 25 - Intake Air Temperature (IAT) Sensor Circuit - High Temp Indicated
(Scan Diagnostics)

Circuit Description Test Description

The Intake Air Temperature (IAT) sensor uses a thermistor 2. DTC 25 will set if signal voltage indicates an intake air
to control the signal voltage to the ECM. The ECM applies 5 temperature above 130°C or 266°F.
volts on CKT 472 to the sensor. When the intake air 3. This test simulates a DTC 23. If the ECM recognizes the
temperature is cold, the sensor (thermistor) resistance is high. high voltage signal and displays a low temperature, the
As the intake air temperature warms up, the sensor resistance ECM and wiring are OK.
becomes less. See intake air temperature sensor table under
“Diagnostic Aids.”
Intake Air Temperature Sensor Table
Diagnostic Aids
Check for the following conditions: °C °F OHMS
Temperature vs Resistance Values (Approximate)
• Poor connection at ECM. Inspect harness connectors
for backed out terminals, improper mating, broken locks, 100 212 177
improperly formed or damaged terminals and poor 80 176 332
terminal to wire connection.
60 140 667
• Damaged harness. Inspect the wiring harness for 45 113 1188
damage. If the harness appears to be OK, observe the
IAT display on the scan tool while moving connectors 35 95 1802
and wiring harnesses related to the IAT sensor. A change 25 77 2796
in the IAT display will indicate the location of the fault. 15 59 4450
• The scan tool displays intake air temperature in degrees 5 41 7280
celsius and fahrenheit. If the engine is cold (not running -5 23 12300
within 8 hours), the scan tool should display an IAT sensor
value within a few degrees of outside air temperature. -15 5 21450
This may help aid in diagnosing a “shifted” IAT sensor. -30 -22 52700
• Check harness routing for a potential short to ground in -40 -40 100700
CKT 472.
After repairs, clear DTC’s following “Clear DTC’s Procedure.
Failure to do so may result in DTC’s not properly being
cleared.

MEFI 4
Engine Engine Controls - 8.1L 6 - 143

DTC 25 - Intake Air Temperature (IAT) Sensor Circuit - High Temp Indicated
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Turn ignition ON, leaving engine OFF.

2 Does scan tool display an intake air temperature greater
than the specified value? 130°C (266°F) Go to Step 3 Go to Step 4

1. Turn ignition OFF.

2. Disconnect IAT sensor harness connector.
3 3. Turn ignition ON, leaving engine OFF.
Does scan tool display an intake air temperature below the
specified value? -30°C (-22°F) Go to Step 6 Go to Step 5

DTC 25 is intermittent. Locate and repair intermittent faulty

4 connections.
• Refer to “Diagnostic Aids.” — Verify Repair —

Locate and repair short to ground in CKT 472. If a problem

5 is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 7

Repair faulty IAT sensor.

6
Is action complete? — Verify Repair —

Repair faulty ECM connections or replace faulty ECM.

7
Is action complete? — Verify Repair —

MEFI 4
6 - 144 Engine Controls - 8.1L Engine

Engine
Control
Module C
(ECM) Manifold
5 Volt Absolute
Reference Pressure To ECT/IAT/
2 J2
(MAP) TP Sensors
B A Sensor
GRY 416E BLK 814 BLK 814

LT GRN 432
BLK 814
8 3 J2
S100
Map Sensor Engine
Sensor Ground Control
Signal Module
(ECM)
To TP Sensor

MEFI4309
4-20-00

DTC 33 - Manifold Absolute Pressure (MAP) Sensor Circuit - Signal Voltage High
(Scan Diagnostics)
Circuit Description • If the idle is rough or unstable, refer to Symptoms for
The Manifold Absolute Pressure (MAP) sensor responds to items which may cause an unstable idle.
changes in manifold pressure (vacuum). The ECM receives • With the ignition “ON,” engine “OFF,” the manifold
this information as a signal voltage that will vary from about pressure is equal to atmospheric pressure and the signal
1.0-1.5 volts at idle to about 4.0-4.5 volts at Wide Open voltage will be high. This information is used by the ECM
Throttle (WOT). as an indication of altitude and is referred to as BARO.
If the MAP sensor fails, the ECM will substitute a default Comparison of this BARO reading, with a known good
MAP value that will vary with RPM. MAP sensor, is a good way to check the accuracy of a
“suspect” sensor. Reading should be the same, plus or
The MAP sensor voltage of 5 volts is delivered to the MAP minus 0.4 volt.
sensor through CKT 416E. CKT 814 is the ground circuit for
the MAP sensor. The MAP signal CKT 432 will send a voltage • If DTC 14 is also set, check for open in ground CKT 814.
signal back to the ECM according to what the manifold • If a MAP sensor circuit failure is present, the TP sensor
pressure is. default value will be used along with the MAP sensor
default value.
Diagnostic Aids
After repairs, clear DTC’s following “Clear DTC’s Procedure.”
Check for the following conditions: Failure to do so may result in DTC’s not properly being
• Poor connection at ECM. Inspect harness connectors cleared.
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor Test Description
terminal to wire connection. 2. This step will determine if there is an adequate vacuum
supply to the MAP sensor. If the vacuum gauge reading
• Damaged harness. Inspect the wiring harness for is erratic, refer to the “Rough or Unstable Idle” symptom.
damage. If the harness appears to be OK, observe the
MAP sensor display on the scan tool while moving 4. This step simulates a DTC 34. If the ECM recognizes
connectors and wiring harnesses related to the MAP the low signal voltage and sets a DTC 34, the ECM and
sensor. A change in the MAP sensor display will indicate wiring are OK.
the location of the fault. 5. This step checks for an open in ground CKT 814.

MEFI 4
Engine Engine Controls - 8.1L 6 - 145

DTC 33 - Manifold Absolute Pressure (MAP) Sensor Circuit - Signal Voltage High
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Install a vacuum gauge to a manifold vacuum source.

2. Start engine and raise to about 1000 RPM in neutral.
2 3. The vacuum reading should be steady.
Is the vacuum gauge reading steady and above the 14” Hg
specified value? (45.5 kPa) Go to Step 3 Go to Step 6

1. Install a scan tool.

2. Start the engine and allow engine to idle.
3 Does scan tool indicate MAP sensor voltage greater than
the specified value? 4 volts Go to Step 4 Go to Step 7

1. Turn the ignition OFF.

2. Disconnect MAP sensor harness connector.
4 3. Turn the ignition ON, leaving the engine OFF.
Does scan tool indicate MAP sensor voltage less than
the specified value? 1 volt Go to Step 5 Go to Step 8

1. Turn the ignition OFF.

2. Connect DMM from harness terminal “A” (CKT 814)
to harness terminal “C” (CKT 416E).
5
3. Turn the ignition ON, leaving the engine OFF.
Does DMM indicate a voltage greater than the specified
value? 4 volts Go to Step 10 Go to Step 9

Repair low or unsteady vacuum problem.

6
Is action complete? — Verify Repair —

DTC 33 is intermittent. Locate and repair intermittent

7 faulty connections.
• Refer to “Diagnostic Aids.” — — —

Locate and repair short to voltage in CKT 432. If a problem

8 is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 11

Locate and repair open in CKT 814. If a problem is found,

9 repair as necessary.
Was a problem found? — Verify Repair Go to Step 11

Check for plugged or leaking sensor vacuum fitting. If OK,

10 replace faulty MAP sensor.
Is action complete? — Verify Repair —

Repair faulty ECM connections or replace faulty ECM.

11
Is action complete? — Verify Repair —

MEFI 4
6 - 146 Engine Controls - 8.1L Engine

Engine
Control
Module C
(ECM) Manifold
5 Volt Absolute
Reference Pressure To ECT/IAT/
2 J2
(MAP) TP Sensors
B A Sensor
GRY 416E BLK 814 BLK 814

LT GRN 432
BLK 814
8 3 J2
S100
Map Sensor Engine
Sensor Ground Control
Signal Module
(ECM)
To TP Sensor

MEFI4309
4-20-00

DTC 34 - Manifold Absolute Pressure (MAP) Sensor Circuit - Signal Voltage Low
(Scan Diagnostics)
Circuit Description • If the idle is rough or unstable, refer to Symptoms for
The Manifold Absolute Pressure (MAP) sensor responds to items which may cause an unstable idle.
changes in manifold pressure (vacuum). The ECM receives • With the ignition “ON,” engine “OFF,” the manifold
this information as a signal voltage that will vary from about pressure is equal to atmospheric pressure and the signal
1.0-1.5 volts at idle to about 4.0-4.5 volts at Wide Open voltage will be high. This information is used by the ECM
Throttle (WOT). as an indication of altitude and is referred to as BARO.
If the MAP sensor fails, the ECM will substitute a default Comparison of this BARO reading, with a known good
MAP value that will vary with RPM. MAP sensor, is a good way to check the accuracy of a
“suspect” sensor. Reading should be the same, plus or
The MAP sensor voltage of 5 volts is delivered to the MAP minus 0.4 volt.
sensor through CKT 416E. CKT 814 is the ground circuit for
the MAP sensor. The MAP signal CKT 432 will send a voltage • If a MAP sensor circuit failure is present, the TP sensor
signal back to the ECM according to what the manifold default value will be used along with the MAP sensor
pressure is. default value.
After repairs, clear DTC’s following “Clear DTC’s Procedure.”
Diagnostic Aids Failure to do so may result in DTC’s not properly being
Check for the following conditions: cleared.
• Poor connection at ECM. Inspect harness connectors Test Description
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor 2. This step will determine if there is an adequate vacuum
terminal to wire connection. supply to the MAP sensor. If the vacuum gauge reading
is erratic, refer to the “Rough or Unstable Idle” symptom.
• Damaged harness. Inspect the wiring harness for 3. This step determines if DTC 34 is the result of a hard
damage. If the harness appears to be OK, observe the
MAP sensor display on the scan tool while moving failure or an intermittent condition. A DTC will set when
connectors and wiring harnesses related to the MAP MAP signal voltage is too low with engine running.
sensor. A change in the MAP sensor display will indicate 4. This step simulates a DTC 33. If the ECM recognizes
the location of the fault. the high signal voltage, the ECM and wiring are OK.
5. This step checks for the 5 volt reference on CKT 416E.

MEFI 4
Engine Engine Controls - 8.1L 6 - 147

DTC 34 - Manifold Absolute Pressure (MAP) Sensor Circuit - Signal Voltage Low
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Turn the ignition OFF.

2. Install a vacuum gauge to a manifold vacuum source.
2 3. Start engine and raise to about 1000 RPM in neutral.
4. The vacuum reading should be steady.
Is the vacuum gauge reading steady and above the 14” Hg
specified value? (45.5 kPa) Go to Step 3 Go to Step 6

1. Install a scan tool.

2. Start the engine and allow the engine to idle.
3 Does scan tool indicate MAP sensor voltage less than
the specified value? 1 volt Go to Step 4 Go to Step 7

1. Turn the ignition OFF.

2. Disconnect MAP sensor harness connector.
3. Connect a jumper wire from harness terminal “B”
4 (CKT 432) to harness terminal “C” (CKT 416E).
4. Turn the ignition ON, leaving the engine OFF.
Does scan tool indicate MAP sensor voltage greater than
the specified value? 4 volts Go to Step 10 Go to Step 5

1. Turn OFF the ignition.

2. Connect DMM from harness terminal “C” (CKT 416E)
to a known good ground.
5
3. Turn ON the ignition, leaving the engine OFF.
Does DMM indicate a voltage greater than the specified
value? 4 volts Go to Step 9 Go to Step 8

Repair low or unsteady vacuum problem.

6
Is action complete? — Verify Repair —
DTC 34 is intermittent. Locate and repair intermittent
7 faulty connections.
• Refer to “Diagnostic Aids.” — — —
Locate and repair open or short to ground in CKT 416E. If
8 a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 11
Locate and repair open or short to ground in CKT 432. If a
9 problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 11
Check for plugged or leaking sensor vacuum fitting. If OK,
10 replace faulty MAP sensor.
Is action complete? — Verify Repair —
Repair faulty ECM connections or replace faulty ECM.
11
Is action complete? — Verify Repair —

MEFI 4
6 - 148 Engine Controls - 8.1L Engine

Hot in Run And Start

From MEFI System Relay
To Injectors

PPL 902 To Fuel Pump Relay

Term. "86"
To Fuel Pump S103 C D S104
Relay Fuse
(Fuse Block term. "A") Fuse Block
INJ/ECM Fuse PNK 439
10A
PPL 902
19 J2
Engine
Ignition Feed
Control
Module
(ECM)
Ignition Control A Ground 3

31 J2 13 J1

PPL 2121 BRN 2129

H G E

S107

PNK 39 PPL 2121

Ignition Coils BRN S105 BRN
(cylinders #3, #5 & #7) D C B 2129 2129

Ignition IC Signal Reference

Low Ignition Coils
Ignition Coil (cylinders #5 & #7) Ignition Coil
(cylinder #1) (cylinder #3)

Ground

A
Spark
Plug
BLK 151
S106

BLK 151

Firing Order: 1-8-7-2-6-5-4-3

Ignition Control: A - B - C - D - E - F - G - H

MEFI4311
7-01-00
DTC 41 - Ignition Coil 1 Control Circuit
Circuit Description when the IC circuit is out of range.
The ignition system on this engine uses an individual ignition Diagnostic Aids
coil/module for each cylinder. The ECM controls the ignition
Check for the following conditions:
system operation. The ECM controls each coil using one of
eight Ignition Control (IC) circuits. The ECM commands the • Poor connection at ECM. Inspect harness
IC circuit low when a spark event is requested. This causes connectors for backed out terminals, improper
the IC module to energize the ignition coil to create a spark mating, broken locks, improperly formed or
at the spark plug. Each ignition coil/module has the following damaged terminals and poor terminal to wire
circuits: connection.
• A power feed • Corrosion
• A ground circuit • Mis-routed harness
• An Ignition Control (IC) circuit • Rubbed through wire insulation
• A reference low circuit
• Broken wire inside the insulation
Sequencing and timing are ECM controlled. This DTC sets

MEFI 4
Engine Engine Controls - 8.1L 6 - 149
Test Description 5. This step tests for a short to ground on the IC signal
2. This step verifies the fault is present. circuit.
4. This step tests the integrity of the IC circuit and the ECM
output.

DTC 41 - Ignition Coil 1 Control Circuit

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Important: If all the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.
2 2. Using a scan tool, clear DTCs.
3. Start and idle the engine for 2 minutes.
4. Check for DTCs. Go to
Does the scan tool indicate a DTC 41 for ignition coil 1? — Go to Step 3 Diagnostic Aids
1. Turn OFF the engine.
2. Disconnect the ignition coil electrical harness.
3 3. Measure the frequency at the ignition control signal
circuit using the DVOM J 39200 on the DC Hertz scale.
Is the frequency within the specified range? 3.0-20 Hz Go to Step 7 Go to Step 4

Measure the voltage at the ignition control signal circuit

4 using the DVOM J 39200.
Is the voltage greater that the specified value? 1.0 volts Go to Step 8 Go to Step 5

1. Turn OFF the engine.

2. Disconnect the ECM connector J2.
3. Test the continuity from the IC circuit (at the ignition
5
coil harness connector) to the ECM connector using
the DVOM J 39200.
Does the DVOM indicate continuity? — Go to Step 6 Go to Step 9

Test the resistance from the IC circuit (at the ignition coil
6 harness connector) to ground using the DVOM J 39200.
Does the DVOM indicate OL? — Go to Step 10 Go to Step 9

Replace the ignition coil.

7 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for a short to voltage.
8 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for an open or grounded
9 circuit.
Is the action complete? — Go to Step 12 —
1. Inspect for poor connections at the ECM connector.
10 2. Replace the terminal if necessary.
Did you find and correct the problem? — Go to Step 12 Go to Step 11

MEFI 4
6 - 150 Engine Controls - 8.1L Engine

DTC 41 - Ignition Coil 1 Control Circuit (cont’d)

Step Action Value Yes No
Replace the ECM.
11 Is the action complete? — Go to Step 12 —
1. Select the Diagnostic Trouble Code (DTC) option and
the Clear DTC information option using the scan tool.
12
2. Idle the engine at the normal operating temperature.
Is DTC 41 indicated? — Go to Step 2 Go to Step 13

Select the Diagnostic Trouble Code (DTC) option. Go to the

13 Does the scan tool display any DTCs that you have not applicable
diagnosed? — DTC table System OK

MEFI 4
Engine Engine Controls - 8.1L 6 - 151

Hot in Run And Start

From MEFI System Relay
To Injectors

PPL 902 To Fuel Pump Relay

Term. "86"
To Fuel Pump S103 C D S104
Relay Fuse
(Fuse Block term. "A") Fuse Block
INJ/ECM Fuse PNK 439
10A
PPL 902
19 J2
Engine
Ignition Feed
Control
Module
(ECM)
Ignition Control D Ground 3

14 J2 13 J1

RED/WHT 2122 BRN 2129

H B E

S107
RED 2122
PNK 39
Ignition Coils BRN S105 BRN
(cylinders #4, #6 & #8) D C B 2129 2129

Ignition IC Signal Reference

Low Ignition Coils
Ignition Coil (cylinders #6 & #8) Ignition Coil
(cylinder #2) (cylinder #4)

Ground

A
Spark
Plug
BLK 151
S106

BLK 151

Firing Order: 1-8-7-2-6-5-4-3

Ignition Control: A - B - C - D - E - F - G - H

MEFI4312
7-01-00
DTC 41 - Ignition Coil 2 Control Circuit
Circuit Description when the IC circuit is out of range.
The ignition system on this engine uses an individual ignition Diagnostic Aids
coil/module for each cylinder. The ECM controls the ignition
Check for the following conditions:
system operation. The ECM controls each coil using one of
eight Ignition Control (IC) circuits. The ECM commands the • Poor connection at ECM. Inspect harness
IC circuit low when a spark event is requested. This causes connectors for backed out terminals, improper
the IC module to energize the ignition coil to create a spark mating, broken locks, improperly formed or
at the spark plug. Each ignition coil/module has the following damaged terminals and poor terminal to wire
circuits: connection.
• A power feed • Corrosion
• A ground circuit • Mis-routed harness
• An Ignition Control (IC) circuit • Rubbed through wire insulation
• A reference low circuit
• Broken wire inside the insulation
Sequencing and timing are ECM controlled. This DTC sets

MEFI 4
6 - 152 Engine Controls - 8.1L Engine
Test Description 5. This step tests for a short to ground on the IC signal
2. This step verifies the fault is present. circuit.
4. This step tests the integrity of the IC circuit and the ECM
output.

DTC 41 - Ignition Coil 2 Control Circuit

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Important: If all the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.
2 2. Using a scan tool, clear DTCs.
3. Start and idle the engine for 2 minutes.
4. Check for DTCs. Go to
Does the scan tool indicate a DTC 41 for ignition coil 2? — Go to Step 3 Diagnostic Aids
1. Turn OFF the engine.
2. Disconnect the ignition coil electrical harness.
3 3. Measure the frequency at the ignition control signal
circuit using the DVOM J 39200 on the DC Hertz scale.
Is the frequency within the specified range? 3.0-20 Hz Go to Step 7 Go to Step 4

Measure the voltage at the ignition control signal circuit

4 using the DVOM J 39200.
Is the voltage greater that the specified value? 1.0 volts Go to Step 8 Go to Step 5

1. Turn OFF the engine.

2. Disconnect the ECM connector J2.
3. Test the continuity from the IC circuit (at the ignition
5
coil harness connector) to the ECM connector using
the DVOM J 39200.
Does the DVOM indicate continuity? — Go to Step 6 Go to Step 9

Test the resistance from the IC circuit (at the ignition coil
6 harness connector) to ground using the DVOM J 39200.
Does the DVOM indicate OL? — Go to Step 10 Go to Step 9

Replace the ignition coil.

7 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for a short to voltage.
8 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for an open or grounded
9 circuit.
Is the action complete? — Go to Step 12 —
1. Inspect for poor connections at the ECM connector.
10 2. Replace the terminal if necessary.
Did you find and correct the problem? — Go to Step 12 Go to Step 11

MEFI 4
Engine Engine Controls - 8.1L 6 - 153

DTC 41 - Ignition Coil 2 Control Circuit (cont’d)

Step Action Value Yes No
Replace the ECM.
11 Is the action complete? — Go to Step 12 —
1. Select the Diagnostic Trouble Code (DTC) option and
the Clear DTC information option using the scan tool.
12
2. Idle the engine at the normal operating temperature.
Is DTC 41 indicated? — Go to Step 2 Go to Step 13

Select the Diagnostic Trouble Code (DTC) option. Go to the

13 Does the scan tool display any DTCs that you have not applicable
diagnosed? — DTC table System OK

MEFI 4
6 - 154 Engine Controls - 8.1L Engine

Hot in Run And Start

From MEFI System Relay
To Injectors

PPL 902 To Fuel Pump Relay

Term. "86"
To Fuel Pump S103 C D S104
Relay Fuse
(Fuse Block term. "A") Fuse Block
INJ/ECM Fuse PNK 439
10A
PPL 902
19 J2
Engine
Ignition Feed
Control
Module
(ECM)
Ignition Control H Ground 3

12 J2 13 J1

LT BLU 2123 BRN 2129

H F E

S107
LT BLU 2123
PNK 39
Ignition Coils BRN S105 BRN
(cylinders #1, #5 & #7) D C B 2129 2129

Ignition IC Signal Reference

Low Ignition Coils
Ignition Coil (cylinders #5 & #7) Ignition Coil
(cylinder #3) (cylinder #1)

Ground

A
Spark
Plug
BLK 151
S106

BLK 151

Firing Order: 1-8-7-2-6-5-4-3

Ignition Control: A - B - C - D - E - F - G - H

MEFI4315
4-26-00
DTC 41 - Ignition Coil 3 Control Circuit
Circuit Description when the IC circuit is out of range.
The ignition system on this engine uses an individual ignition Diagnostic Aids
coil/module for each cylinder. The ECM controls the ignition
Check for the following conditions:
system operation. The ECM controls each coil using one of
eight Ignition Control (IC) circuits. The ECM commands the • Poor connection at ECM. Inspect harness
IC circuit low when a spark event is requested. This causes connectors for backed out terminals, improper
the IC module to energize the ignition coil to create a spark mating, broken locks, improperly formed or
at the spark plug. Each ignition coil/module has the following damaged terminals and poor terminal to wire
circuits: connection.
• A power feed • Corrosion
• A ground circuit • Mis-routed harness
• An Ignition Control (IC) circuit • Rubbed through wire insulation
• A reference low circuit
• Broken wire inside the insulation
Sequencing and timing are ECM controlled. This DTC sets

MEFI 4
Engine Engine Controls - 8.1L 6 - 155
Test Description 5. This step tests for a short to ground on the IC signal
2. This step verifies the fault is present. circuit.
4. This step tests the integrity of the IC circuit and the ECM
output.

DTC 41 - Ignition Coil 3 Control Circuit

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Important: If all the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.
2 2. Using a scan tool, clear DTCs.
3. Start and idle the engine for 2 minutes.
4. Check for DTCs. Go to
Does the scan tool indicate a DTC 41 for ignition coil 3? — Go to Step 3 Diagnostic Aids
1. Turn OFF the engine.
2. Disconnect the ignition coil electrical harness.
3 3. Measure the frequency at the ignition control signal
circuit using the DVOM J 39200 on the DC Hertz scale.
Is the frequency within the specified range? 3.0-20 Hz Go to Step 7 Go to Step 4

Measure the voltage at the ignition control signal circuit

4 using the DVOM J 39200.
Is the voltage greater that the specified value? 1.0 volts Go to Step 8 Go to Step 5

1. Turn OFF the engine.

2. Disconnect the ECM connector J2.
3. Test the continuity from the IC circuit (at the ignition
5
coil harness connector) to the ECM connector using
the DVOM J 39200.
Does the DVOM indicate continuity? — Go to Step 6 Go to Step 9

Test the resistance from the IC circuit (at the ignition coil
6 harness connector) to ground using the DVOM J 39200.
Does the DVOM indicate OL? — Go to Step 10 Go to Step 9

Replace the ignition coil.

7 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for a short to voltage.
8 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for an open or grounded
9 circuit.
Is the action complete? — Go to Step 12 —
1. Inspect for poor connections at the ECM connector.
10 2. Replace the terminal if necessary.
Did you find and correct the problem? — Go to Step 12 Go to Step 11

MEFI 4
6 - 156 Engine Controls - 8.1L Engine

DTC 41 - Ignition Coil 3 Control Circuit (cont’d)

Step Action Value Yes No
Replace the ECM.
11 Is the action complete? — Go to Step 12 —
1. Select the Diagnostic Trouble Code (DTC) option and
the Clear DTC information option using the scan tool.
12
2. Idle the engine at the normal operating temperature.
Is DTC 41 indicated? — Go to Step 2 Go to Step 13

Select the Diagnostic Trouble Code (DTC) option. Go to the

13 Does the scan tool display any DTCs that you have not applicable
diagnosed? — DTC table System OK

MEFI 4
Engine Engine Controls - 8.1L 6 - 157

Hot in Run And Start

From MEFI System Relay
To Injectors

PPL 902 To Fuel Pump Relay

Term. "86"
To Fuel Pump S103 C D S104
Relay Fuse
(Fuse Block term. "A") Fuse Block
INJ/ECM Fuse PNK 439
10A
PPL 902
19 J2
Engine
Ignition Feed
Control
Module
(ECM)
Ignition Control G Ground 3

28 J2 13 J1

DK GRN/WHT 2123
BRN 2129
H C E
C110

S107 DK GRN 2123

PNK 39
Ignition Coils BRN S105 BRN
(cylinders #2, #6 & #8) D C B 2129 2129

Ignition IC Signal Reference

Low Ignition Coils
Ignition Coil (cylinders #6 & #8) Ignition Coil
(cylinder #4) (cylinder #2)

Ground

A
Spark
Plug
BLK 151
S106

BLK 151

Firing Order: 1-8-7-2-6-5-4-3

Ignition Control: A - B - C - D - E - F - G - H

MEFI4316
7-01-00
DTC 41 - Ignition Coil 4 Control Circuit
Circuit Description when the IC circuit is out of range.
The ignition system on this engine uses an individual ignition Diagnostic Aids
coil/module for each cylinder. The ECM controls the ignition
Check for the following conditions:
system operation. The ECM controls each coil using one of
eight Ignition Control (IC) circuits. The ECM commands the • Poor connection at ECM. Inspect harness
IC circuit low when a spark event is requested. This causes connectors for backed out terminals, improper
the IC module to energize the ignition coil to create a spark mating, broken locks, improperly formed or
at the spark plug. Each ignition coil/module has the following damaged terminals and poor terminal to wire
circuits: connection.
• A power feed • Corrosion
• A ground circuit • Mis-routed harness
• An Ignition Control (IC) circuit • Rubbed through wire insulation
• A reference low circuit
• Broken wire inside the insulation
Sequencing and timing are ECM controlled. This DTC sets

MEFI 4
6 - 158 Engine Controls - 8.1L Engine
Test Description 5. This step tests for a short to ground on the IC signal
2. This step verifies the fault is present. circuit.
4. This step tests the integrity of the IC circuit and the ECM
output.

DTC 41 - Ignition Coil 4 Control Circuit

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Important: If all the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.
2 2. Using a scan tool, clear DTCs.
3. Start and idle the engine for 2 minutes.
4. Check for DTCs. Go to
Does the scan tool indicate a DTC 41 for ignition coil 4? — Go to Step 3 Diagnostic Aids
1. Turn OFF the engine.
2. Disconnect the ignition coil electrical harness.
3 3. Measure the frequency at the ignition control signal
circuit using the DVOM J 39200 on the DC Hertz scale.
Is the frequency within the specified range? 3.0-20 Hz Go to Step 7 Go to Step 4

Measure the voltage at the ignition control signal circuit

4 using the DVOM J 39200.
Is the voltage greater that the specified value? 1.0 volts Go to Step 8 Go to Step 5

1. Turn OFF the engine.

2. Disconnect the ECM connector J2.
3. Test the continuity from the IC circuit (at the ignition
5
coil harness connector) to the ECM connector using
the DVOM J 39200.
Does the DVOM indicate continuity? — Go to Step 6 Go to Step 9

Test the resistance from the IC circuit (at the ignition coil
6 harness connector) to ground using the DVOM J 39200.
Does the DVOM indicate OL? — Go to Step 10 Go to Step 9

Replace the ignition coil.

7 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for a short to voltage.
8 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for an open or grounded
9 circuit.
Is the action complete? — Go to Step 12 —
1. Inspect for poor connections at the ECM connector.
10 2. Replace the terminal if necessary.
Did you find and correct the problem? — Go to Step 12 Go to Step 11

MEFI 4
Engine Engine Controls - 8.1L 6 - 159

DTC 41 - Ignition Coil 4 Control Circuit (cont’d)

Step Action Value Yes No
Replace the ECM.
11 Is the action complete? — Go to Step 12 —
1. Select the Diagnostic Trouble Code (DTC) option and
the Clear DTC information option using the scan tool.
12
2. Idle the engine at the normal operating temperature.
Is DTC 41 indicated? — Go to Step 2 Go to Step 13

Select the Diagnostic Trouble Code (DTC) option. Go to the

13 Does the scan tool display any DTCs that you have not applicable
diagnosed? — DTC table System OK

MEFI 4
6 - 160 Engine Controls - 8.1L Engine

Hot in Run And Start

From MEFI System Relay
To Injectors

PPL 902 To Fuel Pump Relay

Term. "86"
To Fuel Pump S103 C D S104
Relay Fuse
(Fuse Block term. "A") Fuse Block
INJ/ECM Fuse PNK 439
10A
PPL 902
19 J2
Engine
Ignition Feed
Control
Module
(ECM)
Ignition Control F Ground 3

13 J2 13 J1

DK GRN 2125 BRN 2129

H C E
C109

DK GRN 2125
S107

PNK 39
Ignition Coils BRN S105 BRN
(cylinders #1, #3 & #7) D C B 2129 2129

Ignition IC Signal Reference

Low Ignition Coils
Ignition Coil (cylinders #1 & #3) Ignition Coil
(cylinder #5) (cylinder #7)

Ground

A
Spark
Plug
BLK 151
S106

BLK 151

Firing Order: 1-8-7-2-6-5-4-3

Ignition Control: A - B - C - D - E - F - G - H

MEFI4317
7-01-00
DTC 41 - Ignition Coil 5 Control Circuit
Circuit Description when the IC circuit is out of range.
The ignition system on this engine uses an individual ignition Diagnostic Aids
coil/module for each cylinder. The ECM controls the ignition
Check for the following conditions:
system operation. The ECM controls each coil using one of
eight Ignition Control (IC) circuits. The ECM commands the • Poor connection at ECM. Inspect harness
IC circuit low when a spark event is requested. This causes connectors for backed out terminals, improper
the IC module to energize the ignition coil to create a spark mating, broken locks, improperly formed or
at the spark plug. Each ignition coil/module has the following damaged terminals and poor terminal to wire
circuits: connection.
• A power feed • Corrosion
• A ground circuit • Mis-routed harness
• An Ignition Control (IC) circuit • Rubbed through wire insulation
• A reference low circuit
• Broken wire inside the insulation
Sequencing and timing are ECM controlled. This DTC sets

MEFI 4
Engine Engine Controls - 8.1L 6 - 161
Test Description 5. This step tests for a short to ground on the IC signal
2. This step verifies the fault is present. circuit.
4. This step tests the integrity of the IC circuit and the ECM
output.

DTC 41 - Ignition Coil 5 Control Circuit

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Important: If all the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.
2 2. Using a scan tool, clear DTCs.
3. Start and idle the engine for 2 minutes.
4. Check for DTCs. Go to
Does the scan tool indicate a DTC 41 for ignition coil 5? — Go to Step 3 Diagnostic Aids
1. Turn OFF the engine.
2. Disconnect the ignition coil electrical harness.
3 3. Measure the frequency at the ignition control signal
circuit using the DVOM J 39200 on the DC Hertz scale.
Is the frequency within the specified range? 3.0-20 Hz Go to Step 7 Go to Step 4

Measure the voltage at the ignition control signal circuit

4 using the DVOM J 39200.
Is the voltage greater that the specified value? 1.0 volts Go to Step 8 Go to Step 5

1. Turn OFF the engine.

2. Disconnect the ECM connector J2.
3. Test the continuity from the IC circuit (at the ignition
5
coil harness connector) to the ECM connector using
the DVOM J 39200.
Does the DVOM indicate continuity? — Go to Step 6 Go to Step 9

Test the resistance from the IC circuit (at the ignition coil
6 harness connector) to ground using the DVOM J 39200.
Does the DVOM indicate OL? — Go to Step 10 Go to Step 9

Replace the ignition coil.

7 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for a short to voltage.
8 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for an open or grounded
9 circuit.
Is the action complete? — Go to Step 12 —
1. Inspect for poor connections at the ECM connector.
10 2. Replace the terminal if necessary.
Did you find and correct the problem? — Go to Step 12 Go to Step 11

MEFI 4
6 - 162 Engine Controls - 8.1L Engine

DTC 41 - Ignition Coil 5 Control Circuit (cont’d)

Step Action Value Yes No
Replace the ECM.
11 Is the action complete? — Go to Step 12 —
1. Select the Diagnostic Trouble Code (DTC) option and
the Clear DTC information option using the scan tool.
12
2. Idle the engine at the normal operating temperature.
Is DTC 41 indicated? — Go to Step 2 Go to Step 13

Select the Diagnostic Trouble Code (DTC) option. Go to the

13 Does the scan tool display any DTCs that you have not applicable
diagnosed? — DTC table System OK

MEFI 4
Engine Engine Controls - 8.1L 6 - 163

Hot in Run And Start

From MEFI System Relay
To Injectors

PPL 902 To Fuel Pump Relay

Term. "86"
To Fuel Pump S103 C D S104
Relay Fuse
(Fuse Block term. "A") Fuse Block
INJ/ECM Fuse PNK 439
10A
PPL 902
19 J2
Engine
Ignition Feed
Control
Module
(ECM)
Ignition Control E Ground 3

29 J2 13 J1

LT BLU/WHT 2126 BRN 2129

H F E
C110

S107
LT BLU 2126

PNK 39
Ignition Coils BRN S105 BRN
(cylinders #2, #4 & #8) D C B 2129 2129

Ignition IC Signal Reference

Low Ignition Coils
Ignition Coil (cylinders #2 & #4) Ignition Coil
(cylinder #6) (cylinder #8)

Ground

A
Spark
Plug
BLK 151
S106

BLK 151

Firing Order: 1-8-7-2-6-5-4-3

Ignition Control: A - B - C - D - E - F - G - H

MEFI4318
7-01-00
DTC 41 - Ignition Coil 6 Control Circuit
Circuit Description when the IC circuit is out of range.
The ignition system on this engine uses an individual ignition Diagnostic Aids
coil/module for each cylinder. The ECM controls the ignition
Check for the following conditions:
system operation. The ECM controls each coil using one of
eight Ignition Control (IC) circuits. The ECM commands the • Poor connection at ECM. Inspect harness
IC circuit low when a spark event is requested. This causes connectors for backed out terminals, improper
the IC module to energize the ignition coil to create a spark mating, broken locks, improperly formed or
at the spark plug. Each ignition coil/module has the following damaged terminals and poor terminal to wire
circuits: connection.
• A power feed • Corrosion
• A ground circuit • Mis-routed harness
• An Ignition Control (IC) circuit • Rubbed through wire insulation
• A reference low circuit
• Broken wire inside the insulation
Sequencing and timing are ECM controlled. This DTC sets

MEFI 4
6 - 164 Engine Controls - 8.1L Engine
Test Description 5. This step tests for a short to ground on the IC signal
2. This step verifies the fault is present. circuit.
4. This step tests the integrity of the IC circuit and the ECM
output.

DTC 41 - Ignition Coil 6 Control Circuit

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Important: If all the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.
2 2. Using a scan tool, clear DTCs.
3. Start and idle the engine for 2 minutes.
4. Check for DTCs. Go to
Does the scan tool indicate a DTC 41 for ignition coil 6? — Go to Step 3 Diagnostic Aids
1. Turn OFF the engine.
2. Disconnect the ignition coil electrical harness.
3 3. Measure the frequency at the ignition control signal
circuit using the DVOM J 39200 on the DC Hertz scale.
Is the frequency within the specified range? 3.0-20 Hz Go to Step 7 Go to Step 4

Measure the voltage at the ignition control signal circuit

4 using the DVOM J 39200.
Is the voltage greater that the specified value? 1.0 volts Go to Step 8 Go to Step 5

1. Turn OFF the engine.

2. Disconnect the ECM connector J2.
3. Test the continuity from the IC circuit (at the ignition
5
coil harness connector) to the ECM connector using
the DVOM J 39200.
Does the DVOM indicate continuity? — Go to Step 6 Go to Step 9

Test the resistance from the IC circuit (at the ignition coil
6 harness connector) to ground using the DVOM J 39200.
Does the DVOM indicate OL? — Go to Step 10 Go to Step 9

Replace the ignition coil.

7 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for a short to voltage.
8 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for an open or grounded
9 circuit.
Is the action complete? — Go to Step 12 —
1. Inspect for poor connections at the ECM connector.
10 2. Replace the terminal if necessary.
Did you find and correct the problem? — Go to Step 12 Go to Step 11

MEFI 4
Engine Engine Controls - 8.1L 6 - 165

DTC 41 - Ignition Coil 6 Control Circuit (cont’d)

Step Action Value Yes No
Replace the ECM.
11 Is the action complete? — Go to Step 12 —
1. Select the Diagnostic Trouble Code (DTC) option and
the Clear DTC information option using the scan tool.
12
2. Idle the engine at the normal operating temperature.
Is DTC 41 indicated? — Go to Step 2 Go to Step 13

Select the Diagnostic Trouble Code (DTC) option. Go to the

13 Does the scan tool display any DTCs that you have not applicable
diagnosed? — DTC table System OK

MEFI 4
6 - 166 Engine Controls - 8.1L Engine

Hot in Run And Start

From MEFI System Relay
To Injectors

PPL 902 To Fuel Pump Relay

Term. "86"
To Fuel Pump S103 C D S104
Relay Fuse
(Fuse Block term. "A") Fuse Block
INJ/ECM Fuse PNK 439
10A
PPL 902
19 J2
Engine
Ignition Feed
Control
Module
(ECM)
Ignition Control C Ground 3

30 J2 13 J1

RED 2127 BRN 2129

H B E
C109

S107
RED 2127
PNK 39
Ignition Coils BRN S105 BRN
(cylinders #1, #3 & #5) D C B 2129 2129

Ignition IC Signal Reference

Low Ignition Coils
Ignition Coil (cylinders #1 & #3) Ignition Coil
(cylinder #7) (cylinder #5)

Ground

A
Spark
Plug
BLK 151
S106

BLK 151

Firing Order: 1-8-7-2-6-5-4-3

Ignition Control: A - B - C - D - E - F - G - H

MEFI4319
4-26-00
DTC 41 - Ignition Coil 7 Control Circuit
Circuit Description when the IC circuit is out of range.
The ignition system on this engine uses an individual ignition Diagnostic Aids
coil/module for each cylinder. The ECM controls the ignition
Check for the following conditions:
system operation. The ECM controls each coil using one of
eight Ignition Control (IC) circuits. The ECM commands the • Poor connection at ECM. Inspect harness
IC circuit low when a spark event is requested. This causes connectors for backed out terminals, improper
the IC module to energize the ignition coil to create a spark mating, broken locks, improperly formed or
at the spark plug. Each ignition coil/module has the following damaged terminals and poor terminal to wire
circuits: connection.
• A power feed • Corrosion
• A ground circuit • Mis-routed harness
• An Ignition Control (IC) circuit • Rubbed through wire insulation
• A reference low circuit
• Broken wire inside the insulation
Sequencing and timing are ECM controlled. This DTC sets

MEFI 4
Engine Engine Controls - 8.1L 6 - 167
Test Description 5. This step tests for a short to ground on the IC signal
2. This step verifies the fault is present. circuit.
4. This step tests the integrity of the IC circuit and the ECM
output.

DTC 41 - Ignition Coil 7 Control Circuit

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Important: If all the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.
2 2. Using a scan tool, clear DTCs.
3. Start and idle the engine for 2 minutes.
4. Check for DTCs. Go to
Does the scan tool indicate a DTC 41 for ignition coil 7? — Go to Step 3 Diagnostic Aids
1. Turn OFF the engine.
2. Disconnect the ignition coil electrical harness.
3 3. Measure the frequency at the ignition control signal
circuit using the DVOM J 39200 on the DC Hertz scale.
Is the frequency within the specified range? 3.0-20 Hz Go to Step 7 Go to Step 4

Measure the voltage at the ignition control signal circuit

4 using the DVOM J 39200.
Is the voltage greater that the specified value? 1.0 volts Go to Step 8 Go to Step 5

1. Turn OFF the engine.

2. Disconnect the ECM connector J2.
3. Test the continuity from the IC circuit (at the ignition
5
coil harness connector) to the ECM connector using
the DVOM J 39200.
Does the DVOM indicate continuity? — Go to Step 6 Go to Step 9

Test the resistance from the IC circuit (at the ignition coil
6 harness connector) to ground using the DVOM J 39200.
Does the DVOM indicate OL? — Go to Step 10 Go to Step 9

Replace the ignition coil.

7 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for a short to voltage.
8 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for an open or grounded
9 circuit.
Is the action complete? — Go to Step 12 —
1. Inspect for poor connections at the ECM connector.
10 2. Replace the terminal if necessary.
Did you find and correct the problem? — Go to Step 12 Go to Step 11

MEFI 4
6 - 168 Engine Controls - 8.1L Engine

DTC 41 - Ignition Coil 7 Control Circuit (cont’d)

Step Action Value Yes No
Replace the ECM.
11 Is the action complete? — Go to Step 12 —
1. Select the Diagnostic Trouble Code (DTC) option and
the Clear DTC information option using the scan tool.
12
2. Idle the engine at the normal operating temperature.
Is DTC 41 indicated? — Go to Step 2 Go to Step 13

Select the Diagnostic Trouble Code (DTC) option. Go to the

13 Does the scan tool display any DTCs that you have not applicable
diagnosed? — DTC table System OK

MEFI 4
Engine Engine Controls - 8.1L 6 - 169

Hot in Run And Start

From MEFI System Relay
To Injectors

PPL 902 To Fuel Pump Relay

Term. "86"
To Fuel Pump S103 C D S104
Relay Fuse
(Fuse Block term. "A") Fuse Block
INJ/ECM Fuse PNK 439
10A
PPL 902
19 J2
Engine
Ignition Feed
Control
Module
(ECM)
Ignition Control B Ground 3

15 J2 13 J1

PPL/WHT 2128 BRN 2129

H G E
C110

S107
PPL 2128
PNK 39
Ignition Coils BRN S105 BRN
(cylinders #2, #4 & #6) D C B 2129 2129

Ignition IC Signal Reference

Low Ignition Coils
Ignition Coil (cylinders #2 & #4) Ignition Coil
(cylinder #8) (cylinder #6)

Ground

A
Spark
Plug
BLK 151
S106

BLK 151

Firing Order: 1-8-7-2-6-5-4-3

Ignition Control: A - B - C - D - E - F - G - H

MEFI4320
7-01-00
DTC 41 - Ignition Coil 8 Control Circuit
Circuit Description when the IC circuit is out of range.
The ignition system on this engine uses an individual ignition Diagnostic Aids
coil/module for each cylinder. The ECM controls the ignition
Check for the following conditions:
system operation. The ECM controls each coil using one of
eight Ignition Control (IC) circuits. The ECM commands the • Poor connection at ECM. Inspect harness
IC circuit low when a spark event is requested. This causes connectors for backed out terminals, improper
the IC module to energize the ignition coil to create a spark mating, broken locks, improperly formed or
at the spark plug. Each ignition coil/module has the following damaged terminals and poor terminal to wire
circuits: connection.
• A power feed • Corrosion
• A ground circuit • Mis-routed harness
• An Ignition Control (IC) circuit • Rubbed through wire insulation
• A reference low circuit
• Broken wire inside the insulation
Sequencing and timing are ECM controlled. This DTC sets

MEFI 4
6 - 170 Engine Controls - 8.1L Engine
Test Description 5. This step tests for a short to ground on the IC signal
2. This step verifies the fault is present. circuit.
4. This step tests the integrity of the IC circuit and the ECM
output.

DTC 41 - Ignition Coil 8 Control Circuit

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Important: If all the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.
2 2. Using a scan tool, clear DTCs.
3. Start and idle the engine for 2 minutes.
4. Check for DTCs. Go to
Does the scan tool indicate a DTC 41 for ignition coil 8? — Go to Step 3 Diagnostic Aids
1. Turn OFF the engine.
2. Disconnect the ignition coil electrical harness.
3 3. Measure the frequency at the ignition control signal
circuit using the DVOM J 39200 on the DC Hertz scale.
Is the frequency within the specified range? 3.0-20 Hz Go to Step 7 Go to Step 4

Measure the voltage at the ignition control signal circuit

4 using the DVOM J 39200.
Is the voltage greater that the specified value? 1.0 volts Go to Step 8 Go to Step 5

1. Turn OFF the engine.

2. Disconnect the ECM connector J2.
3. Test the continuity from the IC circuit (at the ignition
5
coil harness connector) to the ECM connector using
the DVOM J 39200.
Does the DVOM indicate continuity? — Go to Step 6 Go to Step 9

Test the resistance from the IC circuit (at the ignition coil
6 harness connector) to ground using the DVOM J 39200.
Does the DVOM indicate OL? — Go to Step 10 Go to Step 9

Replace the ignition coil.

7 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for a short to voltage.
8 Is the action complete? — Go to Step 12 —
Repair the Ignition Control circuit for an open or grounded
9 circuit.
Is the action complete? — Go to Step 12 —
1. Inspect for poor connections at the ECM connector.
10 2. Replace the terminal if necessary.
Did you find and correct the problem? — Go to Step 12 Go to Step 11

MEFI 4
Engine Engine Controls - 8.1L 6 - 171

DTC 41 - Ignition Coil 8 Control Circuit (cont’d)

Step Action Value Yes No
Replace the ECM.
11 Is the action complete? — Go to Step 12 —
1. Select the Diagnostic Trouble Code (DTC) option and
the Clear DTC information option using the scan tool.
12
2. Idle the engine at the normal operating temperature.
Is DTC 41 indicated? — Go to Step 2 Go to Step 13

Select the Diagnostic Trouble Code (DTC) option. Go to the

13 Does the scan tool display any DTCs that you have not applicable
diagnosed? — DTC table System OK

MEFI 4
6 - 172 Engine Controls - 8.1L Engine

Engine
Control
Module
Knock Knock (ECM)
Sensor 1 Sensor 2
Signal Signal

17 1 J1

DK BLU 496 LT BLU 1876

Knock Knock
Sensor 1 Sensor 2
(KS) (KS)

MEFI4310
6-28-00

DTC 44 - Knock Sensor (KS) 1 Circuit (Scan Diagnostics)

Circuit Description Test Description

The ECM uses the Knock Sensor(s) in order to detect engine 4. This step ensures the knock sensor is secured properly
detonation. This detection allows the ECM to retard spark in the engine block.
timing based on the KS signal coming into the ECM. DTC 44 5. Checks to see that the knock sensor circuit is within
will set only if the ECM does not see any activity on the KS specifications.
signal circuit(s).
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
terminal to wire connection.
• Damaged harness. Inspect the wiring harness for
damage.
• Loose Knock Sensor(s) in engine block.
• Poor connection at the Knock Sensor(s).
After repairs, clear DTC’s following “Clear DTC’s Procedure.”
Failure to do so may result in DTC’s not properly being
cleared.
If CKT 496 or CKT 1876 are routed too close to secondary
ignition wires, the ECM may see the interference as a knock
signal, resulting in false timing retard.

MEFI 4
Engine Engine Controls - 8.1L 6 - 173
DTC 44 - Knock Sensor (KS) 1 Circuit (Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Important: If you can hear the engine knock, repair the

engine mechanical problem before proceeding with this
diagnostic table.
2 Check the KS signal circuit for incorrect routing near the
secondary wires. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 3

Check the KS signal circuit for any terminals not being

fully seated or for incorrect installation. If a problem is
3 found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 4

Check knock sensor for being loose in the engine

4 block. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 5
1. Install scan tool.
2. Select the option to view the data list.
3. Select to view the knock signal 1 parameter.
4. Disconnect “J1” harness connector.
5 5. Connect a DMM from “J1-17” (CKT 496 - Knock Signal
1) to a known good ground near the knock sensor. 93-107K
Is resistance between the specified value? ohms Go to Step 8 Go to Step 6

Locate and repair open or short to ground in the circuit

that were out of range. If a problem is found, repair
6 as necessary.
Was a problem found? — Verify Repair Go to Step 7

Inspect knock sensor terminal contacts. If OK, replace

7 faulty knock sensor.
Is action complete? — Verify Repair —

Replace faulty ECM connections or replace faulty ECM.

8 Is action complete? — Verify Repair —

MEFI 4
6 - 174 Engine Controls - 8.1L Engine

Engine
Control
Module
Knock Knock (ECM)
Sensor 1 Sensor 2
Signal Signal

17 1 J1

DK BLU 496 LT BLU 1876

Knock Knock
Sensor 1 Sensor 2
(KS) (KS)

MEFI4310
6-28-00

DTC 44 - Knock Sensor (KS) 2 Circuit (Scan Diagnostics)

Circuit Description Test Description

The ECM uses the Knock Sensor(s) in order to detect engine 4. This step ensures the knock sensor is secured properly
detonation. This detection allows the ECM to retard spark in the engine block.
timing based on the KS signal coming into the ECM. DTC 44 5. Checks to see that the knock sensor circuit is within
will set only if the ECM does not see any activity on the KS specifications.
signal circuit(s).
Diagnostic Aids
Check for the following conditions:
• Poor connection at ECM. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
terminal to wire connection.
• Damaged harness. Inspect the wiring harness for
damage.
• Loose Knock Sensor(s) in engine block.
• Poor connection at the Knock Sensor(s).
After repairs, clear DTC’s following “Clear DTC’s Procedure.”
Failure to do so may result in DTC’s not properly being
cleared.
If CKT 496 or CKT 1876 are routed too close to secondary
ignition wires, the ECM may see the interference as a knock
signal, resulting in false timing retard.

MEFI 4
Engine Engine Controls - 8.1L 6 - 175

DTC 44 - Knock Sensor (KS) 2 Circuit (Scan Diagnostics)

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

Important: If you can hear the engine knock, repair the

engine mechanical problem before proceeding with this
diagnostic table.
2 Check the KS signal circuit for incorrect routing near the
secondary wires. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 3

Check the KS signal circuit for any terminals not being

fully seated or for incorrect installation. If a problem is
3 found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 4

Check knock sensor for being loose in the engine

4 block. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 5
1. Install scan tool.
2. Select the option to view the data list.
3. Select to view the knock signal 2 parameter.
4. Disconnect “J1” harness connector.
5 5. Connect a DMM from “J1-1” (CKT 1876 - Knock Signal
2) to a known good ground near knock sensor. 93-107K
Is resistance between the specified value? ohms Go to Step 8 Go to Step 6

Locate and repair open or short to ground in the circuit

that were out of range. If a problem is found, repair
6 as necessary.
Was a problem found? — Verify Repair Go to Step 7

Inspect knock sensor terminal contacts. If OK, replace

7 faulty knock sensor.
Is action complete? — Verify Repair —

Replace faulty ECM connections or replace faulty ECM.

8 Is action complete? — Verify Repair —

MEFI 4
6 - 176 Engine Controls - 8.1L Engine

J1 J2

MEFI3004
DTC 51 - Calibration Checksum Failure (Scan Diagnostics)

Circuit Description Diagnostic Aids

This test allows the ECM to check for a calibration failure by If DTC 51 failed more than once, but is intermittent, replace
comparing the calibration value to a known value stored in the ECM.
the EEPROM.
Test Description
This test is also used as a security measure to prevent
improper use of calibration or changes to these calibrations 2. This step checks to see if the fault is present during
that may alter the designed function of MEFI. diagnosis. If present, the ECM is not functioning properly
and must be replaced or reprogrammed.

DTC 51 - Calibration Checksum Failure (Scan Diagnostics)

Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Install Diagnostic Trouble Code (DTC) tool.

2. Using “Clear DTC Procedure,” clear DTC 51.
2 3. Turn the ignition ON, leaving the engine OFF.
4. Switch DTC tool to “service mode,” or “ON.” Refer to
Does DTC 51 reset? — Go to Step 3 Diagnostic Aids

Replace or reprogram faulty ECM and verify DTC does

3 not reset.
Is action complete? — Verify Repair —

MEFI 4
Engine Engine Controls - 8.1L 6 - 177

This page left

intentionally
blank

MEFI 4
6 - 178 Engine Controls - 8.1L Engine

From Ignition

PNK 439 PNK 439

D D

Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2

B A C A B C

GRY 1666 BLK 450 GRY 1666 BLK 450

BLK 1665 BLK 1665

S101

6 3 22 J2
Engine
HO2 Sensor 1 Sensor HO2 Sensor 2 Control
Signal Ground Signal Module
(ECM)

MEFI4313
4-26-00

DTC 54 - Heated Oxygen (HO2) Sensor 1 Circuit Low Voltage - Lean Exhaust Indicated
(Scan Diagnostics)
Circuit Description loads.
The Heated Oxygen (HO2) Sensor varies voltage within a • Exhaust Leaks: If there is an exhaust leak, the engine
range from about 1.0 volt if the exhaust is rich, down to about may pull the outside air into the exhaust and past the
0.1 volt if the exhaust is lean. sensor.
The sensor is like an open circuit and produces no voltage • Vacuum leaks can cause a lean condition or high idle.
when it is below 360° C (600° F). An open oxygen sensor Never solder the HO2 wires. For proper wire and connection
circuit or cold oxygen sensor causes an Open Loop operation. repairs, refer to “Wiring Repair.”
Diagnostic Aids After repairs, clear DTC’s following “Clear DTC’s Procedure.”
Failure to do so may result in DTC’s not properly being
Check for the following conditions:
cleared.
• Poor connection in harness. Inspect harness connectors
for backed out terminals, improper mating, broken locks, Test Description
improperly formed or damaged terminals and poor 2. Running the engine at 1200 RPM keeps the HO2 sensor
terminal to wire connection. hot in order to ensure the oxygen sensor remains active
• An intermittent short to ground in the HO2 sensor signal and can indicate the exhaust oxygen content accurately.
circuit. 3. Opening the heated oxygen sensor circuit should result
• Fuel contamination: Water, even in small amounts in a displayed voltage between 0.423 volt and 0.487 volt.
delivered to the injectors can cause a lean condition. If the display is fixed below 0.100 volt, the fault is a short
to ground in HO 2 sensor signal circuit or a
• Fuel Pressure: If the fuel pressure is too low, the system faulty ECM.
will be lean. In order to confirm, monitor a fuel pressure
gauge while driving the vehicle at various speeds and

MEFI 4
Engine Engine Controls - 8.1L 6 - 179

DTC 54 - Heated Oxygen (HO2) Sensor 1 Circuit Low Voltage - Lean Exhaust Indicated
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Connect a scan tool.

2. Run the engine at the normal operating temperature. 1200
3. Place the vehicle in park or neutral. RPM
2 4. Increase the engine speed to the specified value.
Is the HO2 sensor 1 voltage displayed fixed less than the 0.100
specified value? volt Go to Step 3 Go to Step 4

1. Disconnect the HO2 sensor 1 electrical connector.

2. Using a jumper wire, connect the HO2 sensor 1 Low
circuit to a known good ground.
3 3. Turn the ignition ON, leaving the engine OFF. 0.423 - Refer to
Does the scan tool HO2 Sensor 1 Voltage display indicate 0.487 Diagnostic
a voltage within the specified value? volt Aids Go to Step 5

DTC 54 is intermittent. If no additional DTC’s are stored, Go to

4 refer to the Diagnostic Aids. If any additional DTC’s are Applicable
stored, refer to those table(s) first. — DTC Table —

Locate and repair short to ground in the HO2 sensor 1

signal circuit.
5 If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 6

Repair faulty ECM connections or replace faulty ECM.

6 Is action complete? — Verify Repair —

MEFI 4
6 - 180 Engine Controls - 8.1L Engine

From Ignition

PNK 439 PNK 439

D D

Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2

B A C A B C

GRY 1666 BLK 450 GRY 1666 BLK 450

BLK 1665 BLK 1665

S101

6 3 22 J2
Engine
HO2 Sensor 1 Sensor HO2 Sensor 2 Control
Signal Ground Signal Module
(ECM)

MEFI4313
4-26-00

DTC 54 - Heated Oxygen (HO2) Sensor 2 Circuit Low Voltage - Lean Exhaust Indicated
(Scan Diagnostics)
Circuit Description loads.
The Heated Oxygen (HO2) Sensor varies voltage within a • Exhaust Leaks: If there is an exhaust leak, the engine
range from about 1.0 volt if the exhaust is rich, down to about may pull the outside air into the exhaust and past the
0.1 volt if the exhaust is lean. sensor.
The sensor is like an open circuit and produces no voltage • Vacuum leaks can cause a lean condition or high idle.
when it is below 360° C (600° F). An open oxygen sensor Never solder the HO2 wires. For proper wire and connection
circuit or cold oxygen sensor causes an Open Loop operation. repairs, refer to “Wiring Repair.”
Diagnostic Aids After repairs, clear DTC’s following “Clear DTC’s Procedure.”
Failure to do so may result in DTC’s not properly being
Check for the following conditions:
cleared.
• Poor connection in harness. Inspect harness connectors
for backed out terminals, improper mating, broken locks, Test Description
improperly formed or damaged terminals and poor 2. Running the engine at 1200 RPM keeps the HO2 sensor
terminal to wire connection. hot in order to ensure the oxygen sensor remains active
• An intermittent short to ground in the HO2 sensor signal and can indicate the exhaust oxygen content accurately.
circuit. 3. Opening the heated oxygen sensor circuit should result
• Fuel contamination: Water, even in small amounts in a displayed voltage between 0.423 volt and 0.487 volt.
delivered to the injectors can cause a lean condition. If the display is fixed below 0.100 volt, the fault is a short
to ground in HO 2 sensor signal circuit or a
• Fuel Pressure: If the fuel pressure is too low, the system faulty ECM.
will be lean. In order to confirm, monitor a fuel pressure
gauge while driving the vehicle at various speeds and

MEFI 4
Engine Engine Controls - 8.1L 6 - 181

DTC 54 - Heated Oxygen (HO2) Sensor 2 Circuit Low Voltage - Lean Exhaust Indicated
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Connect scan tool.

2. Run the engine at the normal operating temperature. 1200
3. Place the vehicle in park or neutral. RPM
2 4. Increase the engine speed to the specified value.
Is the HO2 sensor 2 voltage displayed fixed less than the 0.100
specified value? volt Go to Step 3 Go to Step 4

1. Disconnect the HO2 sensor 2 electrical connector.

2. Using a jumper wire, connect the HO2 sensor 2 Low
circuit to a known good ground.
3 3. Turn the ignition ON, leaving the engine OFF. 0.423 - Refer to
Does the scan tool HO2 Sensor 2 Voltage display indicate 0.487 Diagnostic
a voltage within the specified value? volt Aids Go to Step 5

DTC 54 is intermittent. If no additional DTC’s are stored, Go to

4 refer to the Diagnostic Aids. If any additional DTC’s are Applicable
stored, refer to those table(s) first. — DTC Table —

Locate and repair short to ground in the HO2 sensor 2

signal circuit.
5 If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 6

Repair faulty ECM connections or replace faulty ECM.

6 Is action complete? — Verify Repair —

MEFI 4
6 - 182 Engine Controls - 8.1L Engine

From Ignition

PNK 439 PNK 439

D D

Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2

B A C A B C

GRY 1666 BLK 450 GRY 1666 BLK 450

BLK 1665 BLK 1665

S101

6 3 22 J2
Engine
HO2 Sensor 1 Sensor HO2 Sensor 2 Control
Signal Ground Signal Module
(ECM)

MEFI4313
4-26-00

DTC 55 - Heated Oxygen (HO2) Sensor 1 Circuit High Voltage - Rich Exhaust Indicated
(Scan Diagnostics)
Circuit Description • The TP sensor: An intermittent TP sensor output can
The Heated Oxygen (HO2) Sensor varies voltage within a cause the system to run rich due to a false indication of
range from about 1.0 volt if the exhaust is rich, down to about the throttle moving.
0.1 volt if the exhaust is lean. • False rich indication due to silicon contamination of the
The sensor is like an open circuit and produces no voltage HO2 sensor. A DTC 55 accompanied by lean drivability
when it is below 360° C (600° F). An open oxygen sensor conditions and a powdery white deposit on the sensor
circuit or cold oxygen sensor causes an Open Loop indicates a false rich condition.
operation. • Faulty HO2 sensor: The HO2 sensor is internally shorted,
the HO2 Sensor Voltage displayed on the scan tool will
Diagnostic Aids
be over 1.0 volt. Try disconnecting the HO2 electrical
Check for the following conditions: connector, if the displayed voltage goes from over 1.0
• Poor connection in harness. Inspect harness connectors volt down to about 0.5 volt, replace the HO2 sensor.
for backed out terminals, improper mating, broken locks, Never solder the HO2 wires. For proper wire and connection
improperly formed or damaged terminals and poor repairs, refer to “Wiring Repair.”
terminal to wire connection.
After repairs, clear DTC’s following “Clear DTC’s Procedure.”
• A leaking injector. Failure to do so may result in DTC’s not properly being
• Fuel contaminated oil. cleared.
• Fuel Pressure: If the fuel pressure is too high, the system Test Description
will be rich. In order to confirm, monitor a fuel pressure
gauge while driving the vehicle at various speeds and 2. This test determines if the conditions exist in order to set
loads. DTC 55.

• Leaking fuel pressure regulator. Check for fuel in the

vacuum line to regulator.

MEFI 4
Engine Engine Controls - 8.1L 6 - 183
DTC 55 - Heated Oxygen (HO2) Sensor 1 Circuit High Voltage - Rich Exhaust Indicated
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Connect scan tool.

2. Run the engine at the normal operating temperature. 1200
3. Place the vehicle in park or neutral. RPM
2 4. Increase the engine speed to the specified value.
Is the HO2 sensor 1 voltage displayed fixed above than the 0.900
specified value? volt Go to Step 3 Go to Step 5
Turn the ignition ON, leaving the engine OFF.
3 Does the scan tool HO2 Sensor 1 Voltage display indicate 0.900 Refer to
a voltage fixed above the specified value? volt Go to Step 4 Diagnostic Aids

1. Disconnect the HO2 sensor 1 electrical connector.

2. Turn the ignition ON, leaving the engine OFF.
4
Does the scan tool HO2 Sensor 1 Voltage display indicate 0.900
a voltage fixed above the specified value? volt Go to Step 7 Go to Step 6

DTC 55 is intermittent. If no additional DTC’s are stored, Go to

5 refer to the Diagnostic Aids. If any additional DTC’s are Applicable
stored, refer to those table(s) first. — DTC Table —

Replace HO2 sensor 1.

6 Is action complete? — Verify Repair —
Locate and repair short to voltage on the HO2 sensor 1
7 signal circuit. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 8
Repair faulty ECM connections or replace faulty ECM.
8 Is action complete? — Verify Repair —

MEFI 4
6 - 184 Engine Controls - 8.1L Engine

From Ignition

PNK 439 PNK 439

D D

Heated Heated
Oxygen Oxygen
(HO2) (HO2)
Sensor 1 Sensor 2

B A C A B C

GRY 1666 BLK 450 GRY 1666 BLK 450

BLK 1665 BLK 1665

S101

6 3 22 J2
Engine
HO2 Sensor 1 Sensor HO2 Sensor 2 Control
Signal Ground Signal Module
(ECM)

MEFI4313
4-26-00

DTC 55 - Heated Oxygen (HO2) Sensor 2 Circuit High Voltage - Rich Exhaust Indicated
(Scan Diagnostics)
Circuit Description • The TP sensor: An intermittent TP sensor output can
The Heated Oxygen (HO2) Sensor varies voltage within a cause the system to run rich due to a false indication of
range from about 1.0 volt if the exhaust is rich, down to about the throttle moving.
0.1 volt if the exhaust is lean. • False rich indication due to silicon contamination of the
The sensor is like an open circuit and produces no voltage HO2 sensor. A DTC 55 accompanied by lean drivability
when it is below 360° C (600° F). An open oxygen sensor conditions and a powdery white deposit on the sensor
circuit or cold oxygen sensor causes an Open Loop indicates a false rich condition.
operation. • Faulty HO2 sensor:The HO2 sensor is internally shorted,
the HO2 Sensor Voltage displayed on the scan tool will
Diagnostic Aids
be over 1.0 volt. Try disconnecting the HO2 electrical
Check for the following conditions: connector, if the displayed voltage goes from over 1.0
• Poor connection in harness. Inspect harness connectors volt down to about 0.5 volt, replace the HO2 sensor.
for backed out terminals, improper mating, broken locks, Never solder the HO2 wires. For proper wire and connection
improperly formed or damaged terminals and poor repairs, refer to “Wiring Repair.”
terminal to wire connection.
After repairs, clear DTC’s following “Clear DTC’s Procedure.”
• A leaking injector. Failure to do so may result in DTC’s not properly being
• Fuel contaminated oil. cleared.
• Fuel Pressure: If the fuel pressure is too high, the system Test Description
will be rich. In order to confirm, monitor a fuel pressure
gauge while driving the vehicle at various speeds and 2. This test determines if the conditions exist in order to set
loads. DTC 55.

• Leaking fuel pressure regulator. Check for fuel in the

vacuum line to regulator.

MEFI 4
Engine Engine Controls - 8.1L 6 - 185
DTC 55 - Heated Oxygen (HO2) Sensor 2 Circuit High Voltage - Rich Exhaust Indicated
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Connect scan tool.

2. Run the engine at the normal operating temperature. 1200
3. Place the vehicle in park or neutral. RPM
2 4. Increase the engine speed to the specified value.
Is the HO2 sensor 2 voltage displayed fixed above than the 0.900
specified value? volt Go to Step 3 Go to Step 5
Turn the ignition ON, leaving the engine OFF.
3 Does the scan tool HO2 Sensor 2 Voltage display indicate 0.900 Refer to
a voltage fixed above the specified value? volt Go to Step 4 Diagnostic Aids

1. Disconnect the HO2 sensor 2 electrical connector.

2. Turn the ignition ON, leaving the engine OFF.
4
Does the scan tool HO2 Sensor 2 Voltage display indicate 0.900
a voltage fixed above the specified value? volt Go to Step 7 Go to Step 6

DTC 55 is intermittent. If no additional DTC’s are stored, Go to

5 refer to the Diagnostic Aids. If any additional DTC’s are Applicable
stored, refer to those table(s) first. — DTC Table —

Replace HO2 sensor 2.

6 Is action complete? — Verify Repair —
Locate and repair short to voltage on the HO2 sensor 2
7 signal circuit. If a problem is found, repair as necessary.
Was a problem found? — Verify Repair Go to Step 8
Repair faulty ECM connections or replace faulty ECM.
8 Is action complete? — Verify Repair —

MEFI 4
6 - 186 Engine Controls - 8.1L Engine

Crankshaft
Solid Position
State (CKP)
Sensor

C B A

YEL/BLK 1868

DK BLU/WHT 1869

RED 631

16 18 17 J2

CKP Sensor DepsLo Depspower Engine

Signal Control
Module
(ECM)

MEFI4325
6-15-00

DTC 81 - Crankshaft Position (CKP) Sensor Circuit Fault

(Scan Diagnostics)
Circuit Description could result in any one of the following:
The CKP sensor works in conjunction with a 24X reluctor • A no start
wheel. The CKP sensor has a B+ power supply, a ground
and a signal circuit.
• A start and stall
As the crankshaft rotates, the reluctor wheel teeth interrupt
• Erratic performance
a magnetic field produced by a magnet within the sensor. Test Description
The sensor’s internal circuitry detects this and produces a 2. This test determines if the conditions exist in order to set
signal which the ECM reads. The ECM uses this signal to DTC 55.
accurately measure crankshaft velocity which is a variable
used in order to detect misfire, and control spark and fueling.
Diagnostic Aids
Check for the following conditions:
• Poor connection in harness. Inspect harness connectors
for backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals and poor
terminal to wire connection.
• Crankshaft reluctor wheel damage or improper
installation
• Excessive air gap between the CKP sensor and the
reluctor wheel
Excess crankshaft end play causes the CKP sensor reluctor
wheel to move out of alignment with the CKP sensor. This

MEFI 4
Engine Engine Controls - 8.1L 6 - 187
DTC 81 - Crankshaft Position (CKP) Sensor Circuit Fault
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

2 Does the engine start and continue to run? — Go to Step 3 Go to Step 4

Caution: Before proceeding, remove the fuses for the
ignition coil and fuel injector feed circuits in order to
prevent personal injury from engine rotation, sparks and
excessive engine fueling.
1. Turn ON the ignition leaving the engine OFF.
3 2. Disconnect the Crankshaft Position (CKP) sensor
harness connector.
3. Using a DMM connected to a known good ground,
measure the voltage at terminal “A” (Depspower) at
the CKP sensor harness.
Does the DMM display the specified value? B+ Go to Step 4 Go to Step 7

Using a DMM, measure the voltage between the CKP

sensor harness connector terminals “A” (Depspower) and
4
“B” (Depslo).
Does the DMM display the specified value? B+ Go to Step 5 Go to Step 8

Using a test lamp connected to harness connector

terminal “A” (Depspower), momentarily touch the other
5 end to terminal “C” (CKP sensor signal).
Does the fuel pump operate when the ignition voltage was
applied to the CKP sensor signal circuit? — Go to Step 10 Go to Step 6
1. Jumper terminal “A” of the CKP sensor harness
connector to terminal “A” of the CKP sensor using a
fused jumper wire.
2. Jumper terminal “B” of the CKP sensor harness
connector to terminal “B” of the CKP sensor.
6
3. Using a DMM connected to a known good ground,
probe terminal “C” (sensor signal) of the CKP sensor.
4. Hand crank the engine.
Does the voltage transition between O and more than
7 volts? — Go to Step 13 Go to Step 9
Locate and repair an open in the CKP sensor “Depspower”
7 circuit.
Was a problem found? — Verify repair Go to Step 13
Locate and repair an open or poor connection in the CKP
8 sensor “Depslo” circuit.
Was a problem found? — Verify repair Go to Step 13

MEFI 4
6 - 188 Engine Controls - 8.1L Engine
DTC 81 - Crankshaft Position (CKP) Sensor Circuit Fault (cont’d)
(Scan Diagnostics)
Step Action Value Yes No
Locate and repair an open, short to ground or short to
9 voltage in the CKP sensor signal circuit.
Was a problem found? — Verify Repair Go to Step 10
1. Remove the CKP sensor.
2. Visually inspect the CKP sensor for physical damage,
loose or improper installation or wiring routed too
10 closely to secondary ignition components.
3. Repair the circuit as necessary.
Was a problem found? — Verify Repair Go to Step 11
Inspect for poor connections at the CKP sensor.
11
Was a problem found? — Verify Repair Go to Step 12

Replace the faulty CKP sensor.

12
Is the action complete? — Verify Repair —

Replace the ECM.

13
Is the action complete? — Verify Repair —

MEFI 4
Engine Engine Controls - 8.1L 6 - 189

Camshaft
Solid Position
State (CMP)
Sensor

C B A

YEL/BLK 1868

BRN/WHT 633
RED 631

32 18 17 J2

CMP Sensor DepsLo Depspower Engine

Signal Control
Module
(ECM)

MEFI4326
6-15-00
DTC 81 - Camshaft Position (CMP) Sensor Circuit Fault
(Scan Diagnostics)
Circuit Description Diagnostic Aids
The CMP sensor works in conjunction with a 1X reluctor Check for the following conditions:
wheel on the camshaft. The Engine Control Module (ECM)
provides a 12 volt reference to the CMP sensor as well as a
• Camshaft reluctor wheel damage
low reference and a signal circuit. • The sensor coming in contact with the reluctor wheel
The CMP sensor determines whethe a cylinder is on a firing • A cracked or damaged sensor
stroke or on an exhaust stroke. As the camshaft rotates, the • Foreign material passing between the sensor and
reluctor wheel interrupts a magnetic field produced by a reluctor wheel
magnet within the sensor. The sensor’s internal circuitry If you find damage to the reluctor wheel or camshaft, refer
detects this and produces a signal which the ECM reads. to Camshaft Replacement in Engine Mechanical.
The ECM uses this 1X signal in combination with the If the condition is suspected to be intermittent, refer to
crankshaft position (CKP) sensor 24X signal in order to Intermittent Conditions.
determine crankshaft position and stroke.
Observe that as long as the ECM receives the CKP sensor Test Description
24X signal, the engine will start. The ECM can determine 2. This test determines if the conditions exist in order to set
top dead center for all cylinders by using the CKP sensor DTC 55.
24X signal alone. The CMP sensor 1X signal is used by the
ECM to determine if the cylinder at top dead center is on the
firing stroke or the exhaust stroke. The system attempts
synchronization and looks for an increase in engine speed
indicating the engine started. If the ECM does not detect an
increase in engine speed, the ECM assumes it incorrectly
synchronized to the exhaust stroke and re-syncs to the
exhaust stroke and re-syncs to the opposite cam position. A
slightly longer cranking time may be a symtpom of this
condition.

MEFI 4
6 - 190 Engine Controls - 8.1L Engine
DTC 81 - Camshaft Position (CMP) Sensor Circuit Fault
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Disconnect the Camshaft Position (CMP) sensor

harness connector.
2. Turn ON the ignition, with the engine OFF.
2 3. Using a DMM connected to a known good ground,
measure the voltage at terminal “A” (Depspower) at
the CMP sensor harness.
Does the DMM display the specified value? B+ Go to Step 3 Go to Step 5

Using a DMM, measure the voltage between the CKP

sensor harness connector terminal “A” (Depspower) and
3
terminal “B” (Depslo).
Does the DMM display the specified value? B+ Go to Step 4 Go to Step 7

1. Start the engine.

2. Monitor the CAM signal input - high to low and low to
high transition using the scan tool.
3. Using a test lamp connected to harness connector
4 terminal “A” (Depspower), momentarily touch the other
end to terminal “C” (CMP sensor signal).
Does the CAM signal input - High to Low and Low to High
transition counters increment when the test lamp contacts
the signal circuit? — Go to Step14 Go to Step 9
1. Turn OFF the engine.
2. Disconnect ECM connector J2.
3. Using a DMM, measure the resistance of the CMP
5
sensor depspower circuit between the ECM and the
CMP sensor.
Does the resistance measure with the specified range? 0-5 ohms Go to Step 6 Go to Step 11
Locate and repair a short to ground or poor connection
6 in the CMP sensor “Depspower” circuit.
Was a problem found? — Verify repair Go to Step 15
1. Turn OFF the ignition.
2. Disconnect ECM connector J2.
3. Using a DMM, measure the resistance of the CMP
7
sensor depslo circuit between the ECM and the CMP
sensor.
Does the resistance measure with the specified range? 0-5 ohms Go to Step15 Go to Step 8
Locate and repair an open or poor connection in the CMP
8 sensor “Depslo” circuit.
Is action complete? — Verify repair —

MEFI 4
Engine Engine Controls - 8.1L 6 - 191
DTC 81 - Camshaft Position (CMP) Sensor Circuit Fault (cont’d)
(Scan Diagnostics)
Step Action Value Yes No
1. Turn OFF the ignition.
2. Disconnect ECM connector J2.
3. Using a DMM, measure the resistance of the CMP
9
sensor signal circuit between the ECM and the CMP
sensor.
Does the resistance measure with the specified range? 0-5 ohms Go to Step 10 Go to Step 13
1. Turn ON the ignition, with the engine OFF.
2. Locate and repair a short to ground or a short to
10
voltage on the CMP sensor signal circuit.
Was a problem found? — Verify Repair Go to Step 15
Locate and repair an open in the CMP sensor depspower
11
circuit.
Was a problem found? — Verify Repair Go to Step15
Locate and repair an open in the CMP sensor depslo
12 circuit.
Is the action complete? — Verify Repair —
Locate and repair an open in the CMP sensor signal
13 circuit.
Is action complete? — Verify Repair —
Locate and repair a poor connection at the CMP sensor
14 harness connector.
Was a problem found? — Verify Repair Go to Step 16
Locate and repair a poor connection at the ECM
15 harness connector.
Was a problem found? — Verify Repair Go to Step17
Replace the faulty CMP sensor.
16
Is action complete? — Verify Repair —
Replace the ECM.
17
Is the action complete? — Verify Repair —

MEFI 4
6 - 192 Engine Controls - 8.1L Engine

To Fuel Pump

GRY 120
Not Used

87A 87 85 Fuel Pump

Relay

30 86

Fuse Block
A B PNK 339
From MEFI
System Relay
DK GRN/WHT 485
Fuel Pump
Relay Fuse
15A

From S104

6 J1

Fuel
Engine
Pump Control
Relay Module
Control (ECM)

MEFI4327
6-21-00
DTC 81 - Fuel Pump Relay Driver Circuit High, Low or Open
(Scan Diagnostics)
Circuit Description 3. This test can detect a partially shorted coil which would
The Engine Control Module (ECM) controls the relay by cause an excessive current flow. Leaving the circuit
grounding the control circuit via an internal switch called a energized for 2 minutes allows the coil to warm up. When
driver. The primary function of the driver is to supply the warm, the coil may open, and the current drops to 0, or
ground for the controlled component. This driver has a fault the coil may short, and the current goes above 0.75 amp.
line which the ECM monitors. When the ECM commands 5. Identify and test the relay coil terminals in order to avoid
the relay ON, the voltage of the control circuit should be low, improper diagnosis.
near 0 volts. When the ECM commands the relay OFF, the
12. If no trouble is found in the control circuit or the connection
voltage should be high, near battery voltage. If the fault
at the ECM, the ECM may be faulty. However, this is an
detection circuit senses a voltage other than what the ECM
extremely unlikely failure.
expects, the fault line stauts changes causing the DTC to
set.
The relay controls the high current flow to the fuel pump.
This allows the ECM driver to only have to control the
relatively low current used by the relay.
Diagnostic Aids
If the condition is suspected to be intermittent, refer to
Intermittent Conditions.
Test Description
2. Listen for an audible click when the relay operates.
Command both the ON and OFF states. Repeat the
commands if necessary.

MEFI 4
Engine Engine Controls - 8.1L 6 - 193
DTC 81 - Fuel Pump Relay Driver Circuit High, Low or Open
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check

1. Turn ON the ignition, with the engine OFF.

2 2. Command the relay ON and OFF using a scan tool.
Does the relay turn ON and OFF when commanded? — Go to Step 3 Go to Step 5

1. Turn OFF the ignition.

2. Disconnect the ECM connector J1.
3. Install a 5 amp fused jumper wire from a known good
ground to the control circuit at the ECM harness
connector (J1-6).
4. Turn ON the ignition, with the engine OFF.
3 Important: Replace the relay if the DMM goes to 0 during
the current draw test.
5. Using a DMM on 40 amp scale, measure the current
from the relay control circuit in the ECM harness
connector to ground for 2 minutes.
Does the current draw measure less than the specified Go to
value? 0.75 A Diagnostic Aids Go to Step 4

1. Turn OFF the ignition.

2. Disconnect the fuel pump relay connector.
4 3. Using a DMM, measure the resistance from the relay
control circuit in the ECM harness connector to ground.
Does the DMM display infinite resistance or OL? — Go to Step 12 Go to Step 10
1. Turn OFF the engine.
2. Disconnect the fuel pump relay connector.
3. Connect a test lamp between the fuel pump relay
control circuit and the fuel pump relay ignition feed
5 circuit, on the coil side of the relay, at the fuel pump
relay harness connector.
4. Turn ON the ignition, with the engine OFF.
5. Using a scan tool, command the relay ON and OFF.
Does the test lamp turn ON and OFF when commanded? — Go to Step 8 Go to Step 6
Using a test lamp connected to ground, probe the ignition
feed circuit, on the coil side of the fuel pump relay harness
6
connector.
Is the test lamp illuminated? — Go to Step 7 Go to Step 11

MEFI 4
6 - 194 Engine Controls - 8.1L Engine
DTC 81 - Fuel Pump Relay Driver Circuit High, Low or Open (cont’d)
(Scan Diagnostics)
Step Action Value Yes No
1. Turn OFF the ignition.
2. Reconnect the relay.
3. Disconnect the ECM connector J2.
4. Turn ON the ignition, with the engine OFF.
7 5. Using a fused jumper wire connected to ground,
momentarily probe the relay control circuit in the ECM
harness connector.
Does the relay turn ON when the circuit is grounded and
OFF when the circuit is opened? — Go to Step 9 Go to Step 10
Locate and repair faulty connections at the relay.
8
Was a problem found? — Verify Repair Go to Step 12
Locate and repair faulty connections at the ECM.
9
Was a problem found? — Verify Repair Go to Step 13
Repair the faulty relay control circuit.
10
Is action complete? — Verify Repair —
Repair the faulty relay ignition feed circuit.
11
Is action complete? — Verify Repair —
Replace the faulty relay.
12
Is action complete? — Verify Repair —
Replace the ECM
13
Is action complete? — Verify Repair —

MEFI 4
Engine Engine Controls - 8.1L 6 - 195

Hot in Run And Start

C Fuse Block
To ECM Term "J2-19"" To Fuel Pump
INJ/ECM Fuse
10A Relay Term. "86"
PNK 439 PNK 439
D

S104

PNK 439

S112

PNK 439 PNK 439 PNK 439 PNK 439

B B B B
Fuel Fuel Fuel Fuel
Injector Injector Injector Injector
Cylinder #1 Cylinder #4 Cylinder #6 Cylinder #7

A A A A

A C E G
S114
DK BLU 467
26 J1

Fuel
Engine
Injector
Control
Driver A Module
(ECM)

MEFI4328
6-21-00
DTC 81 - Fuel Injector Driver A Circuit High, Low or Open
(Scan Diagnostics)
Circuit Description Engine Coolant Temperature (ECT) Between 10-35
The Engine Control Module (ECM) enables the fuel injector Degrees C (50-95 Degrees F) or Fuel Injector Coil Test -
drivers. An ignition voltage is supplied to the fuel injectors. Engine Coolant Temperature (ECT) Outside 10-35
The ECM controls each fuel injector driver by grounding the Degrees C (50-95 Degrees F).
control circuit via a solid state device called a driver. The If the condition is suspected to be intermittent, refer to
ECM monitors the status of each driver. If the ECM detects Intermittent Conditions.
an incorrect voltage for the commanded state of the driver, a
fuel injector control DTC sets. Test Description
4. This step tests for voltage at the fuel injector harness
Diagnostic Aids connector. The ECM/INJ fuse supplies power to the coil
Performing the Fuel Injector Coil test may help isolate an side of the fuel injector harness connector. If the fuse is
intermittent condition. Refer to Fuel Injector Coil Test - open, a short to ground on the fuel injector B+ supply

MEFI 4
6 - 196 Engine Controls - 8.1L Engine
circuit is indicated. The ECM/INJ fuse also supplies injector. If the test lamp blinks, then the ECM and wiring
voltage to the ignition coils. If the fuse is open, inspect are OK.
the circuits to the ignition coils for a short to ground. 6. This step tests if a ground is constantly being applied to
5. This test verifies that the ECM is able to control the fuel the fuel injector.

DTC 81 - Fuel Injector Driver A Circuit High, Low or Open

(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check
1. Disconnect the appropriate harness connectors of the
four fuel injectors.
2. Turn ON the ignition, with the engine OFF.
2 3. Using a test lamp connected to a know good ground,
probe the ignition voltage circuits of each fuel injector
on the harness connector.
Does the test lamp illuminate on all four circuits? — Go to Step 3 Go to Step 8
1. Connect the fuel injector test lamp J 34730-2C
between the control circuit and the ignition voltage
circuit of the fuel injector harness connector. Repeat for
3 all four fuel injectors.
2. Start the engine.
Does the test lamp blink on all four fuel injector harness
connectors? — Go to Step 7 Go to Step 4
Does the test lamp remain illuminated at all times on any
4
of the four fuel injector harness connectors? — Go to Step 6 Go to Step 5
Locate and repair an open or short to voltage in the fuel
5 injector control circuit.
Was a problem found? — Verify Repair Go to Step 8
Locate and repair a short to ground in the fuel injector
6 control circuit.
Was a problem found? — Verify Repair Go to Step 11
Locate and repair poor connections at the harness
7 connector of the fuel injector.
Was a problem found? — Verify Repair Go to Step 10
Locate and repair poor connections at the harness
8 connector of the ECM.
Was a problem found? — Verify Repair Go to Step 11
Important: The ECM/INJ fuse also supplies voltage to the
ignition coils. If the fuse is open, inspect all related circuits
for a short to ground.
9
Repair an open or short to ground in the fuel injector
ignition voltage circuit.
Was a problem found? — Verify Repair —

MEFI 4
Engine Engine Controls - 8.1L 6 - 197
DTC 81 - Fuel Injector Driver A Circuit High, Low or Open (cont’d)
(Scan Diagnostics)
Step Action Value Yes No
Replace the fuel injector.
10 Is action complete? — Verify Repair —
Replace the ECM.
11
Is action complete? — Verify Repair —

MEFI 4
6 - 198 Engine Controls - 8.1L Engine

Hot in Run And Start

To ECM Term "J2-19"" C Fuse Block

INJ/ECM Fuse To Fuel Pump
10A Relay Term. "86"
PNK 439 PNK 439
D

S104

PNK 439

S112a

PNK 439 PNK 439 PNK 439 PNK 439

B B B B
Fuel Fuel Fuel Fuel
Injector Injector Injector Injector
Cylinder #2 Cylinder #3 Cylinder #5 Cylinder #8

A A A A

H D F B
S113
DK GRN 468
11 J1

Fuel Engine
Injector Control
Driver B Module
(ECM)

MEFI4329
6-21-00
DTC 81 - Fuel Injector Driver B Circuit High, Low or Open
(Scan Diagnostics)
Circuit Description Engine Coolant Temperature (ECT) Between 10-35
The Engine Control Module (ECM) enables the fuel injector Degrees C (50-95 Degrees F) or Fuel Injector Coil Test -
drivers. An ignition voltage is supplied to the fuel injectors. Engine Coolant Temperature (ECT) Outside 10-35
The ECM controls each fuel injector driver by grounding the Degrees C (50-95 Degrees F).
control circuit via a solid state device called a driver. The If the condition is suspected to be intermittent, refer to
ECM monitors the status of each driver. If the ECM detects Intermittent Conditions.
an incorrect voltage for the commanded state of the driver, a
fuel injector control DTC sets. Test Description
4. This step tests for voltage at the fuel injector harness
Diagnostic Aids connector. The ECM/INJ fuse supplies power to the coil
Performing the Fuel Injector Coil test may help isolate an side of the fuel injector harness connector. If the fuse is
intermittent condition. Refer to Fuel Injector Coil Test - open, a short to ground on the fuel injector B+ supply

MEFI 4
Engine Engine Controls - 8.1L 6 - 199
circuit is indicated. The ECM/INJ fuse also supplies voltage injector. If the test lamp blinks, then the ECM and wiring
to the ignition coils. If the fuse is open, inspect the circuits are OK.
to the ignition coils for a short to ground. 6. This step tests if a ground is constantly being applied to
5. This test verifies that the ECM is able to control the fuel the fuel injector.

DTC 81 - Fuel Injector Driver B Circuit High, Low or Open

(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check
1. Disconnect the appropriate harness connectors of the
four fuel injectors.
2. Turn ON the ignition, with the engine OFF.
2 3. Using a test lamp connected to a know good ground,
probe the ignition voltage circuits of each fuel injector
on the harness connector.
Does the test lamp illuminate on all four circuits? — Go to Step 3 Go to Step 8
1. Connect the fuel injector test lamp J 34730-2C
between the control circuit and the ignition voltage
circuit of the fuel injector harness connector. Repeat for
3 all four fuel injectors.
2. Start the engine.
Does the test lamp blink on all four fuel injector harness
connectors? — Go to Step 7 Go to Step 4
Does the test lamp remain illuminated at all times on any
4
of the four fuel injector harness connectors? — Go to Step 6 Go to Step 5
Locate and repair an open or short to voltage in the fuel
5 injector control circuit.
Was a problem found? — Verify Repair Go to Step 8
Locate and repair a short to ground in the fuel injector
6 control circuit.
Was a problem found? — Verify Repair Go to Step 11
Locate and repair poor connections at the harness
7 connector of the fuel injector.
Was a problem found? — Verify Repair Go to Step 10
Locate and repair poor connections at the harness
8 connector of the ECM.
Was a problem found? — Verify Repair Go to Step 11
Important: The ECM/INJ fuse also supplies voltage to the
ignition coils. If the fuse is open, inspect all related circuits
for a short to ground.
9
Repair an open or short to ground in the fuel injector
ignition voltage circuit.
Was a problem found? — Verify Repair —

MEFI 4
6 - 200 Engine Controls - 8.1L Engine
DTC 81 - Fuel Injector Driver B Circuit High, Low or Open (cont’d)
(Scan Diagnostics)
Step Action Value Yes No
Replace the fuel injector.
10 Is action complete? — Verify Repair —
Replace the ECM.
11
Is action complete? — Verify Repair —

MEFI 4
Engine Engine Controls - 8.1L 6 - 201

MEFI 4
6 - 202 Engine Controls - 8.1L Engine

Engine
Control
Module
(ECM)
5 Volt
Reference
2 J2

S100

GRY 416E
GRY 416

C
Manifold
Absolute
Pressure A
(MAP)
Sensor Throttle
B A Position(TP)
Sensor
BLK 814
B C
To ECT,IAT
S102 Sensors

DK BLU 417
LT GRN 432
BLK 814

8 3 23 J2

TP Sensor
Engine
Map Sensor
Sensor Ground Signal
Control
Signal
Module
(ECM)

MEFI4330
6-21-00

DTC 81 - 5 Volt Reference Circuit Out of Range

(Scan Diagnostics)
Circuit Description Test Description
The Engine Control Module (ECM) uses a common 5 volt 3. The 5 volt reference circuit may be shorted to another
reference circuit as a sensor feed. This circuit supplies 5 ECM circuit. The shorted circuit may not be apparent
volts to the Manifold Absolute Pressure (MAP) sensor and when the ECM harness connector is disconnected.
the Throttle Position (TP) sensor. The ECM monitors the
voltage on the 5 volt reference circuit. This DTC sets if the
voltage is out of range.
Diagnostic Aids
If the condition is suspected to be intermittent, refer to
Intermittent Conditions.

MEFI 4
Engine Engine Controls - 8.1L 6 - 203
DTC 81 - 5 Volt Reference Circuit Out of Range
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check
1. Disconnect the ECM harness connector J2.
2. Turn ON the ignition, with the engine OFF.
3. Using a DMM connected to a known good ground,
2
probe the other lead of the DMM to the 5 volt
reference circuit (J2-2) at the ECM harness connector.
Does the circuit measure more than the specified value? 5.1 V Go to Step 6 Go to Step 3
Before proceeding, remove the following fuses:
• ECM/BAT
• INJ/ECM
• MEFI System Relay
1. Disconnect the MAP sensor and the TP sensor
3 harness connectors.
2. Using a DMM, test the continuity from the 5 volt
reference circuit to all other ECM circuits at the ECM
J2 harness connector.
Do any of the circuits indicate a resistance within the
specified range? 0-2 ohms Go to Step 7 Go to Step 9
1. Turn OFF the ignition.
2. Disconnect the ECM connector J2.
4 3. Using a test lamp connected to B+, probe 5 volt
reference circuit (J2-2) at the ECM harness connector.
Does the test lamp illuminate? — Go to Step 8 Go to Step 5
Using a DMM, test the continuity from the 5 volt
reference circuit to all other ECM circuits at the ECM
5 J2 harness connector.
Do any of the circuits indicate a resistance within the
specified range? 0-2 ohms Go to Step 7 Go to Step 9
Locate and repair a short to voltage on the 5 volt
6 reference circuit.
Is action complete? — Verify Repair —
Locate and repair short between the 5 volt reference circuit
7 and the ECM circuit that had continuity.
Is action complete? — Verify Repair —
Locate and repair short to ground on the 5 volt reference
8 circuit.
Is action complete? — Verify Repair —
Replace the ECM.
9
Is action complete? — Verify Repair —

MEFI 4
6 - 204 Engine Controls - 8.1L Engine

Solid Camshaft
Crankshaft State Position
Solid Position (CMP)
State (CKP) Sensor
Sensor

A B C
C B A
RED
631 S108

S109
YEL/BLK
1868

YEL/BLK 1868 RED 631

DK BLU/WHT 1869 BRN/WHT 633

16 18 17 32 J2
CKP Sensor DepsLo Depspower CMP Sensor Engine
Signal Signal Control
Module
(ECM)

MEFI4331
6-21-00

DTC 81 - Depspower Circuit Out of Range

(Scan Diagnostics)
Circuit Description Test Description
The Engine Control Module (ECM) uses a dedicated 5 volt 3. The Depspower circuit may be shorted to another ECM
reference circuit for the Crankshaft Position (CKP) sensor circuit. The shorted circuit may not be apparent when
and the Camshaft Position (CMP) sensor.This circuit supplies the ECM harness connector is disconnected.
5 volts to only the CKP and the CMP sensor circuits. This
circuit is referred to as Depspower. The ECM monitors the
voltage on the Depspower circuit.This DTC sets if the voltage
is out of range.
Diagnostic Aids
If the condition is suspected to be intermittent, refer to
Intermittent Conditions.

MEFI 4
Engine Engine Controls - 8.1L 6 - 205
DTC 81 - Depspower Circuit Out of Range
(Scan Diagnostics)
Step Action Value Yes No
Was the “On-Board Diagnostic” (OBD) system check Go to OBD
1 performed? — Go to Step 2 System Check
1. Disconnect the ECM harness connector J2.
2. Turn ON the ignition, with the engine OFF.
3. Using a DMM connected to a known good ground,
2
probe the other lead of the DMM to the Depspower
circuit (J2-17) at the ECM harness connector.
Does the circuit measure more than the specified value? 5.1 V Go to Step 6 Go to Step 3
Before proceeding, remove the following fuses:
• ECM/BAT
• INJ/ECM
• MEFI System Relay
1. Disconnect the CKP sensor and the CMP sensor
3 harness connectors.
2. Using a DMM, test the continuity from the Depspower
circuit to all other ECM circuits at the ECM J2 harness
connector.
Do any of the circuits indicate a resistance within the
specified range? 0-2 ohms Go to Step 7 Go to Step 9
1. Turn OFF the ignition.
2. Disconnect the ECM connector J2.
4 3. Using a test lamp connected to B+, probe Depspower
circuit (J2-17) at the ECM harness connector.
Does the test lamp illuminate? — Go to Step 8 Go to Step 5
Using a DMM, test the continuity from the Depspower
circuit to all other ECM circuits at the ECM J2 harness
5 connector.
Do any of the circuits indicate a resistance within the
specified range? 0-2 ohms Go to Step 7 Go to Step 9
Locate and repair a short to voltage on the Depspower
6 circuit.
Is action complete? — Verify Repair —
Locate and repair short between the Depspower circuit
7 and the ECM circuit that had continuity.
Is action complete? — Verify Repair —
Locate and repair short to ground on the Depspower
8 circuit.
Is action complete? — Verify Repair —
Replace the ECM.
9
Is action complete? — Verify Repair —

MEFI 4
6 - 206 Engine Controls - 8.1L Engine

Symptoms - Engine Controls • All connector terminals in the problem circuit should be
carefully checked for proper contact tension.
Important Preliminary Checks Before • Poor terminal to wire connection (crimping).This requires
removing the terminal from the connector body to check.
Starting
Refer to “Wiring Harness Service” in the General
Before using this section you should have performed the “On- Information section.
Board Diagnostic (OBD) System Check” and determined that:
The vehicle may be driven with a J 39200 Digital Multimeter
• The ECM and MIL (Malfunction Indicator Lamp) are connected to a suspected circuit. An abnormal voltage when
operating correctly. malfunction occurs is a good indication that there is a fault in
• There are no DTC(s) stored. the circuit being monitored.
• Ensure that the engine is not in RPM reduction mode. A scan tool may also be used to help detect intermittent
The ECM turns certain injectors off when the ECM conditions. The Snapshot feature (if applicable) can be
detects certain conditions such as engine over-temp. triggered to capture and store engine parameters within the
• Verify the customer complaint and locate the correct scan tool when the malfunction occurs. This stored
symptom in the table of contents. Check the items information then can be reviewed by the service technician
indicated under that symptom. to see what caused the malfunction.
To check loss of DTC memory, disconnect TP sensor and
Visual/Physical Check idle engine until the MIL comes “ON.” DTC 22 should be
Several of the symptom procedures call for a careful Visual/ stored and kept in memory when ignition is turned “OFF.” If
Physical Check. The importance of this step cannot be not the ECM is faulty. When this test is completed, make
stressed too strongly - it can lead to correcting a problem sure that you clear the DTC 22 from memory using “Clearing
without further checks and can save valuable time.This check DTC Procedure.”
should include: An intermittent MIL with no stored DTC may be caused by
• ECM grounds and sensor connections for being clean, the following:
tight and in their proper location. • Ignition coil shorted to ground and arcing at ignition wires
• Vacuum hoses for splits, kinks and proper connections. or plugs.
Check thoroughly for any type of leak or restriction. • MIL wire to ECM shorted to ground.
• Air leaks at throttle body mounting area and intake • Poor ECM grounds.
manifold sealing surfaces.
• Check for an electrical system interference caused by a
• Ignition wires for cracking, hardness, proper routing and sharp electrical surge. Normally, the problem will occur
carbon tracking. when the faulty component is operated.
• Wiring for proper connections, pinches and cuts. • Check for improper installation of electrical options such
• Moisture in primary or secondary ignition circuit as lights, radios, etc.
connections. • Check that knock sensor wire(s) are routed away from
• Corrosion on electrical connections and exposed throttle spark plug wires, ignition system components and
body linkages. charging system components.
• Check for secondary ignition components shorted to
Intermittents ground, or an open ignition coil ground (coil mounting
Important: Check for improper installation of electrical brackets).
components if an intermittent condition exists. Inspect for
• Check for components internally shorted to ground such
aftermarket theft deterrent devices, lights, cellular phones,
as starters, alternators or relays.
etc. If you cannot locate an intermittent condition, a cellular
phone signal communication may cause the condition. All Ignition Coil wiring should kept away from the alternator.
Check all wires from the ECM to the ignition coils for poor
Important: Problem may or may not turn “ON” the
connections.
Malfunction Indicator Lamp (MIL) or store a DTC. DO NOT
use the Diagnostic Trouble Code (DTC) tables for intermittent If problem has not been found go to “ECM Connector
problems. The fault must be present to locate the problem. Symptom Tables” at the end of Symptoms section.
Most intermittent problems are caused by faulty electrical
connections or wiring. Perform careful visual/physical check.
Check for the following conditions:
• Poor mating of the connector halves, or a terminal not
fully seated in the connector body (backed out or loose).
• Improperly formed or damaged terminals and/or
connectors.

MEFI 4
Engine Engine Controls - 8.1L 6 - 207
Hard Start Symptom
Checks Action
Definition: Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies.
Preliminary • Refer to Important Preliminary Checks Before Starting in Symptoms -
Engine Controls.
• Check the ECM grounds for being clean, tight and in the proper locations.
• Search for bulletins.
Sensor/System • Check the engine coolant temperature (ECT) sensor for being shifted in
value. Connect a scan tool. Compare the engine coolant temperature
against the intake air temperature (IAT) on a cold engine. The ECT and
IAT sensor values should be within 3 C (5 F) of each other. If the ECT
sensor is out of range with the IAT sensor, check the resistance of the
ECT sensor. Replace the ECT sensor is the resistance is not within
specification. If the sensor is within specification, repair the ECT signal
circuit for high resistance.
• Check the camshaft position (CMP) sensor for proper mounting and/or a
bad connection. A long crank time occurs if the ECM does not receive a
CMP signal.
Fuel System • Check the fuel pump relay operation. The fuel pump should turn ON for 2
seconds when you turn ON the ignition.
• A faulty fuel pump check valve allows the fuel in the lines to drain back to
the tank after the engine stops.
• Check for incorrect fuel pressure.
• Check for a restricted fuel filter.
• Check for a contaminated fuel condition.
Ignition System • Check for proper ignition voltage output per manufacturers
recommendations.
• Remove the spark plugs and check for the following:
– Correct heat range
– Wet plugs
– Cracks
– Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Determine the cause of the fouling before replacing the spark plugs if the
spark plugs are gas, coolant or oil fouled.
• Check for bare or shorted ignition wires.
• Check for loose ignition coil grounds.
Engine Mechanical • Excessive oil in combustion chamber - Leaking valve seals.
• Low cylinder compression
• Combustion chambers for excessive carbon buildup. Clean the chambers
using top engine cleaner. Follow the instructions on the can.
• Inspect the following components for incorrect basic engine parts:
– Cylinder Heads
– Camshaft
– Pistons, etc.
Refer to the appropriate procedures in Engine Mechanical.

MEFI 4
6 - 208 Engine Controls - 8.1L Engine
Surges/Chuggles Symptom
Checks Action
Definition: Engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no
change in the accelerator pedal position.
Preliminary • Refer to Important Preliminary Checks Before Starting in Symptoms -
Engine Controls.
• Check the ECM grounds for being clean, tight and in the proper locations.
• Search for bulletins.
Sensor/System • Check the heated oxygen sensors (HO2s). The HO2s should respond
quickly to different throttle positions. If they do not, check the HO2s for
silicon or other contaminates from fuel or the use of improper RTV sealant.
The sensors may have a white powdery coating and result in a high but
false rich exhaust indication. The ECM will then reduce the amount of
fuel delivered to the engine causing a severe drivability problem.
Fuel System • Check for incorrect fuel pressure.
• Check for a restricted fuel filter.
• Check for a contaminated fuel condition.
• Check that each injector harness is connected to the correct injector or
cylinder according to the firing order.
• Check the items that cause an engine to run rich long term.
• Check the items that cause an engine to run lean long term.
Ignition System • Wet down the secondary ignition system with water from a spray bottle.
Wetting down the secondary ignition system may help locate damaged
or deteriorated components. Look and listen for arcing or misfiring as you
apply the water.
• Check for proper ignition voltage output per manufacturers
recommendations.
• Remove the spark plugs and check for the following:
– Correct heat range
– Wet plugs
– Cracks
– Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Determine the cause of the fouling before replacing the spark plugs if the
spark plugs are gas, coolant or oil fouled.
• Check for bare or shorted ignition wires.
• Check for loose ignition coil grounds.
Engine Mechanical • Ensure that the engine is not overheating, causing the engine to go into
RPM reduction mode.
Additional Checks • Visually (physically) check vacuum hoses for splits, kinks and proper
connections and routing.

MEFI 4
Engine Engine Controls - 8.1L 6 - 209
Lack of Power, Sluggishness or Sponginess Symptom
Checks Action
Definition: Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies.
Preliminary • Refer to Important Preliminary Checks Before Starting in Symptoms -
Engine Controls.
• Check the ECM grounds for being clean, tight and in the proper locations.
• Search for bulletins.
• Remove the spark arrestor/air filter element and check for dirt or for being
restricted.
Sensor/System • Ensure that the engine is not going into RPM reduction mode.
• Use a scan tool in order to monitor the knock sensor system for excessive
spark retark activity.
Fuel System • Check for incorrect fuel pressure.
• Check for a restricted fuel filter.
• Check for a contaminated fuel condition.
• Check the fuel injectors. Refer to Fuel Injector Coil Test - Engine Coolant
Temperature (ECT) Between 10-35 degrees C (50-95 Degrees F).
• Check the items that cause an engine to run rich long term.
• Check the items that cause an engine to run lean long term.
Ignition System • Wet down the secondary ignition system with water from a spray bottle.
Wetting down the secondary ignition system may help locate damaged
or deteriorated components. Look and listen for arcing or misfiring as you
apply the water.
• Check for proper ignition voltage output per manufacturers
recommendations.
• Remove the spark plugs and check for the following:
– Correct heat range
– Wet plugs
– Cracks
– Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Determine the cause of the fouling before replacing the spark plugs if the
spark plugs are gas, coolant or oil fouled.
• Check for bare or shorted ignition wires.
• Check for loose ignition coil grounds.
Engine Mechanical • Excessive oil in combustion chamber - Leaking valve seals.
• Low cylinder compression
• Combustion chambers for excessive carbon buildup. Clean the chambers
using top engine cleaner. Follow the instructions on the can.
• Inspect the following components for incorrect basic engine parts:
– Cylinder Heads
– Camshaft
– Pistons, etc.
Refer to the appropriate procedures in Engine Mechanical.
Additional Checks • Inspect the exhaust system for possible restrictions.

MEFI 4
6 - 210 Engine Controls - 8.1L Engine
Detonation/Spark Knock Symptom
Checks Action
Definition: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change
with throttle opening.
Preliminary • Refer to Important Preliminary Checks Before Starting in Symptoms -
Engine Controls.
• Check the ECM grounds for being clean, tight and in the proper locations.
• Search for bulletins.
• If the scan tool readings are normal, refer to supporting text of the Engine
Controls Diagnostic Check, and there are no engine mechanical faults,
fill the fuel tank with a known high quality fuel that meets the vehicles
minimum octane requirements. Refer to Fuel System Specifications. Road
test vehicle and re-evaluate the vehicles performance.
Fuel System • Check for incorrect fuel pressure.
• Check for a restricted fuel filter.
• Check for a contaminated fuel condition.
• Check the items that cause an engine to run lean long term.
Ignition System • Check the spark plugs for being the proper heat range.
Engine Cooling System • Check for obvious overheating problems.
– Low engine coolant
– Restricted air flow to the radiator
– Insufficient coolant flow through the radiator
– Wrong or stuck thermostat
– Inoperative cooling fan
Engine Mechanical • Excessive oil in combustion chamber - Leaking valve seals.
• Low cylinder compression
• Combustion chambers for excessive carbon buildup. Clean the chambers
using top engine cleaner. Follow the instructions on the can.
• Inspect the following components for incorrect basic engine parts:
– Cylinder Heads
– Camshaft
– Pistons, etc.
Refer to the appropriate procedures in Engine Mechanical.

MEFI 4
Engine Engine Controls - 8.1L 6 - 211
Hesitation, Sag or Stumble Symptom
Checks Action
Definition: Momentary lack of response as the accelerator is pushed down. Can occur at any vehicle speed. Usually more
pronounced when first trying to make the vehicle move, as from a stop. May cause the engine to stall if severe enough.
Preliminary • Refer to Important Preliminary Checks Before Starting in Symptoms -
Engine Controls.
• Check the ECM grounds for being clean, tight and in the proper locations.
• Search for bulletins.
Sensor/System • Check the MAP sensor operation.
• Check the TP sensor operation.
Fuel System • Check for incorrect fuel pressure.
• Check for a restricted fuel filter.
• Check for a contaminated fuel condition.
• Check the fuel injectors. Refer to Fuel Injector Coil Test - Engine Coolant
Temperature (ECT) Between 10-35 degrees C (50-95 Degrees F).
• Check the items that cause an engine to run rich long term.
• Check the items that cause an engine to run lean long term.
Ignition System • Wet down the secondary ignition system with water from a spray bottle.
Wetting down the secondary ignition system may help locate damaged
or deteriorated components. Look and listen for arcing or misfiring as you
apply the water.
• Check for proper ignition voltage output per manufacturers
recommendations.
• Remove the spark plugs and check for the following:
– Correct heat range
– Wet plugs
– Cracks
– Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Determine the cause of the fouling before replacing the spark plugs if the
spark plugs are gas, coolant or oil fouled.
• Check for bare or shorted ignition wires.
• Check for loose ignition coil grounds.
Engine Cooling System • Check the engine thermostat for proper operation and heat range.
Additional Checks • Check the alternator output voltage. Repair the charging system if the
alternator output voltage is less than 10 volts or more than 16 volts.

MEFI 4
6 - 212 Engine Controls - 8.1L Engine
Cuts Out, Misses Symptom
Checks Action
Definition: Steady pulsation or jerking that follows engine speed, usually more pronounced as engine load increases. This
condition is not normally felt above 1,500 RPM. The exhaust has a steady spitting sound at idle or low speed.
Preliminary • Refer to Important Preliminary Checks Before Starting in Symptoms -
Engine Controls.
• Check the ECM grounds for being clean, tight and in the proper locations.
• Search for bulletins.
• Remove the flame arrestor/air filter element and check for dirt or for being
restricted.
Fuel System • Check for incorrect fuel pressure.
• Check for a restricted fuel filter.
• Check for a contaminated fuel condition.
• Check the items that cause an engine to run rich long term.
• Check the items that cause an engine to run lean long term.
Sensor System • Use a scan to in order to monitor the knock sensor system for excessive
spark retard activity.
Ignition System • Wet down the secondary ignition system with water from a spray bottle.
Wetting down the secondary ignition system may help locate damaged
or deteriorated components. Look and listen for arcing or misfiring as you
apply the water.
• Check for proper ignition voltage output per manufacturers
recommendations.
• Remove the spark plugs and check for the following:
– Correct heat range
– Wet plugs
– Cracks
– Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Determine the cause of the fouling before replacing the spark plugs if the
spark plugs are gas, coolant or oil fouled.
• Check for bare or shorted ignition wires.
• Check for loose ignition coil grounds.
• Visually and physically inspect the secondary ignition for the following:
– Ignition wires arcing to ground
– Ignition wires for proper engagement to spark plug and coil
– Ignition coils for cracks or carbon tracking
Engine Mechanical • Check engine mechanical for the following:
– Low compression
– Sticking or leaking valves
– Worn camshaft lobes
– Valve timing
– Bent push rods
– Worn rocker arms
– Broken Valve Springs
– Excessive oil in the combustion chamber - Leaking valve seals.

MEFI 4
Engine Engine Controls - 8.1L 6 - 213
Cuts Out, Misses Symptom (cont’d)
Checks Action
Engine Mechanical (cont’d) • Inspect the following components for incorrect basic engine parts:
– Camshaft
– Cylinder heads
– Pistons, etc.
Refer to the appropriate procedures in Engine Mechanical.
Additional Checks • Inspect the exhaust system for possible restriction.
• Electromagnetic interference (EMI) on the reference circuit can cause an
engine miss condition. A sudden increase in indicated RPM with little
change in actual engine RPM change indicates EMI is present. Check
for high voltage components near ignition control circuits if a problem
exists.
• Check the intake manifold and the exhaust manifold passages for casting
flash.

Poor Fuel Economy Symptom

Checks Action
Definition: Fuel economy, as measured by actual fuel used, is noticeably lower than expected. Also, fuel economy is
noticeably lower than it was on this vehicle at one time, as previously shown by actual measurement.
Preliminary • Refer to Important Preliminary Checks Before Starting in Symptoms -
Engine Controls.
• Check the ECM grounds for being clean, tight and in the proper locations.
• Search for bulletins.
• Check the owners driving habits.
– Is there excessively heavy loads being carried?
– Is the acceleration rate too much, too often?
– Remove the flame arrestor/air filter element and check for dirt or for
being restricted.
Fuel System • Check the type, quality and alcohol content of the fuel. Oxygenated fuels
have lower energy and may deliver reduced fuel economy.
• Check the fuel injectors. Refer to Fuel Injector Coil Test - Engine Coolant
Temperature (ECT) Between 10-35 degrees C (50-95 Degrees F).
• Check for incorrect fuel pressure.
• Check for a restricted fuel filter.
• Check for a contaminated fuel condition.
• Check that each injector harness is connected to the correct injector and
cylinder.
• Check for foreign material accumulation in the throttle bore, coking on
the throttle valve or on the throttle shaft. Also check for throttle body
tampering.
• Check the items that cause an engine to run rich long term.
Sensor System • Check the air intake system and crankcase for air leaks.o
• Check the crankcase ventilation valve for proper operation. Place a finger
over the inlet hole in the valve end several times. The valve should snap
back. If not, replace valve.
• Use a scan tool in order to monitor the knock sensor (KS) system for
excessive spark retard activity.

MEFI 4
6 - 214 Engine Controls - 8.1L Engine
Poor Fuel Economy Symptom (cont’d)
Checks Action
Ignition System • Wet down the secondary ignition system with water from a spray bottle.
Wetting down the secondary ignition system may help locate damaged
or deteriorated components. Look and listen for arcing or misfiring as you
apply the water.
• Check for proper ignition voltage output per manufacturers
recommendations.
• Remove the spark plugs and check for the following:
– Correct heat range
– Wet plugs
– Cracks
– Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Determine the cause of the fouling before replacing the spark plugs if the
spark plugs are gas, coolant or oil fouled.
• Check for bare or shorted ignition wires.
• Check for loose ignition coil grounds.
• Visually and physically inspect the secondary ignition for the following:
– Ignition wires arcing to ground
– Ignition wires for proper engagement to spark plug and coil
– Ignition coils for cracks or carbon tracking
Engine Cooling System • Check for engine coolant level for being low.
• Check the engine thermostat for proper operation and for the correct
heat range.
Engine Mechanical • Check engine mechanical for the following:
– Low compression
– Sticking or leaking valves
– Worn camshaft lobes
– Valve timing
– Bent push rods
– Worn rocker arms
– Broken Valve Springs
– Excessive oil in the combustion chamber - Leaking valve seals.
• Inspect the following components for incorrect basic engine parts:
– Camshaft
– Cylinder heads
– Pistons, etc.
Refer to the appropriate procedures in Engine Mechanical.
Additional Checks • Inspect the exhaust system for possible restriction.
• Electromagnetic interference (EMI) on the reference circuit can cause an
engine miss condition. A sudden increase in indicated RPM with little
change in actual engine RPM change indicates EMI is present. Check
for high voltage components near ignition control circuits if a problem
exists.

MEFI 4
Engine Engine Controls - 8.1L 6 - 215
Poor Fuel Economy Symptom (cont’d)
Checks Action
Additional Checks (cont’d) • Check the intake manifold and the exhaust manifold passages for casting
flash.
• Check for excessive drag on the vehicle.

Rough, Unstable or Incorrect Idle and Stalling Symptom

Checks Action
Definition: Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM.
Either condition may be severe enough to stall the engine.
Preliminary • Refer to Important Preliminary Checks Before Starting in Symptoms -
Engine Controls.
• Check the ECM grounds for being clean, tight and in the proper locations.
• Search for bulletins.
• Remove the flame arrestor/air filter element and check for dirt or for
being restricted.
Fuel System • Check the fuel injectors. Refer to Fuel Injector Coil Test - Engine Coolant
Temperature (ECT) Between 10-35 degrees C (50-95 Degrees F).
• Check for incorrect fuel pressure.
• Check for a restricted fuel filter.
• Check for a contaminated fuel condition.
• Check that each injector harness is connected to the correct injector and
cylinder.
• Check for foreign material accumulation in the throttle bore, coking on
the throttle valve or on the throttle shaft. Also check for throttle body
tampering.
Check the items that cause an engine to run rich long term.
• Check the items that cause an engine to run lean long term.
Sensor System • Check the air intake system and crankcase for air leaks.o
• Check the crankcase ventilation valve for proper operation. Place a finger
over the inlet hole in the valve end several times. The valve should snap
back. If not, replace valve.
• Check the idle air control (IAC) valve for proper operation.
• Use a scan tool in order to monitor the knock sensor (KS) system for
excessive spark retard activity.
Ignition System • Wet down the secondary ignition system with water from a spray bottle.
Wetting down the secondary ignition system may help locate damaged
or deteriorated components. Look and listen for arcing or misfiring as you
apply the water.
• Check for proper ignition voltage output per manufacturers
recommendations.
• Remove the spark plugs and check for the following:
– Correct heat range
– Wet plugs
– Cracks
– Wear
– Improper gap

MEFI 4
6 - 216 Engine Controls - 8.1L Engine

Rough, Unstable or Incorrect Idle and Stalling Symptom (cont’d)

Checks Action
Ignition System – Burned electrodes
– Heavy deposits
• Determine the cause of the fouling before replacing the spark plugs if the
spark plugs are gas, coolant or oil fouled.
• Check for bare or shorted ignition wires.
• Check for loose ignition coil grounds.
• Visually and physically inspect the secondary ignition for the following:
– Ignition wires arcing to ground
– Ignition wires for proper engagement to spark plug and coil
– Ignition coils for cracks or carbon tracking
Engine Mechanical • Check engine mechanical for the following:
– Low compression
– Sticking or leaking valves
– Worn camshaft lobes
– Valve timing
– Bent push rods
– Worn rocker arms
– Broken Valve Springs
– Excessive oil in the combustion chamber - Leaking valve seals.
• Inspect the following components for incorrect basic engine parts:
– Camshaft
– Cylinder heads
– Pistons, etc.
Refer to the appropriate procedures in Engine Mechanical.
Additional Checks • Inspect the exhaust system for possible restriction.
• Electromagnetic interference (EMI) on the reference circuit can cause an
engine miss condition. A sudden increase in indicated RPM with little
change in actual engine RPM change indicates EMI is present. Check
for high voltage components near ignition control circuits if a problem
exists.
• Check for faulty motor mounts.
• Check the intake manifold and the exhaust manifold passages for casting
flash.
• Check for an exhaust gas recirculation (EGR) valve stuck open or EGR
pintle not seating properly. Inspect EGR valve gasket for leaks.

Dieseling, Run-On Symptom

Checks Action
Definition: Engine contiunes to run after key is turned OFF, but runs very rough. If the engine runs smooth, check the
ignition switch and the ignition switch adjustment.
Preliminary • Refer to Important Preliminary Checks Before Starting in Symptoms -
Engine Controls.
• Check the ECM grounds for being clean, tight and in the proper locations.
• Search for bulletins.
Fuel System • Inspect the injectors for a leaking condition.

MEFI 4
Engine Engine Controls - 8.1L 6 - 217
Backfire Symptom
Checks Action
Definition: Fuel ignites in the intake manifold or in the exhaust system, making a loud popping noise.
Preliminary • Refer to Important Preliminary Checks Before Starting in Symptoms -
Engine Controls.
• Check the ECM grounds for being clean, tight and in the proper locations.
• Search for bulletins.
Fuel System • Check for incorrect fuel pressure.
• Check for a restricted fuel filter.
• Check for a contaminated fuel condition.
• Check the fuel injectors. Refer to Fuel Injector Coil Test - Engine Coolant
Temperature (ECT) Between 10-35 degrees C (50-95 Degrees F).
• Check that each injector harness is connected to the correct injector and
cylinder.
Sensor System • Check the air intake system and crankcase for air leaks.
• Check the crankcase ventilation valve for proper operation. Place a finger
over the inlet hole in the valve end several times. The valve should snap
back. If not, replace the valve.
• Use a scan to in order to monitor the knock sensor system for excessive
spark retard activity.
Ignition System • Wet down the secondary ignition system with water from a spray bottle.
Wetting down the secondary ignition system may help locate damaged
or deteriorated components. Look and listen for arcing or misfiring as you
apply the water.
• Check for proper ignition voltage output per manufacturers
recommendations.
• Remove the spark plugs and check for the following:
– Correct heat range
– Wet plugs
– Cracks
– Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Determine the cause of the fouling before replacing the spark plugs if the
spark plugs are gas, coolant or oil fouled.
• Check for bare or shorted ignition wires.
• Check for loose ignition coil grounds.
• Visually and physically inspect the secondary ignition for the following:
– Ignition wires arcing to ground
– Ignition wires for proper routing
– Ignition coils for cracks or carbon tracking
Engine Cooling System • Check the engine coolant level for being low.
• Check the engine thermostat for proper operation and for the correct
heat range.

MEFI 4
6 - 218 Engine Controls - 8.1L Engine

Backfire Symptom (cont’d)

Checks Action
Engine Mechanical • Check engine mechanical for the following:
– Low compression
– Sticking or leaking valves
– Worn camshaft lobes
– Valve timing
– Bent push rods
– Worn rocker arms
– Broken Valve Springs
– Excessive oil in the combustion chamber - Leaking valve seals.
• Inspect the following components for incorrect basic engine parts:
– Camshaft
– Cylinder heads
– Pistons, etc.
Refer to the appropriate procedures in Engine Mechanical.
Additional Checks • Inspect the exhaust system for possible restriction.
• Electromagnetic interference (EMI) on the reference circuit can cause an
engine miss condition. A sudden increase in indicated RPM with little
change in actual engine RPM change indicates EMI is present. Check
for high voltage components near ignition control circuits if a problem
exists.
• Check for faulty motor mounts.
• Check the intake manifold and the exhaust manifold passages for casting
flash.
• Visually and physically check the vacuum hoses for splits, kinks and
proper connections and routing.

MEFI 4
Engine Engine Controls - 8.1L 6 - 219

Repair Instructions
Wiring Harness Service
Wiring harnesses should be replaced with proper part number
harnesses. When wires are spliced into a harness, use the
same gauge wire with high temperature insulation only.
With the low current and voltage levels found in the system,
it is important that the best possible bond be made at all wire
splices by soldering the splices as shown in Figure 1-4.
Use care when probing a connector or replacing a connector
terminal. It is possible to short between opposite terminals. If
this happens, certain components can be damaged. Always
use jumper wires with the corresponding mating terminals
between connectors for circuit checking. NEVER probe
through connector seals, wire insulation, secondary ignition
wires, boots, nipples or covers. Microscopic damage or holes
may result in water intrusion, corrosion and/or component
failure.

DRAIN WIRE

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.

3 SPLICE TWO WIRES TOGETHER USING SPLICE

3 UNTWIST CONDUCTORS. STRIP INSULATION AS
CLIPS AND ROSIN CORE SOLDER.
NECESSARY.
DRAIN WIRE

4 SPLICE WIRES USING SPLICE CLIPS AND ROSIN CORE 4 COVER SPLICE WITH TAPE TO INSULATE
SOLDER. WRAP EACH SPLICE TO INSULATE. FROM OTHER WIRES.
5 WRAP WITH MYLAR AND DRAIN (UNINSULATED) WIRE. 5 RETWIST AS BEFORE AND TAPE WITH
ELECTRICAL TAPE AND HOLD IN PLACE.

6 TAPE OVER WHOLE BUNDLE TO SECURE AS BEFORE. 8-24-94

RS 22186
Wiring Harness Repair

MEFI 4
6 - 220 Engine Controls - 8.1L Engine

Wiring Connector Service Metri-Pack Series 150 Terminals

Most connectors in the engine compartment are protected Some ECM harness connectors contain terminals called
against moisture and dirt which could create oxidation and Metri-Pack . These are used at some of the sensors and the
deposits on the terminals. This protection is important distributor connector.
because of the very low voltage and current levels found in Metri-Pack terminals are also called “Pull-To-Seat” terminals
the electronic system. The connectors have a lock which because, to install a terminal on a wire, the wire is first inserted
secures the male and female terminals together. A secondary through the seal and connector. The terminal is then crimped
lock holds the seal and terminal into the connector. on the wire, and the terminal is pulled back into the connector
When diagnosing, open circuits are often difficult to locate to seat it in place.
by sight because oxidation or terminal misalignment are To remove a terminal:
hidden by the connectors. Merely wiggling a connector on a 1. Slide the seal back on the wire.
sensor, or in the wiring harness, may locate the open circuit
2. Insert tool J 35689 or equivalent to release the terminal
condition. This should always be considered when an open
locking tang.
circuit or failed sensors is indicated. Intermittent problems
may also be caused by oxidized or loose connections. 3. Push the wire and terminal out through the connector. If
the terminal is being reused, reshape the locking tang.
Before making a connector repair, be certain of the type of
connector. Some connectors look similar but are serviced
differently. Replacement connectors and terminals are listed
in the parts catalog.

A B

1 1

3 2 4 2

1. METRI-PACK SERIES 3. TOOL J35689 OR BT-8446.

150 FEMALE TERMINAL. 4. CONNECTOR BODY.
2. LOCKING TANG. 5. SEAL. RS 22187

Metri-Pack Series 150 Terminal Removal

MEFI 4
Engine Engine Controls - 8.1L 6 - 221

Weather-Pack Connectors MALE FEMALE

CONNECTOR CONNECTOR
This figue shows a Weather-Pack connector and the tool BODY BODY
(J 28742 or equivalent) required to service it. This tool is used
to remove the pin and sleeve terminals. If terminal removal is
attempted without using the special tool required, there is a
good chance that the terminal will be bent or deformed, and
unlike standard blade type terminals, these terminals cannot
be straightened once they are bent. 1. OPEN SECONDARY LOCK HINGE ON CONNECTOR
Make certain that the connectors are properly seated and all
of the sealing rings in place when connecting leads. The
hinge-type flap provides a secondary locking feature for the
connector. It improves the connector reliability by retaining
the terminals if the small terminal lock tangs are not positioned
properly.
2. REMOVE TERMINAL USING TOOL
Weather-Pack connections cannot be replaced with standard
connections. Instructions are provided with Weather-Pack ➧ ➧ PUSH TO
RELEASE
connector and terminal packages.

TERMINAL REMOVAL TOOL

J 28742, J 38125-10 OR BT-8234-A

3. CUT WIRE IMMEDIATELY BEHIND CABLE SEAL

WIRE
SEAL

4. REPLACE TERMINAL
A. SLIP NEW SEAL ONTO WIRE
B. STRIP 5mm (.2") OF INSULATION FROM WIRE
C. CRIMP TERMINAL OVER WIRE AND SEAL

SEAL

5. PUSH TERMINAL INTO CONNECTOR

UNTIL LOCKING TANGS ENGAGE
6. CLOSE SECONDARY LOCK HINGE RS 22188

Weather-Pack Terminal Repair

MEFI 4
6 - 222 Engine Controls - 8.1L Engine

Micro-Pack 100/W Series Connectors numbered for identifying wire location.

The harness connectors used with the ECM “J1” and “J2” 10. Index cover (4) by pushing in on Tabs C with a small
connectors are Micro-Pack 100/W Series. It is used for its screwdriver.
ruggedized construction, capable of carrying more current 11. Terminals by pulling out of connector.
and provides good sealing ability. The connector is made up
12. Seal (2) from wires.
of five different parts : Strain Relief (1), Seal (2), Connector
(3), Index Cover (4) and Terminals (not shown). 13. Strain relief (1) from wires.

Remove or Disconnect Clean and Inspect

1. Negative battery cable. • Terminals for corrosion.
2. Connector from ECM by lifting up locking tab with thumb – Use spray electrical contact cleaner.
and pulling on connector body.
• Loose crimps on terminals.
Inspect • Broken wires at terminals.
Notice: For terminal replacement, refer to instructions found
• Check strain relief for being cracked or locking tab with terminal repair kit and crimper tool.
damaged.
• Check index cover for being cracked. Install or Connect
• Check seal for being torn, twisted or out of shape from 1. Align index cover (4) on connector (3) and lock into
improper installation. position. Make sure Tabs C are locked.
• Check terminals for being corroded, out of position, bent 2. Align seal (2) on connector (3) and slide all the way on.
or stretched out.
• DO NOT install strain relief (1) onto connector (3)
– Use a wire gauge .038 for checking terminal internal yet.
fit. Wire gauge should slide with smooth feel and
3. One wire with terminal installed, through strain relief (1)
not be loose.
in location that it was removed.
Notice: If you are only going to clean terminals, complete
disassembly is not necessary. Remove index cover from the • Start with the lowest numbered wire position for that
connector.
connector by pushing on Tab C on both sides and sliding off
cover. Care must be taken not to move terminals out of their 4. Terminal through seal (2), connector (3) and into index
position. The index cover locks the terminals in position. If cover (4) until it locks in place.
repair or replacement of parts is needed, DO NOT remove 5. Remaining wires one at a time per same method.
index cover at this time. • Keep wires straight.
3. With a small screwdriver, move Tabs A on strain relief • DO NOT kink wires.
(1) to unlock position.
6. Strain relief (1) onto seal (2) and connector (3).
4. Open strain relief as shown in View B.
7. Lock Tabs B into strain relief (1).
5. Release Tabs B (View C) on connector (3) by pushing
8. Plugs into strain relief (1) where there are not any wires.
inward with both thumbs or small screwdriver.
9. Fold strain relief (1) together and lock Tabs A.
6. Push Tabs B through strain relief (1) with thumbs or small
screwdriver while in released position. 10. Connector assembly to ECM.
11. Negative battery cable.
Important
• Where there are not wires in strain relief, small plugs
are installed. DO NOT lose the plugs, they are important
to help keep connector assembly sealed.
7. Remove plugs where there are not any wires.
8. Slide strain relief off of seal and back on wires.
9. Slide seal off of connector and back on wires.

Important
• To insure proper engine operation after repair of
connector assembly, wires must be in proper connector
location. Before removing index cover, note if there are
any wires of the same color. Mark these wires from the
location that they were removed. The strain relief is

MEFI 4
Engine Engine Controls - 8.1L 6 - 223

1 2 TAB C 3 4
TAB B

➤
➤

➤
➤

➤
➤

➤
TAB B TAB C

FIGURE A - EXPLODED VIEW OF CONNECTOR ASSEMBLY

1 STRAIN RELIEF 3 CONNECTOR

2 SEAL 4 INDEX COVER

TAB A
➤

TAB A

TAB A
➤

TAB B ➤ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
➤ TAB B

FIGURE B - STRAIN RELIEF CLOSED 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

FIGURE C - STRAIN RELIEF OPENED

PS 19745
Micro-Pack 100/W Series
MEFI 4
6 - 224 Engine Controls - 8.1L Engine

Engine Control Module (ECM) Replacement

Notice: When replacing the ECM, the ignition must be “OFF”
and disconnect the battery before disconnecting or
reconnecting the ECM “J1” and “J2” connectors to prevent
internal damage to the ECM.
Notice: To prevent possible electrostatic discharge damage
to the ECM, do not touch the connector pins. The ECM is an
electrical component. Do Not soak in any liquid cleaner or
J1 J2
solvent, as damage may result.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the “J1” and “J2” connectors from ECM.
3. Remove the three ECM mounting screws.
4. Remove the ECM from mounting bracket.

mefi4332

Installation Procedure
Important: Make sure the new ECM has the same part
number and service number as the old ECM, to ensure
proper engine performance.
1. Install the new ECM to the mounting bracket.
2. Install the three ECM mounting screws.
Tighten
J1 J2
Tighten the ECM to 10-14 N•m (88-124 lb in).
3. Reconnect the “J1” and “J2” connectors to the ECM.
4. Reconnect the negative battery cable.

mefi4332

System Relay Replacement

Removal Procedure
1. Turn the ignition OFF.
2. Remove the retainer.
3. Disconnect the system relay electrical connector.
4. Remove the system relay.
Important: The system relay is an electrical component.
Do Not soak in any liquid or solvent as damage may result.
Installation Procedure
1. Install the system relay.
2. Reconnect the system electrical connector.
3. Install the retainer clip.

mefi4337

MEFI 4
Engine Engine Controls - 8.1L 6 - 225
Fuel Pump Relay Replacement
Removal Procedure
1. Turn the ignition OFF.
2. Remove the retainer.
3. Disconnect the fuel pump relay electrical connector.
4. Remove the fuel pump relay.
Important: The fuel pump relay is an electrical
component. Do Not soak in any liquid or solvent as
damage may result.
Installation Procedure
1. Install the fuel pump relay.
2. Reconnect the fuel pump relay electrical connector.
3. Install the retainer clip.

mefi4337

Engine Coolant Temperature (ECT) Sensor

Replacement
Notice: Care must be taken when handling the ECT sensor.
Damage to the sensor will affect proper operation of the MEFI
system.
Remove or Disconnect
1. Turn OFF the ignition.
2. Drain the cooling system below the level of the ECT
sensor.
3. Disconnect the ECT electrical connector.
4. Remove the ECT sensor.

mefi4333

Installation Procedure
Important: Coat ECT sensor threads with teflon tape
sealant prior to installation.
1. Install the ECT sensor.
Tighten
Tighten the ECT sensor to 20 N•m (15 lb ft).
2. Reconnect the ECT electrical connector.
3. Refill the cooling system.

mefi4333

MEFI 4
6 - 226 Engine Controls - 8.1L Engine

Heated Oxygen (HO2) Sensor Replacement

Removal Procedure
Notice: The Heated Oxygen (HO2) sensor uses a
permanently attached pigtail and connector. Do not
remove this pigtail from the HO2 sensor. Damage or the
removal of the pigtail or the connector may affect the
proper operation of the sensor.
Take care when handling the HO2 sensor. Keep the
in-line electrical connector and the louvered end free of
grease, dirt or other contaminants. Also avoid using
cleaning solvents of any type. Do not drop or roughly
handle the HO2 sensor.
If the heated oxygen sensor pigtail wiring, connector or
terminal is damaged, the entire oxygen sensor assembly
must be replaced. Do not attempt to repair the wiring,
connector or terminals. In order for the sensor to function
properly, it must have provided to it a clean air reference.
This clean air reference is obtained by way of the oxygen
sensor signal and heater wires. Any attempt to repair the
wires, connectors or terminals may result in the
obstruction of the air reference and degraded sensor
performance.
The following guidelines should be used when servicing the
heated oxygen sensor:
• Do not apply contact cleaner or other materials to the
sensor or vehicle harness connectors. These materials
may get into the sensor causing poor performance.
• The sensor pigtail and harness wires must not be
damaged in such a way that the wires inside are exposed.
This could provide a path for foreign materials to enter
the sensor and cause performance problems.
• Neither the sensor or vehicle lead wires should be bent
sharply or kinked. Sharp bends, kinks, etc., could block
the reference air path through the lead wire.
• To prevent damage due to water intrusion, be sure that
the peripheral seal remains intact on the vehicle harness
connector. Under no circumstances should repairs be
soldered since this could result in the air reference being
obstructed.
The HO2 sensor may be difficult to remove when the
engine temperature is below 48° C (120°F). Excessive
force may damage the threads in the exhaust manifold or
exhaust pipe.
1. Disconnect the negative battery cable.
2. Disconnect the HO2 sensor electrical connector.
3. Remove the HO2 sensor from the exhaust.

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MEFI 4
Engine Engine Controls - 8.1L 6 - 227
Installation Procedure
Important: A special anti-seize compound is used on the
HO2 sensor threads. The compound consists of liquid
graphite and glass beads. The graphite tends to burn away,
but the glass beads remain, making the sensor easier to
remove. New, or service replacement sensors already
have the compound applied to the threads. If the sensor is
removed from an engine and if for any reason it is to be
reinstalled, the threads must have anti-seize compound
applied before reinstallation.
1. Coat threads of the HO2 sensor with anti-seize compound
GM P/N 5613695 or the equivalent if necessary.
2. Install the HO2 sensor.
Tighten
Tighten the HO2 sensor to 41 N•m (30 lb. ft.).
3. Reconnect HO2 sensor electrical connector.
4. Reconnect the negative battery cable. mefi4334

Vehicle Speed Sensor (VSS) Procedure

Removal Procedure
Important: The VSS is an electrical component. Do Not
soak it in any liquid cleaner or solvent, as damage may
result.
1. Disconnect the negative battery cable.
2. Disconnect the VSS electrical connector.
3. Remove the vehicle speed sensor.
Installation Procedure
1. Install the vehicle speed sensor.
2. Reconnect the VSS electrical connector.
3. Reconnect the negative battery cable.

MEFI 4
6 - 228 Engine Controls - 8.1L Engine
Manifold Absolute Pressure (MAP) Sensor
Replacement
Removal Procedure
1. Loosen the fastener (4) from the intake manifold sight
shield.
2. Remove the sight shield (1) from the intake manifold (3).
3. Disconnect the manifold absolute pressure (MAP) sensor
electrical connector.

684798

4. Remove the MAP sensor retaining bolt and washer (1).

5. Remove the MAP sensor (3) from the intake manifold
(2).
6. Inspect the MAP sensor seal for wear or damage and
replace as necessary.

684801

Installation Procedure
Important: Lightly coat the MAP sensor seal with rubber
lubricant part number 9985770 before installing the sensor.
The lubricant should be applied with a sponge or brush. To
prevent blockage, avoid dipping the sensor port directly
into the lubricant.
1. Install the MAP sensor (3).
2. Install the MAP sensor retaining bolt and washer (1).
Tighten
Tighten the MAP sensor retaining bolt to 12 N.m (106 lb
in).

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MEFI 4
Engine Engine Controls - 8.1L 6 - 229
3. Connect the MAP sensor electrical connetor (2).
4. Install the intake manifold sight shield (1).
Tighten
Tighten the sight shield fastener to 10 N.m (89 lb in).

684798

Flame Arrestor/Air Filter Element

Replacement
Removal Procedure
1. Loosen the flame arrestor/air filter element retaining
clamp.
2. Disconnet any hoses from the flame arrestor/air filter.
3. Remove the flame arrestor/air filter element.
Important: Inspect the flame arrestor/air filter element for
dust, dirt or water. Replace if required.
Installation Procedure
Notice: Flame arrestor/air filter element may be baffled, install
it per manufacturer’s instructions for correct air distribution.
1. Install the flame arrestor/air filter element to the throttle
body.
2. Tighten the flame arrestor retaining clamp to flame
arrestor/air filter element.
3. Reconnect any hoses to the flame arrestor/air filter
element.

MEFI 4
6 - 230 Engine Controls - 8.1L Engine

Throttle Body Assembly Replacement

Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the flame arrestor/air filter, breather hoses and
gasket (if applicable).
3. Disconnect the electrical connectors from the IAC valve
and the TP sensor.
4. Disconnect the throttle linkage and return spring(s).
5. Remove the throttle body assembly attaching nuts.
6. Remove the throttle body assembly and gasket.
7. Discard the gasket.
Important: To o prevent damage to the throttle valve, it is
essential that the unit be placed on a holding fixture before
performing service.
Notice: Stuff a rag in the intake manifold opening to prevent
mefi4335 foreign material from entering the engine.
Inspect
• Manifold bore for loose parts and foreign material.
• Manifold mating surface for cleanliness or burrs that
could affect gasket sealing.
Important: Clean the throttle bore and valve deposits
using carburetor cleaner and a parts cleaning brush. Do
Not use a cleaner that contains methyl ethyl ketone, an
extremely strong solvent, and not necessary for this type
of deposit.
The throttle body metal parts may be cleaned in a cold,
immersion type cleaner following the disassembly of the
unit.
Notice: The TP sensor and IAC valve should not come in
contact with solvent or cleaner, as they may be damaged.
These components must be removed before immersion.
Follow the procedures outlined in this section.
Caution: Safety glasses must be worn when using
compressed air, as flying dirt particles may cause
eye injury.
• Clean all metal parts thoroughly and blow dry with
compressed air. Be sure that all fuel and air passages
are free of dirt and burrs.
• Inspect the mating surfaces for damage that could affect
gasket sealing.
• Inspect throttle body for cracks in casting.
• The thread-locking compound supplied in the service
repair kit is a small vial of thread-locking compound with
directions for use. If this material is not available, use
Loctite® 262 or equivalent.
Notice: When precoating the mounting bolts, do not use a
higher strength locking compound than recommended. This
may cause the removal of the bolts to be very difficult.

MEFI 4
Engine Engine Controls - 8.1L 6 - 231
Installation Procedure
1. Install a new throttle body gasket.
2. Install the throttle body assembly and the throttle body
assembly attaching nuts.
Tighten
Tighten the throttle body assembly attaching nuts to 10
N.m (89 lb in).
3. Reconnect the throttle linkage and return spring(s).
4. Reconnect the electrical connectors to the IAC valve and
the TP sensor.
5. Install the flame arrestor/air filter, breather hoses and
gasket (if applicable).
6. Reconnect the negative battery cable.

mefi4335

Fuel Pressure Relief Procedure

Caution: To reduce the risk of fire and personal injury,
relieve fuel system pressure before servicing fuel system
components.
After relieving fuel pressure, a small amount of fuel may
be released when servicing fuel lines or connections.
To reduce the chance of personal injury, cover fuel line
fittings with a shop towel before disconnecting to catch
any fuel that may leak out. Place the towel in an approved
container when disconnection is completed.
The following is general information required when working
on the fuel system:
• Always keep a dry chemical fire extinguisher near
the work area.
• Do not replace fuel pipe with fuel hose.
• Always bleed off fuel pressure before servicing any
fuel system components.
• Do not do any repairs on the fuel system until you
have read the instructions and checked the figures
relating the repair.
• Observe all notices and cautions.
Tools Required
J 34730-1A Fuel Pressure Gauge
1. Turn the ignition OFF.
2. Disconnect the negative battery cable in order to avoid
possible fuel discharge if an accidental attempt is made
to start the engine.
3. Remove the fuel injector sight shield.

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MEFI 4
6 - 232 Engine Controls - 8.1L Engine
4. Connect the J 34730-1A fuel pressure gauge to the fuel
pressure valve. Wrap a shop towel around the fitting while
connecting the gauge in order to avoid spillage.
5. Install the bleed hose of the gauge into an approved
container.
6. Open the valve on the gauge to bleed the system
pressure.The fuel connections are now safe for servicing.
7. Drain any fuel remaining in the gauge into an approved
container.

180378

Quick Connect Fitting(s) Service (Metal

Collar)
Tools Required
J 37088-A Tool Set, Fuel Line Quick-Connect Separator
J 44581 Fuel Line Quick Connect Separator
Removal Procedure
1. Relieve the fuel system pressure before servicing any
fuel system connection. Refer to Fuel Pressure Relief
Procedure.
2. Remove the retainer from the quick-connect fitting.
Caution: Wear safety glasses in order to avoid eye
damage.
3. Blow dirt out of the fittig using compressed air.

12776

4. Choose the correct tool from the tool set for the size of
the fitting. Insert the tool into the female connector, then
push inward in order to release the locking tabs.

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MEFI 4
Engine Engine Controls - 8.1L 6 - 233
5. Pull the connection apart.
6. Use a clean shop towel in order to wipe off the male
pipe end.
7. Inspect both ends of the fitting for dirt and burrs. Clean
or replace the components as required.

12782

Installation Procedure
1. Apply a few drops of clean engine oil to the male pipe
end.

12784

2. Push both sides of the fitting together in order to snap

the retaining tabs into place.

12786

MEFI 4
6 - 234 Engine Controls - 8.1L Engine
3. Once installed, pull on both sides of the fitting in order to
make sure the connection is secure.
4. Install the retainer to the quick-connect fitting.

12787

Quick Connect Fitting(s) Service (Plastic

Collar)
Removal Procedure
1. Relieve the fuel system pressure before servicing any
fuel system connection. Refer to Fuel Pressure Relief
Procedure.
Caution: Wear safety glasses in order to avoid eye
damage.
2. Blow dirt out of the fittig using compressed air.

155410

3. Squeeze the plastic retainer release tabs.

12777

MEFI 4
Engine Engine Controls - 8.1L 6 - 235
4. Pull the connection apart.

12778

Installation Procedure
1. Apply a few drops of clean engine oil to the male pipe
end.

155425

2. Push both sides of the quick-connect fitting together in

order to cause the retaining tabs to snap into place.

21855

MEFI 4
6 - 236 Engine Controls - 8.1L Engine
3. Once installed, pull on both sides of the fitting in order to
make sure the connection is secure.

155399

In-Line Fuel Filter Replacement

Removal Procedure
1. Disconnect negative battery cable.
2. Relieve the fuel system pressure before servicing any
fuel system component. Refer to Fuel Pressure Relief
Procedure.
3. Clean all the fuel filter connections and the surrounding
areas before disconnecting the fuel pipes in order to avoid
possible contamination of the fuel system.
4. Disconnect the threaded fittings (2) from the filter.
5. Cap the fuel pipes in order to prevent possible fuel system
contamination.
6. Slide the fuel filter from the bracket (1).
7. Inspect the fuel pipe O-rings for cuts, cracks, nicks,
swelling or distortion. Replace the O-rings if necessary.
713146

Installation Procedure
1. Slide the filter into the bracket (1).
2. Remove the caps from the fuel pipes.
3. Connect the threaded fittings (2) to the fuel filter.
Tighten
Tighten the fittings to 25 N.m (18 lb ft).
4. Connect the negative battery cable.
5. Inspect for leaks.
5.1. Turn the ignition ON for 2 seconds.
5.2. Turn the ignition OFF for 10 seconds.
5.3. Turn the ignition ON.
5.4. Inspect for fuel leaks.

713146

MEFI 4
Engine Engine Controls - 8.1L 6 - 237

Fuel Pump Replacement

Removal Procedure
1. Disconnect negative battery cable.
2. Relieve the fuel system pressure before servicing any
fuel system component. Refer to Fuel Pressure Relief PUMP OUTLET
Procedure. (TO FUEL FILTER)

3. Clean all the fuel fitting connections and the surrounding

areas before disconnecting the fuel pipes in order to avoid
possible contamination of the fuel system.
4. Disconnect the threaded fittings from the fuel pump.
5. Cap the fuel pipes in order to prevent possible fuel system
contamination.
6. Disconnect the fuel pump electrical connector.
7. Remove the fuel pump. PUMP ELECTRICAL
CONNECTOR

Installation Procedure
Notice: Make sure to replace the fuel pump with the identical
part number.
1. Install the fuel pump.
2. Reconnect the fuel pump electrical connector.
3. Remove the caps from the fuel pipes.
4. Reconnect the threaded fittings into the fuel pump.
Tighten
VAPOR RETURN
Tighten the fittings to 25 N.m (18 lb ft).
5. Connect the negative battery cable.
6. Inspect for leaks.
PUMP INLET
6.1. Turn the ignition ON for 2 seconds.
6.2. Turn the ignition OFF for 10 seconds.
6.3. Turn the ignition ON.
6.4. Inspect for fuel leaks.
mefi4336

MEFI 4
6 - 238 Engine Controls - 8.1L Engine
Fuel Rail Assembly Replacement
Removal Procedure
An eight digit identification number is located on the fuel
rail assembly. Refer to this model identification number if
servicing or part replacement is required.
1. Relieve the fuel system pressure. Refer to Fuel Pressure
Relief Procedure.
2. Before removal, clean the fuel rail assembly with a spray
type engine cleaner, GM X-30A or equivalent, if
necessary. Follow the package instructions. Do not soak
fuel rails in liquid cleaning solvent.
3. Remove the engine sight shield bracket (1) nuts and
bracket.

665445

4. Disconnect the generator harness connector (1).

5. Disconnect the TP sensor harness connector (2).
6. Disconnect the IAC valve harness connector (3).
7. Remove the upper engine wiring harness bracket studs
and position the upper engine wire harness aside.

mefi4338

8. Identify the connectors to their corresponding injectors

to ensure correct injector firing order after reassembly.
9. Pull the top portion (2) of the injector connector up. Do
not pull the top portion of the connector past the top of
the white portion (1).

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MEFI 4
Engine Engine Controls - 8.1L 6 - 239
10. Push the tab (1) on the ower side of the injector connector
in order to release the connector from the injector.
11. Repeat step 9 and step 10 for each injector connector.

372753

12. Disconnect the fuel feed and return pipes (1), (2) from
the fuel rail.

300360

13. Disconnect the fuel pressure regulator vacuum line.

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MEFI 4
6 - 240 Engine Controls - 8.1L Engine
14. Remove the fuel rail attaching bolts.
15. Remove the fuel rail assembly.

665443

16. Remove the injector lower O-ring seal (4) from the spray
tip end of each injector (3).
17. Discard the O-ring seals.

351185

Installation Procedure
1. Lubricate the new lower injector O-ring seals (4) with
clean engine oil.
2. Install the new O-ring seals (4) on the spray tip end of
each injector (3).

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MEFI 4
Engine Engine Controls - 8.1L 6 - 241
3. Install the fuel rail assembly to the intake manifold.
4. Apply a 5 mm (0.020 in) band of GM P/N 12345382
threadlock or equivalent to the threads of the fuel rail
attaching bolts.
5. Install the fuel rail attaching bolts.
Tighten
Tighten the fuel rail attaching bolts to 12 N.m (106 lb in).

665443

6. Connect the fuel pressure regulator vacuum line.

665447

7. Connect the fuel feed and return pipes (1), (2) to the fuel
rail.

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MEFI 4
6 - 242 Engine Controls - 8.1L Engine
8. Connect the injector electrical connectors
• Install each connector on the proper injector in order
to ensure correct injector firing order.
• Rotate the injectors as required in order to avoid
stretching the wire harness.
9. Install the upper engine wire harness bracket.
10. Install the retainer studs to the upper engine wire
harness.
Tighten
Tighten the nut to 10 N.m (89 lb in).

mefi4338

11. Reconnect the generator harness connector (1).

12. Reconnect the TP sensor harness connector (2).
13. Reconnect the IAC valve harness connector (3).

mefi4338

14. Install the engine sight shield mounting bracket and nuts.
Tighten
Tighten the bolts 10 N.m (89 lb in).
15. Connect the negative battery cable.
16. Inspect for leaks.
16.1. Turn the ignition ON for 2 seconds.
16.2. Turn the ignition OFF for 10 seconds.
16.3. Turn the ignition ON.
16.4. Inspect for fuel leaks.
17. Install the engine sight shield.
Tighten
Tighten the bolts 10 N.m (89 lb in).

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MEFI 4
Engine Engine Controls - 8.1L 6 - 243

Fuel Pressure Regulator Replacement

Removal Procedure
1. Relieve the fuel system pressure. Refer to Fuel Pressure
Relief Procedure.
2. Disconnect the fuel pressure regulator vacuum line (1).

665447

3. Clean any dirt from the fuel pressure regulator retainer

and the surrounding area.
4. Remove the fuel pressure regulator retainer (9).
5. Remove the fuel pressure regulator (8) from the fuel
pressure regulator housing.

705539

Installation Procedure
1. Install the backup ring (10) on the fuel pressure regulator
(8).
2. Install the new large O-ring (11) on the fuel pressure
regulator.
3. Install the regulator filter (12) on the fuel pressure
regulator.
4. Install the new small O-ring (13) on the fuel pressure
regulator.
5. Lubricate the fuel pressure regulator large O-ring and
the small O-ring with clean engine oil.
6. Push the fuel pressure regulator into the regulator
housing on the fuel rail.
7. Install a new fuel pressure regulator retainer (9).

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MEFI 4
6 - 244 Engine Controls - 8.1L Engine
8. Connect the fuel pressure regulator vacuum line.
9. Connect the negative battery cable.
10. Inspect for leaks.
10.1. Turn the ignition ON for 2 seconds.
10.2. Turn the ignition OFF for 10 seconds.
10.3. Turn the ignition ON.
10.4. Inspect for fuel leaks.

665447

11. Install the engine sight shield.

665445

Fuel Injector Replacement

Removal Procedure
Important: The engine oil may be contaminated with fuel if
the fuel injectors are leaking.
1. Remove the fuel rail assembly. Refer to Fuel Rail
Assembly Replacement.
2. Remove the injector retainer clip (4).
3. Insert the fork of J 43013, the fuel injector assembly
removal tool, between the fuel rail pod and the 3
protruding retaining clip ledges. Use a prying motion while
inserting the tool in order to force the injector out of the
fuel rail pod.

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MEFI 4
Engine Engine Controls - 8.1L 6 - 245
4. Discard the injector retainer clip (1).
5. Remove the injector O-ring seals (2), (4) from both ends
of the injector. Discard the O-ring seals.

351185

Installation Procedure
Important: When ordering new fuel injectors, be sure to
order the correct injector for the application being serviced.
The fuel injector assembly (1) is stamped with a part
number identification (2). A four digit build date code (3)
indicates the month (4), day (5), year (6) and the shift (7)
that built the injector.

351196

1. Lubricate the new O-ring seals (2), (4) with clean engine
oil.
2. Install the new injector O-ring seals on the injector.
3. Install a new retainer clip (1) on the injector.

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MEFI 4
6 - 246 Engine Controls - 8.1L Engine
4. Push the fuel injector (5) into the fuel rail injector socket
with the electrical connector facing outwards.The retainer
clip (4) locks on to a flange on the fuel rail injector socket.
5. Install the fuel rail assembly. Refer to Fuel Rail Assembly
Replacement.

705539

Ignition Coil(s) Replacement

Removal Procedure
1. Disconnect the spark plug wires at the ignition coils. Refer
to Spark Plug Wire Replacement.
2. Disconnect the ignition coil harness connector.
3. Remove the ignition coil mounting bolts.
4. Remove the ignitiion coil.

703554

Installation Procedure
1. Install the ignition coil.
2. Install the ignition coil mounting bolts.
Tighten
Tighten the ignition coil mounting bolts to 12 N.m (106 lb
in).
3. Connect the ignition coil harness connector.
4. Connect the spark plug wires at the ignition coils. Refer
to Spark Plug Wire Replacement.

703554

MEFI 4
Engine Engine Controls - 8.1L 6 - 247

Spark Plug Wire Inspection • Tearing

Spark plug wire integrity is vital for proper engine • Piercing
operation. A thorough inspection will be necessary to
accurately identify conditions that may affect engine
• Arcing
operation. Inspect for the following conditions: • Carbon tracking
1. Correct routing of the spark plug wires. Incorrect • Correded terminal
routing may cause cross-firing.
If corrosion, carbon tracking or arcing are indicated on a
2. Any signs of cracks or splits in the wires. spark plug wire boot or on a terminal, replace the wire and
3. Inspect each boot for the following conditions: the component connected to the wire.

MEFI 4
6 - 248 Engine Controls - 8.1L Engine
Spark Plug Wire Replacement
Removal Procedure
1. Disconnect the spark plug wire at each spark plug.
1.1. Twist each spark plug wire 1/2 turn.
1.2. Pull only on the boot in order to remove the wire
from each spark plug.
2. Disconnect the spark plug wire from each ignition coil.
2.1. Twist each spark plug wire 1/2 turn.
2.1. Pull only on the boot in order to remove the wire
from each ignition coil.

470666

Installation Procedure
1. Install the spark plug wire at each ignition coil.
2. Install the spark plug wire at each spark plug.
3. Inspect the wires for proper installation:
3.1. Push sideways on each boot in order to inspect the
seating.
3.2. Reinstall any loose boot.

470666

Spark Plug Inspection

Spark Plug Usage
• Ensure that the correct spark plug is installed. An
incorrect spark plug causes drivability conditions.
• Ensure that the spark plug has the correct heat
range. An incorrect heat range causes the following
conditions:
– Spark plug fouling - colder plug
– Pre-ignition causing spark plug and/or engine
damage - hotter plug
Spark Plug Inspection
• Inspect the terminal post (1) for damage.
– Inspect for a bent or broken terminal post (1).
622530

MEFI 4
Engine Engine Controls - 8.1L 6 - 249

– Test for a loose terminal post (1) by twisting an

pulling the post. The terminal post (1) should NOT
move.
• Inspect the insulator (2) for flashover or carbon
tracking, soot. This is caused by the electrical
charge traveling across the insulator (2) between the
terminal post (1) and ground. Inspect for the
following conditions:

622529

– Inspect the spark plug boot for damage.

– Inspect the spark plug recess area of the cylinder
head for moisture, such as oil, coolant or water. A
spark plug boot that is saturated causes arcing to
ground.
• Inspect the insulator (2) for cracks. All or part of the
electrical charge may arc through the crack instead
of the electrodes (3,4).

622528

MEFI 4
6 - 250 Engine Controls - 8.1L Engine

• Inspect for evidence of improper arcing.

– Measure the gap between the center electrode (4)
and the side electrode (3) terminals. An
excessively wide electrode gap can prevent
correct spark plug operation.
– Inspect for the correct spark plug torque.
Insufficient torque can prevent correct spark plug
operation. An over torqued spark plug may cause
the insulator (2) to crack.
– Inspect for signs of tracking that occurred near the
insulator tip instead of the center electrode (4).
– Inspect for a broken or worn side electrode (3).
– Inspect for a broken, worn or loose center
electrode (4) by shaking the spark plug.
• A rattling sound indicates internal damage.
622527
• A loose center electrode (4) reduces the spark
intensity.
– Inspect for bridged electrodes (3, 4). Deposits on
the electrodes (3, 4) reduce or eliminates the gap.
– Inspect for worn or missing platinum pads on the
electrodes (3, 4), if equipped.
– Inspect for excessive fouling.
• Inspect the spark plug recess area of the cylinder
head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during
installation.
Spark Plug Visual Inspection
• Normal Operation - Brown to grayish-tan with small
amounts of white powdery deposits are normal
combustion by-products from fuels with additives.
• Carbon Fouled - Dry, fluffy black carbon, or soot
caused by the following condition:
– Rich fuel mixtures
• Leaking fuel injectors
• Excessive fuel pressure
• Restricted flame arrestor/air filter element
• Incorrect combustion
– Reduced ignition system voltage output
• Weak coil(s)
• Worn ignition wires
• Incorrect spark plug gap
– Excessive idling or slow speeds under light loads
can keep spark plug temperatures so low that
normal combustion deposits may not burn off.

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Engine Engine Controls - 8.1L 6 - 251

• Deposit Fouling - Oil, coolant or additives that

include substances such as silicone, very white
coating, reduces the spark intensity. Most powdery
deposits will not effect spark intensity unless they
form into a glazing over the electrode.

Spark Plug Replacement

Removal Procedure
1. Remove the spark plug wires. Refer to Spark Plug Wire
Replacement.
2. Loosen each spark plug one or two turns.
3. Brush or air blast away any dirt from around the spark
plugs.
4. Remove the spark plugs one at a time and place each
plug in a tray marked with the corresponding cylinder
numbers.

mefi4339

Installation Procedure
1. Properly position each spark plug washer.
2. Inspect each spark plug gap. Adjust each plug as
needed.
Specification
Spark plug gap: 1.524 mm (0.060 in)
3. Install the spark plugs.
Tighten
• For (IRON Head - all Subsequent Installations),
tighten the spark plugs to 20 N.m (15 lb ft).
• For new iron heads, tighten the spark plugs to 30
N.m (22 lb ft).
4. Install the spark plug wires. Refer to Spark Plug Wire
Replacement.

mefi4339

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6 - 252 Engine Controls - 8.1L Engine

Crankshaft Position (CKP) Sensor

Replacement
Removal Procedure
1. Disconnect the crankshaft position (CKP) sensor
harness connector at the CKP sensor.

674728

2. Remove the CKP sensor retaining bolt.

3. Remove the CKP sensor.

624728

Installation Procedure
Important: Inspect the CKP sensor O-ring for wear or
damage. If a problem is found, replace the O-ring.
Lubricate the new O-ring with clean engine oil before
installing.
1. Install the CKP sensor.
2. Install the CKP sensor retaining bolt.
Tighten
Tighten the bolt 10 N.m (88 lb in).
3. Connect the CKP sensor harness connector.

624728

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Engine Engine Controls - 8.1L 6 - 253

Camshaft Position (CMP) Sensor

Replacement
Removal Procedure
1. Disconnect the camshaft position (CMP) sensor harness
connector (3) from the CMP sensor (1).
2. Remove the CMP sensor retaining bolt (2).
3. Remove the CMP sensor (1).
4. Inspect the CMP sensor for wear, cracks or leakage if
the sensor is not being replaced.

690593

Installation Procedure
Important: Inspect the CMP sensor O-ring for wear or
damage. If a problem is found, replace the O-ring.
Lubricate the new O-ring with clean engine oil before
installing.
1. Install the CMP sensor (1).
2. Install the CMP sensor retaining bolt (2).
Tighten
Tighten the bolt 10 N.m (88 lb in).
3. Connect the CMP sensor harness connector (3).

690593

Knock Sensor (KS) 1 Replacement

Removal Procedure
1. Remove the wiring harness connector (1) from the knock
sensor (2).
2. Remove the knock sensor (2) from the engine block.

678815

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6 - 254 Engine Controls - 8.1L Engine
Installation Procedure
1. Install the knock sensor (2) into the engine block.
Tighten
Tighten the knock sensor to 19 N.m (14 lb ft).
2. Connect the knock sensor harness connector (1) to the
knock sensor (2).

678815

Knock Sensor (KS) 2 Replacement

Removal Procedure
1. Remove the wiring harness connector from the knock
sensor (2).
2. Remove the knock sensor (2) from the engine block (1).

20272

Installation Procedure
1. Install the knock sensor (2) into the engine block (1).
Tighten
Tighten the knock sensor to 19 N.m (14 lb ft).
2. Connect the knock sensor harness connector to the
knock sensor (2).

20272

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Engine Engine Controls - 8.1L 6 - 255

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6 - 256 Engine Controls - 8.1L Engine

Description and Operation lamp does not illuminate when connected to the circuit. In
some cases, even an ordinary shop voltmeter does not
Engine Control Module (ECM) Description give an accurate reading because the voltmeters
resistance is too low. Therefore, a DMM with a minumum
The engine control module (ECM) is designed to maintain of 10 megaohms input impedance is required to ensure
exhaust emission levels while maintaining excellent accurate voltage readings.
driveability and fuel efficiency. The ECM controls the
The ECM controls output circuits such as the fuel injectors,
following conditions:
ignition coils, the idle air control (IAC) and various relays by
• The fuel control controlling the ground or power feed circuit through
• The ignition control (IC) transistors or a device called an output driver module
(ODM).
• The knock sensor (KS) system
• The idle air control (IAC) RPM Reduction Mode
RPM reduction mode is a function of the ECM that
• The exhaust gas recirculation (EGR)
reduces engine power under certain conditions. RPM
• Various other discrete outputs reduction will disable one fuel injector driver when the
engine speed goes above a certain RPM and enable the
Engine Control Module (ECM)
fuel injector driver when the engine speed drops below a
certain RPM. RPM reduction may be active for the
following conditions:
• Engine coolant temperature too high
• Low oil pressure
• General warning 1
• General warning 2
J1 J2
ECM Function
The ECM supplies a buffered voltage to various sensors
and switches. The ECM controls most components with
electronic switches which complete a ground circuit when
turned ON.

Use of Circuit Testing Tools

Do not use a test lamp in order to diagnose the engine
electrical systems unless specifically instructed by the
mefi4332
diagnostic procedures. Use the J 35616-A connector test
The engine control module (ECM) is the control center of adapter kit whenever diagnostic procedures call for
the engine and controls the following systems: probing any connectors.
• The fuel metering system Basic Knowledge Required
• The ignition timing Without basic knowledge of electricity, it will be difficult to
• The on-board diagnostics use the diagnostic procedures contained in this section.
You should understand the basic theory of electricity and
The ECM constantly monitors the information from various
know the meaning of voltage (volts), current (amps) and
sensors and controls the systems that affect vehicle
resistance (ohms). You should understand what happens
performance and emissions. The ECM also performs the
in a circuit with an open or shorted wire. You should be
diagnostic functions for those systems. The ECM can
able to read and understand a wiring diagram.
recognize operational problems and alert the operator
through the malfunction indicator lamp (MIL) when a ECM Service Precautions
malfunction has occurred. When a malfunction is detected,
The ECM is designed to withstand normal current draws
the ECM stores a diagnostic trouble code (DTC) or a
associated with engine operation. Avoid overloading any
logged warning which helps to identify problem areas. This
circuit. When testing for opens or shorts, do not ground
is done to aid the technician in making repairs.
any of the ECM circuits unless instructed. When testing for
The ECM supplies either 5.0 or 12.0 volts to power various opens or shorts, do not apply voltage to any of the ECM
sensors and switches. This is done through resistances in circuits unless instructed. Only test these circuits with a
the ECM. The resistance is so high in value that a test DMM while the ECM connectors remain connected.

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Engine Engine Controls - 8.1L 6 - 257

Aftermarket (Add-On) Electrical And Vacuum • Component and circuit description

Equipment • Service for each sub-system
Aftermarket, add-on electrical and vacuum equipment is • Functional checks and diagnostic tables
defined as any equipment installed on a vehicle after
leaving the factory that connects to the vehicles electrical The DTCs also contain diagnostic support information
or vacuum systems. containing circuit diagrams, circuit or system information
and helpful diagnostic information.
Notice: Do not attach add-on vacuum operated equipment
to this engine. The use of add-on vacuum equipment may Visual and Physical Inspection
result in damage to engine components or systems.
Important: This visual and physical inspection is very
Notice: Connect any add-on electrically operated important. Perform this inspection carefully and thoroughly.
equipment to the vehicle’s electrical system at the battery Perform a careful visual and physical inspection when
(power and ground) in order to prevent damage to the performing any diagnostic procedure. This can often lead
vehicle. to repairing a problem without further steps. Use the
Add-on electrical equipment, even when installed to these following guidelines when performing a visual and physical
strict guidelines, may still cause the powertrain system to inspection:
malfunction. This may also include equipment not • Inspect all vacuum hoses for the following
connected to the vehicle’s electrical system such as
conditions:
portable telephones and radios. Therefore, the first step in
diagnosing any powertrain problem, is to eliminate all – Correct routing
aftermarket electrical equipment from the vehicle. After this – Pinches
is done, if the problem still exists, diagnose the problem in
the normal manner. – Cuts
– Disconnects
Electrostatic Discharge Damage
Notice: In order to prevent possible Electrostatic
• Inspect all wires in the engine compartment for the
following conditions:
Discharge damage to the ECM, Do Not touch the
connector pins. – Proper connections
Electronic components used in the control systems are – Burned or chafed spots
often designed in order to carry very low voltage.
Electronic components are susceptible to damage caused – Pinched wires
by electrostatic discharge. Less than 100 volts of static – Contact with sharp edges
electricity can cause damage to some electronic
– Contact with hot exhaust manifolds
components. There are several ways for a person to
become statically charged. The most common methods of Basic Knowledge Of Tools Required
charging are by friction and by induction. An example of
Important: Lack of basic knowledge of this powertrain
charging by friction is a person sliding across a car seat.
when performing diagnostic procedures could result in
Charging by induction occurs when a person with well
incorrect diagnosis or damage to powertrain components.
insulated shoes stands near a highly charged object and
Do not attempt to diagnose a powertrain problem without
momentarily touches ground. Charges of the same polarity
this basic knowledge.
are drained off, leaving the person highly charged with the
opposite polarity. Static charges can cause damage. A basic understanding of hand tools is necessary in order
Therefore, it is important to use care when handling and to effectively use this information.
testing electronic components.
Heated Oxygen Sensors
Engine Controls Information The main function of the heated oxygen sensor (HO2S) is
The driveability and emissions information describes the to provide the ECM with exhaust stream information in
function and operation of the engine control module order to maintain proper fueling to hold emissions within
(ECM). acceptable levels. After the sensor reaches the operating
The engine controls information contains the following: temperature, the sensor generates a voltage inversely
proportional to the amount of oxygen present in the
• Wiring diagrams exhaust gases.
• ECM terminal end views and terminal definitions The ECM uses the signal voltage from the heated oxygen
• On-Board Diagnostic (OBD) System Check sensors in order to adjust the fuel injector pulse width.
• Diagnostic Trouble Code (DTC) tables While in a Closed Loop, the ECM can adjust fuel delivery
The Component System includes the following items: in order to maintain an air fuel ratio which allows the best
combination of emission control and driveability.

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6 - 258 Engine Controls - 8.1L Engine
If the oxygen sensor pigtail wiring, connector or terminal Molded-on connectors require complete replacement of
are damaged, replace the entire oxygen sensor assembly. the connector. Splice a new connector into the harness.
Do not attempt to repair the wiring, the connector or the
terminals. In order for the sensor to function properly, the Connector and Terminals
sensor must have a clean air reference provided to it. This In order to prevent shorting between opposite terminals,
clean air reference is obtained by way of the oxygen use care when probing a connector and when replacing
sensor wires. Any attempt to repair the wires, connector or terminals. Damage to the components could result.
terminals, could result in the obstruction of the air Always use jumper wires between connectors for circuit
reference. This could also degrade oxygen sensor checking.
performance.
Never probe through Weather-Pack seals.
Input Components The J 35616-A connector test adapter kit, or the
The ECM monitors the input components for circuit equivalent, contains an assortment of flexible connectors
continuity and out-of-range values. This includes used to probe terminals during diagnosis.
performance checking. Performance checking refers to Open circuits are often difficult to locate by sight because
indicating a fault when the signal from a sensor does not oxidation or terminal misalignment are hidden by the
seem reasonable, such as a throttle position (TP) sensor connectors. Merely wiggling a connector on a sensor, or in
that indicates high throttle position at low engine loads or the wiring harness, may temporarily correct the open
MAP voltage. The input components may include, but are circuit. Oxidized or loose connections may cause
not limited to, the following sensors: intermittent problems.
• Vehicle speed sensor (VSS) Be certain of the type of connector and terminal before
making any connector or terminal repair.
• Intake air temperature (IAT) sensor
• Crankshaft position (CKP) sensor Fuel System Description
• Camshaft position (CMP) sensor Fuel System Overview
• Knock sensor (KS) The fuel tank stores the fuel supply. An electric fuel pump
pumps fuel through an in-line fuel filter to the fuel rail
• Throttle position (TP) sensor assembly. The fuel pump supplies fuel at a pressure more
• Engine coolant temperature (ECT) sensor than is needed by the injectors. The fuel pressure
regulator, part of the fuel rail assembly, keeps fuel available
• Manifold absolute pressure (MAP) sensor to the fuel injectors at a regulated pressure. A separate
pipe returns unused fuel to the fuel tank.

Output Components Fuel Pump

Diagnose the output components for the proper response The fuel pump is an electric high pressure pump. Fuel is
to ECM commands. Components where functional pumped to the fuel rail at a specified flow and pressure.
monitoring is not feasible, will be monitored for circuit Excess fuel from the fuel rail assembly returns to the fuel
continuity and out-of-range values, if applicable. tank through the fuel return pipe. The fuel pump delivers a
Output components to be monitored include, but are not constant flow of fuel to the engine even during low fuel
limited to, the following circuits: conditions and aggressive vehicle maneuvers. The engine
control module (ECM) controls the eletric fuel pump
• The vehicle speed sensor (VSS) operation through a fuel pump relay.
• The malfunction indicator lamp (MIL) control
• The check gauges lamp control
• The general warning 1 and general warning 2 lamp
controls
• The buzzer control
Wiring Harness Service
Replace the wire harnesses with the proper part number
replacement. When splicing signal wires into a harness,
use the wiring that has high temperature insulation.
Consider the low amperage and voltage levels utilized in
the engine control systems. Make the best possible bond
at all splices. Use rosin-core solder in these areas.

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Engine Engine Controls - 8.1L 6 - 259
In-Line Fuel Filter Fuel Pipe O-Rings
O-rings seal the threaded connections in the fuel system.
Fuel system O-ring seals are made of special material.
Service the O-ring seals with the correct service part.
Fuel Rail Assembly

12628
The fuel filter is located on the fuel feed pipe, between the
fuel pump and the fuel injectors. The paper filter element
(2) traps particles in the fuel that may damage the fuel
injection system. The filter housing (1) is made to
341661
withstand maximum fuel system pressure, exposure to fuel
additives and changes in temperature. The fuel rail assembly attaches to the engine intake
manifold. The fuel rail assembly performs the following
Fuel Feed and Return Pipes functions:
The fuel feed pipe carries fuel from the fuel tank to the fuel
• Positions the injectors (3) in the intake manifold
rail assembly. The fuel return pipe carries unused fuel from
the fuel rail assembly back to the fuel tank. • Distributes fuel evenly to the injectors
Nylon Fuel Pipes • Integrates the fuel pressure regulator (2) with the
fuel metering system
Nylon pipes are constructed to withstand maximum fuel
system pressure, exposure to fuel additives and changes Fuel Injectors
in temperature. There are 3 sizes of nylon pipes used: 3/8
in. ID for the fuel feed, 5/16 in. ID for the fuel return and 1/2
in. ID for the vent. Heat resistant rubber hose or corrugated
plastic conduit protect the sections of the pipes that are
exposed to chafing, high temperature or vibration.
Nylon fuel pipes are somewhat flexible and can be formed
around gradual turns. However, if nylon fuel pipes are
forced into sharp bends, the pipes kink and restrict the fuel
flow. Also, once exposed to fuel, nylon pipes may become
stiffer and are more likely to kink if bent too far. Take
special care when working on a vehicle with nylon fuel
pipes.
Quick-Connect Fittings
Quick-Connect fittings provide a simplified means of
installing and connecting fuel system components. The
fittings consists of a unique female connector and a
compatible male pipe end. O-rings, located inside the
female connector, provide the fuel seal. Integral locking
tabs inside the female connector hold the fittings together.

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6 - 260 Engine Controls - 8.1L Engine
Fuel Injectors

69059

Fuel Metering Modes of Operation

The engine control module (ECM) reads voltages from
several sensors in order to determine how much fuel to
give the engine. The fuel is delivered under one of several
conditions called modes. The ECM controls all modes.
Starting Mode
With the ignition switch in the ON position, before engaging
the starter, the ECM energizes the fuel pump relay for 2
seconds allowing the fuel pump to build up pressure. The
351198 ECM uses the engine coolant temperature (ECT), the
throttle position (TP) and the manifold absolute pressure
The Multec 2 fuel injector assembly is a solenoid operated (MAP) sensors to determine the proper air/fuel ratio for
device, controlled by the ECM, that meters pressurized starting. The ECM controls the amount of fuel delivered in
fuel to a single engine cylinder. The ECM energizes the the starting mode by changing the pulse width of the
high-impedence (12.2 ohms) injector solenoid (1) to open injectors. This is done by pulsing the injectors for very
a normally closed ball valve (2). This allows fuel to flow into short times.
the top of the injector, past the ball valve and through a
director plate (3) at the injector outlet. The director plate Clear Flood Mode
has four machined holes that control the fuel flow, If the engine floods, clear the engine by opening the
generating a spray of finely atomized fuel at the injector tip. throttle plates to 100 percent. When the throttle position
Fuel from the injector tip is directed at the intake valve, (TP) sensor is at wide open throttle, the ECM reduces the
causing it to become further atomized and vaporized injector pulse width in order to increase the air to fuel ratio.
before entering the combustion chamber. An injector stuck The ECM holds this injector rate as long as the throttle
partly open can cause a loss of pressure after engine stays wide open and the engine speed is below a
shutdown. Consequently, long engine cranking times predetermined RPM. If the throttle is not held wide open,
would be noticed on some engines. the ECM returns to the starting mode.
Fuel Pressure Regulator Assembly Run Mode
The fuel pressure regulator is a vacuum operated The run mode has 2 conditions called Open Loop and
diaphragm relief valve with fuel pump pressure on one Closed Loop. When the engine is first started and the
side and regulator spring pressure oand intake manifold engine speed is above a predetermined RPM, the system
vacuum on the other side. The fuel pressure regulator begins Open Loop operation. The ECM ignores the signal
maintains a constant pressure differential across the from the heated oxygen sensor (HO2S) and calculates the
injectors at all times. The pressure regulator compensates air/fuel ratio based on inputs from the ECT, MAP and TP
for engine load by increasing fuel pressure as the engine sensors. The system stays in Open Loop until meeting the
vacuum drops. following conditions:
• The HO2S has varying voltage output, showing that

MEFI 4
Engine Engine Controls - 8.1L 6 - 261
it is hot enough to operate properly. This depends on • The 8 ignition control (IC) circuits
the engine temperature.
• The camshaft position (CMP) sensor
• The ECT sensor is above a specified temperature.
• The camshaft reluctor wheel
• A specific amount of time has elapsed after starting
the engine.
• The crankshaft position (CKP) sensor
Specified values for the above conditions exist for each • The crankshaft reluctor wheel
different engine, and are stored in the electrically erasable • The related connecting wires
programmable read-only memory (EEPROM). The system
begins Closed Loop operation after reaching these values. • The engine control module (ECM)
In Closed Loop, the ECM calculates the air/fuel ratio Crankshaft Position (CKP) Sensor and Reluctor
(injector on-time) based upon the signal from various Wheel
sensors, but mainly from the HO2S.
Acceleration Mode
When the driver moves the accelerator, air flow into the
cylinders increases rapidly, while fuel flow tends to lag
behind. To prevent possible hesitation, the ECM incrases
the pulse width to the injectors to provide extra fuel during
acceleration. The ECM determines the amount of fuel
required based upon the throttle position, the coolant
temperature, the manifold pressure and the engine speed.
Deceleration Mode
When the driver releases the accelerator, air flow into the
engine is reduced. The ECM reads the corresponding
changes in throttle position and manifold pressure. The
ECM shuts OFF fuel completely if the deceleration is very
rapid, or for long periods.
Battery Correction Mode
When the battery voltage is low, the ECM compensates for 65872
the weak spark delivered by the ignition system in the The crankshaft position (CKP) sensor is a magneto
following ways: resistive type sensor. The CKP sensor works in
• Increasing the amount of fuel delivered conjunction with a 24X reluctor wheel. The reluctor wheel
is mounted on the rear of the crankshaft. The 24X reluctor
• Increasing the idle RPM
wheel uses 2 different width notches that are 15 degrees
• Increasing the ignition dwell time apart. This pulse width encoded pattern allows cylinder
position identification within 90 degrees of crankshaft
Fuel Cutoff Mode rotation. In some cases, this can be achieved within 45
The ECM cuts off fuel from the fuel injectors when the degrees of crankshaft rotation. The reluctor wheel also has
following conditions are met in order to protect the dual track notches that are 180 degrees out of phase. This
powertrain from damage and improve driveability: design allows for quicker starts and accuracy. The CKP
• The ignition is OFF. This prevents engine run-on. sensor also outputs a 4X signal for spark control,
tachometer output and fuel control. All CKP signals are
• The ignition is ON but there is no ignition reference output as a digital waveform.
signal. This prevents flooding or backfiring.
Camshaft Position (CMP) Sensor and Reluctor
• Engine speed is too high, above rev limit.
Wheel
Electronic Ignition (EI) System Description The camshaft position (CMP) sensor works in conjunction
with a 1X reluctor wheel mounted at the rear of the
Ignition System Overview camshaft. The CMP is used to determine the top dead
The ignition system consists of the following components center position of cylinder #1, and will synchronize with the
or circuits: 24X CKP sensor signal for quicker starting. The CMP
• The 8 ignition secondary wires signals are output as a digital waveform.

• The 8 ignition coils

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6 - 262 Engine Controls - 8.1L Engine

690593 260177

Ignition Coils The ignition voltage circuits also supply the power for the
fuel injectors. Each coil is serviced separately.
This system puts out very high ignition energy for plug
firing. Less energy is lost to ignition wire resistance
because the ignition wires are much shorter than in a
conventional ignition system.
Circuits Affecting Ignition Control
To properly control ignition timing, the ECM relies on the
following information:
• The engine load, manifold pressure or vacuum
• The atmospheric, barometric, pressure
• The engine temperature
• The intake air temperature, if applicable
• The crankshaft position
• The engine speed (RPM)
The ignition control (IC) system consists of the following
703554
components:
The ignition system on this engine features a multiple coil • The ignition coils
configuration and is known as coil near plug. There are two
styles of ignition coil assemblies (1,2). The engine could • The 24X crankshaft position sensor
have either style. The ignition coil mounting bracket is • The engine control module (ECM)
attached to the rocker cover.
• All connnecting wires
The 8 ignition coils are individually mounted above each
cylinder on the rocker covers, the coils are fired The ignition control utilizes the following to control spark
sequentially. There is an ignition control (IC) circuit for each timing functions:
ignition coil. The 8 ignition control circuits are connected to • The 24X signal - The 24X crankshaft position sensor
the ECM. The ECM triggers each ignitiion coil individually sends a signal to the ECM. The ECM uses this
and makes all timing decisions. The ignition coils are signal to determine crankshaft position.
supplied with the following circuits:
• The ignition control (IC) circuits - The ECM uses
• The ignition voltage circuit these circuits to trigger the ignition coils.
• The ignition control circuit Noteworthy Ignition Information
• The ground circuit There are important considerations to point out when
• The reference low circuit servicing the ignition system. The following noteworthy

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Engine Engine Controls - 8.1L 6 - 263
information will list some of these to help the technician in voltage range above and below the average voltage value.
servicing the ignition system. The ECM checks the KS and related wiring by comparing
• The ignition coils secondary voltage output the actual knock signal to the assigned voltage range. A
cpabilities are very high - more than 40,000 volts. normal KS signal should vary outside the assigned voltage
Avoid body contact with ignition high voltage range as shown in the NORMAL KS figure. If the ECM
secondary components when the engine is running detects a KS signal within the assigned voltage range as
or personal injury may result. shown in the ABNORMAL KS figure, the applicable DTC
will set.
• The 24X crankshaft position (CKP) sensor is the
most critical part of the ignition system. If the sensor Normal Knock Sensor Signal
is damaged so that the pulses are not generated,
the engine does not start.
• The CKP sensor clearance is very important. If the
interrupter ring is bent or damaged in any way, the
CKP sensor may be destroyed. Extrene care must
be exercised during removal and installation
procedures.
• The ignition timing is not adjustable. There are no
timing marks on the crankshaft balancer or the
timing chain cover.
• Be careful not to damage the secondary ignition
wires or boots when servicing the ignition system.
Rotate each boot in order to dislodge the boot from
the plug or coil tower before pulling the boot from the
spark plug or the ignition coil tower.
Engine Control Module (ECM)
The ECM is responsible for maintaining proper spark and 245253
fuel injection timing for all driving conditions. To provide Abnormal Knock Sensor Signal
optimum driveability and emissions, the ECM monitors
input signals from the additional following components in
calculating ignition control (IC) spark timing:
• The engine coolant temperature (ECT) sensor
• The intake air temperature (IAT) sensor
• The throttle position (TP) sensor
• The vehicle speed sensor (VSS)

Knock Sensor (KS) System Description

Purpose:
To control spark knock (detonation), a knock sensor (KS)
system is used. This system is designed to retard spark
timing when excessive spark knock is detected in the
engine. The KS system allows the engine to use maximum
spark advance for optimal driveability and fuel economy
under all operating conditions.
245257
Operation:
Legend
The ECM uses a knock sensor(s) to detect abnormal
1. Upper fail region
vibration in the engine (detonation/spark knock). Mounted
on the engine block, the knock sensor(s) produces an AC 2. Knock sensor calculated average
voltage signal at all engine speeds and loads. The ECM 3. Knock sensor signal
then adjusts the spark timing based on the amplitude and 4. Lower fail region
frequency of the KS signal. The ECM uses the KS signal to
calculate an average voltage. Then, the ECM assigns a

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6 - 264 Engine Controls - 8.1L Engine
Ignition Coils
A diagnostic trouble code (DTC) may set for the following
conditions or faults:
The ECM malfunctions in a manner which will not allow the
ECM to run a diagnostic of the KS circuit.
The KS signal is within the assigned voltage range.
The KS signal is not present.
The ECM is unable to eliminate the knocking condition
using maximum spark retard.

Exhaust Gas Recirculation (EGR) System

Description
EGR Valve

11696
Legend
1. Cap-Sensor
2. Sensor-EGR Pintle Position
3. Pole Piece-Primary
4. Bobbin and Coil Assembly
5. Sleeve-Armature
6. Valve-Pintle
7. Armature and Base Assembly
The ECM monitors the position of the EGR valve through
a feedback signal. The ECM supplies a 5.0 volt reference
and a ground to the EGR valve. A voltage signal
representing the EGR valve pintle position is sent to the
14441 ECM from the EGR valve. This feedback signal can also
be monitored on a scan tool and is the actual position of
Purpose
the EGR valve pintle. The actual EGR position should
An exhaust gas recirculation (EGR) system is used in always be near the commanded or desired EGR position.
order to lower oxides of nitrogen (NOx) emission levels.
The EGR valve is usually activated under the following
The EGR system accomplishes this by feeding small
conditions:
amounts of exhaust gas back into the combustion
chamber. High combustion temperatures cause NOx. • The engine is warm.
Combustion temperatures are reduced when the air-fuel • The engine is above the idle speed.
mixture is diluted with the exhaust gases.
Diagnosis
Operation
Too much EGR flow causes any of the following conditions
The EGR valve is designed to accurately supply exhaust to occur:
gases to the engine without the use of intake manifold
vacuum. The EGR valve controls the exhaust flow into the • The engine stalls after a cold start.
intake manifold from the exhaust manifold through an • The engine stalls during closed throttle conditions.
orfice with a engine contol module (ECM) controlled pintle.
The ECM controls the pintle position using inputs from the • The engine surges during a cruise condition.
engine coolant temperature (ECT) sensor, the throttle • A rough idle
position (TP) sensor and the manifold absolute pressure
(MAP) sensor. The ECM commands the EGR valve in
order to supply the correct amount of exhaust gas
recirculation for the current engine operating conditions.
This can be monitored on a scan tool as the Desired EGR
Position.

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Engine Engine Controls - 8.1L 6 - 265

11699
Legend
1. Linear EGR Valve
2. Exhaust Gas
3. To Cylinders
4. Pintle
Too little or no EGR flow allows the combustion
temperatures to increase. This causes the following
symptoms:
• Spark knock, detonation
• Engine overheating
• Poor fuel economy

MEFI 4
6 - 266 Engine Controls - 8.1L Engine

Special Tools and Equipment

Illustration Tool Number/Description Illustration Tool Number/Description

J 23738-A J 34730-1A
Vacuum Pump Fuel Pressure Gauge

J 26792 J 34730-405
Spark Tester Injector Test Lamp

J 28742-A J 35314-A
Weather Pack Exhaust Back Pressure
Terminal Remover Tester

J 34142-B J 35616-A
Test Lamp Connector Test Adapter
Kit

J 35689-A
J 34730-E Metri-Pack Terminal Kit
Fuel Pressure Gauge Kit

MEFI 4
Engine Engine Controls - 8.1L 6 - 267

Illustration Tool Number/Description Illustration Tool Number/Description

J 37088-A J 43013
Fuel Line Quick Connect Fuel Injector Assembly
Separator Removal Tool

6T
EJ
6T BX
EJ
BX
J 37287
Inlet and Return Fuel Scan Tool
Line Shut-Off Adapters

J 39021
Fuel Injector Coil and
Balance Tester

J 39021-380
Fuel Injector Test
Harness

J 39200
Digital Multimeter

MEFI 4