LIGHT DUTY TRUCK

FUEL, DRIVABILITY
AND EMISSIONS

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1987

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SERVICE MANUAL
This manual covers fuel Injected gas engines
(Includes 1988 C/K Models)
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 FOREWORD
This service manual replaces Section 6C and 6E for 2.5 L, 2.8 L, 4.3 L, 5.0 L, 5.7 L, and
7.4 L gasoline engines with throttle body injection and supplements the following shop
manuals:

• X-8732 10-30 Series R-V-G-P Light Duty Truck Service Manual

• X-8729 10 Series Light Duty Truck Service Manual
• X-8730 10 Series M-Van Light Duty Truck Service Manual
• X-8731 10-30 Series C-K Light Duty Truck Service Manual

This manual includes the general description of a system, diagnosis and on-vehicle
service procedures for the fuel control and emissions used on light duty truck with a
throttle body injection fuel control system.

Wiring diagrams for the above vehicles are also published in a separate “Truck Wiring
Diagram” booklet.

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This manual should be kept in a handy place for ready reference. If properly used, it will
meet the needs of technicians and vehicle owners.

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CAUTION:
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These vehicles contain some parts dimensioned in the metric system as well as in
the customary system. Some fasteners are metric and are very close in dimension to
familiar customary fasteners in the inch system. It is important to note that, during
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any vehicle maintenance procedures, replacement fasteners must have the same
measurements and strength as those removed, whether metric or customary. (Num­
bers on the heads of metric bolts and on surfaces of metric nuts indicate their
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strength. Customary bolts use radial lines for this purpose, while most customary
nuts do not have strength markings.) Mismatched or incorrect fasteners can result in
vehicle damage or malfunction, or possibly personal injury. Therefore, fasteners re­
moved from the vehicle should be saved for re-use in the same location whenever
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possible. Where the fasteners are not satisfactory for re-use, care should be taken to
select a replacement that matches the original. For information and assistance, see
your authorized dealer.
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GMC TRUCK OPERATION

TRUCK & BUS GROUP
General Motors Corporation
Pontiac, Michigan
 CAUTION:
To reduce the chance of personal injury and/or property damage, the following instructions must be
carefully observed.

Proper service and repair are important to the safety of the service technician and the safe, reliable
operation of all motor vehicles. If part replacement is necessary, the part must be replaced with one of
the same part number or with an equivalent part. Do not use a replacement part of lesser quality.

The service procedures recommended and described in this service manual are effective methods of
performing service and repair. Some of these procedures require the use of tools specially designed for
the prupose.

Accordingly, anyone who intends to use a replacement part, service procedure or tool, which is not
recommended by the vehicle manufacturer, must first determine that neither his safety nor the safe

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operation of the vehicle will be jeopardized by the replacement part, service procedure or tool selected.

It is important to note that this manual contains various Cautions and Notices that must be carefully
observed in order to reduce the risk of personal injury during service or repair, or the possibility that

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improper service or repair may damage the vehicle or render it unsafe. It is also important to
understand that these "Cautions" and "Notices" are not exhaustive, because it is impossible to warn of
all the possible hazardous consequences that might result from failure to follow these instructions.

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ACTION SYMBOL USAGE
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The general narrative writing style has been replaced in

some procedures with action symbols. To improve readability
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and to provide emphases when needed, the follow ing

symbols are used in the text.
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Remove or Disconnect Inspect

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Install or Connect

Disassemble | ^ j Tighten
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+ Assemble | 9 |Important

Clean \<f \ Adjust

 1987 TABLE OF CONTENTS SECTION

LIGHT DUTY TRUCK GENERAL INFORMATION 1

FUEL AND EMISSIONS DRIVEABILITY

«*
SYMPTOMS 2

SERVICE MANUAL COMPUTER COMMAND CONTROL 3

FOR GASOLINE ENGINES FUEL CONTROL 4

WITH EVAPORATIVE EMISSION CONTROL 5

THROTTLE BODY INJECTION IGNITION SYSTEM/EST 6

CfK,P,R,V,S,T TRUCK ELECTRONIC SPARK CONTROL 7

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AND AIR MANAGEMENT 8

M-VAN, G-VAN EXHAUST GAS RECIRCULATION 9

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AUTOMATIC TRANSMISSION
MODELS CONVERTER CLUTCH OR DOWN­
10
SHIFT CONTROL AND MANUAL

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10/1500 - 20/2500 - 30/3500 TRANSMISSION SHIFT LIGHT
SERIES ar POSITIVE CRANKCASE VENTILATION 11

THERMOSTATIC AIR CLEANER 12

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The Table of Contents on this page indicates the
sections covered in this manual. At the beginning SPECIAL TOOLS AND SPECIFICATIONS 13
of each individual section is a Table of Contents
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which gives the page number on which each major ABBREVIATIONS 14

subject begins.
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ALPHABETICAL INDEX
When reference is made in this manual to a
brand name, number, or specific tool, an equivalent
product may be used in place of the recommended
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item.
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All information, illustrations, and specifications

contained in this Manual are based on the latest
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product information available at the time of

publication approval. The right is reserved to make
changes at any time without notice.
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The 1988 C-K 10 through 30 series light duty truck

TBI fuel and emission service is included in this
service manual.

Printed in U.S.A.
1986 General Motors Corporation Sept., 1986
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He knows ar
quality parts
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make a difference
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even on
simplejobs.
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Mr. Goodwrench wants you to have the right parts for So keep that great GM feeling with genuine GM parts
your truck—whether you see him for service or whether at participating independent Mr. Goodwrench dealers
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you do the work yourself. selling Chevrolets, Pontiacs, Oldsmobiles, Buicks,

Cadillacs, GMC and Chevy Trucks.
That’s why Mr. Goodwrench wants to have a good
stock of genuine GM Parts available. Everything from
exclusive GM Goodwrench replacement engines and GM QUALITY
SERVICE PARTS
transmissions to GM Goodwrench Motor Oil that meets
O iN IR A L MOTORS CORPORATION
or exceeds all specifications for General Motors cars
or light trucks. And Mr. Goodwrench has a complete
line of GM chemicals for fine care of your GM vehicle.
Plus accessories to add convenience—
or just a little extra style.
B-05884
 GENERAL INFORMATION 1-1

SECTION 1
GENERAL INFORMATION
CONTENTS
GENERAL......................................................... 1-2 Positive Crankcase Ventilation (PCV) . . . . 1-4
DRIVEABILITY................................................ 1-2 Thermostatic Air Cleaner (THERMAC) . . . . 1-4
VISUAL/PHYSICAL UNDERHOOD INSPEC____ 1-2 Special T o o ls ................................................1-4
BASIC ELECTRIC CIRCUITS............................... 1-2 Abbreviations............................................ .1-4
EMISSIONS....................................................... 1-2 COMPONENT LOCATIONS
MAINTENANCE SCHEDULE............................. 1-2 2.5L-M S e rie s ............................................ .1-5
VEHICLE EMISSION CONTROL INFO. LABEL . . 1-2 2.5L-ST S e rie s............................................ .1-6
COMPONENT SYSTEMS................................... 1-4 2.8L-ST Se rie s..............................................1-7
Computer Command Co n tro l.................... 1-4 4.3L-CK Series..............................................1-8

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Fuel Control System ................................... 1-4 4.3L-G Series ............................................ .1-9
Evaporative Emission Control .................. 1-4 4.3L-M S e rie s ............................................ .1-10

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Ignition/Electronic Spark Timing .............. 1-4 4.3L-RV Series............................................ .1-11
Electronic Spark Control............................. 1-4 5.0L/5.7L-CK Se rie s.....................................1-12
Air Management ...................................... 1-4 5.0L/5.7L- G Series .....................................1-13
Exhaust Gas Recirculation ......................... 1-4 5.0L/5.7L-RV Series ...................................1-14

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Transmission Converter Clutch, Downshift 5.0L- P Series................................................1-15
Control and Manual Transmission Shift 7.4L-CK RV S e rie s.......................................1-16
Light Con trol.......................................... 1-4

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A LL NEW GENERAL MOTORS V EH ICLES ARE CER TIFIED BY THE UN ITED STA TES
ENVIRONMENTAL PROTECTION AGENCY AS CONFORMING TO THE REQUIREMENTS OF THE
REGULATIONS FOR THE CONTROL OF AIR POLLUTION FROM NEW MOTOR VEHICLES. THIS
CERTIFICATION IS CONTINGENT ON CERTAIN ADJUSTM ENTS BEING SET TO FACTORY
STANDARDS. IN MOST CA SES, THESE ADJUSTM EN T POINTS EITHER HAVE BEEN
PERMANENTLY SEALED AND/OR MADE INACCESSIBLE TO PREVENT INDISCRIMINATE OR
ROUTINE ADJUSTMENT IN THE FIELD. FOR THIS REASON, THE FACTORY PROCEDURE FOR
TEMPORARILY REMOVING PLUGS, CAPS, ETC., FOR PURPOSES OF SERVICING THE PRODUCT,
MUST BE STRICTLY FOLLOWED AND, WHEREVER PRACTICABLE, RETURNED TO THE
ORIGINAL INTENT OF THE DESIGN.
1-2 GENERAL INFORMATION

GENERAL BASIC ELECTRIC CIRCUITS

All engines in this manual have a Computer You should understand the basic th eo ry of
Command Control system with Electronic Control electricity, and know the meaning of voltage, amps,
Module (ECM) to control the Throttle Body Injection and ohms. You should understand what happens in a
(TBI) fuel system. The ECM varies the air/fuel ratio. circuit with an open or a shorted wire. You should be
In addition, the ECM controls the ignition timing able to read and understand a wiring diagram. A
system as well as other emission control systems such short to ground is re fe rre d to as a ground to
as the exhaust gas recirculation system. distinguish it from a short between wires.
It is important to review the emission sections and
ECM wiring diagram s for a specific engine to EMISSIONS
determine what is controlled by the ECM and what
systems are non-ECM controlled. The exhaust emission control systems used on
• This Section has a brief description of systems General Motors engines perform a specific function to
used to control fuel and emissions. lower exhaust emissions while maintaining good fuel

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• Abbreviations that are used in Driveability and economy and driveability.
Emissions are listed at the end of the manual.
• Wiring harness service information for harnesses MAINTENANCE SCHEDULE

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used with the ECM is also provided in the
Computer Command Control section. Refer to the G eneral Motors M aintenance
• Special tools used to diagnose and repair a system Schedule in Section OB of the Truck Service Manual or

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are illustrated at the end of the manual. in the glove box for the maintenance service that
should be performed to retain emission control
DRIVEABILITY performance.

The fuel and emissions driveability diagnosis

procedures apply to various systems in current GM
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LABEL
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vehicles. The procedures assume that the vehicle
worked right at one time and the problem is due to The Vehicle Emission Control Information label
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time, wear, dirt or other causes. Start with the ECM (F ig u re 1-1) c o n ta in s im p o r ta n t e m is sio n
diagnosis in Section 3 and then to Section 2 which specifications and setting procedures. In the upper
references driveability symptoms. left corner is exhaust emission information which
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identifies the year, the manufacturing division of the

VISUAL/PHYSICAL UNDERHOOD INSPECTION engine, the displacement in liters of the engine, the
class of vehicle and type of fuel metering. Also there is
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One of the most important checks that must be an illustrated emission component and vacuum hose
done as part of any diagnostic procedure is a careful schematic. This label is located in the engine
visual/physical underhood inspection. This can often compartment of every General Motors Corporation
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lead to fixing a problem without further steps. Inspect vehicle. If the label has been removed, it can be
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all vacuum hoses for correct routing, pinches, cuts, or ordered from the parts division, (WDDGM).
disconnects. Be sure to inspect hoses that are difficult
to see beneath the air cleaner, compressor, generator,
etc. Inspect all the wires in the engine compartment
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for correct and good connections, burned or chaffed

spots, pinched wires, or contact with sharp edges or
hot exhaust m anifolds. This v isu al/p h y sic a l
inspection is very im portant. It m ust be done
carefully and thoroughly.
 GENERAL INFORMATION 1-3

ENGINE AD JU STM EN T
SP ECIFICA TIO N S
AD JU STM EN T
PRO CEDURE
LA B EL CODE

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EM ISSION COM PONENT
AND VACUUM HOSE SCH EM A TIC

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"ALW AYS REFER TO THE VEHICLE EMISSION CONTROL INFORMATION LABEL
FOR THE CORRECT AND MOST CURRENT SPECIFICATIONS".
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EVAPO RATIVE EM ISSION SYSTEM

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EXHAUST EMISSION SYSTEM

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7S3236-6E

Figure 1-1 Vehicle Emission Control Information Label

1-4 GENERAL INFORMATION

COMPONENT SYSTEMS Section 8

Air Management
There are many component systems used to
control fuel and emissions. Each system is divided in This system provides additional oxygen to the
a section which includes general description of the exhaust gases to continue the combustion process.
system, diagnosis and on-vehicle service. Component This system is on all engines except the 2.5L.
locations for all series vehicles and all engines are
illustrated in Figures 1-2 through 1-13. Below is a Section 9
brief description of each component system: Exhaust Gas Recirculation (EGR)
Section 3 The EGR system uses a valve to feed a small
Computer Command Control amount of exhaust gas back into the intake manifold
to control formation of NOx. This system is used on all
This is an electronically controlled exhaust engines and is controlled by the ECM.
emission system th a t uses an electronic control
Section 10

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module (ECM) to control fuel delivery, ignition
tim in g , a ir m a n a g e m e n t and e x h a u s t gas Transmission Converter Clutch (TCC),
recirculation. It also controls the engagement of the Downshift Control and Manual

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transm ission converter clutch and the m anual Transmission Shift Light Control
transmission shift light.
The TCC is ECM controlled and is used on all
Section 4 engines with a THM 700R4 automatic transmission.

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Fuel Control System This system reduces slippage losses in the torque
convertor by coupling the engine flywheel to the
The ECM controls the air/fuel delivery to the
combustion chamber by controlling the fuel flow
through the injector(s). The ECM also controls idle
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output shaft of the transmission.
The ECM controls the downshift solenoid in the
THM 400 automatic transm ission for wide-open
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speed. The in-tank fuel pump is controlled by the throttle downshift.
ECM. When ignition is turned "ON”, the pump will The ECM controls the shift light on all engines
run for 2 seconds for most systems, then stop unless with manual transmission to indicate the best shift
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the engine is cranking or running. On some vehicles, point for maximum fuel economy.
the fuel pump will run for 20 seconds. The Fuel
Section 11
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Control system is used on all engines. The ECM may

control the A/C clutch of the com pression and Positive Crankcase Ventilation (PCV)
maintain idle speed to improve idle quality.
The PCV system passes crankcase vapors into the
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Section 5 intake manifold. This system is not controlled by the

Evaporative Emission Control ECM and is used on all engines.
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This system has a canister which stores fuel vapor Section 12

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from the fuel tank. The fuel vapor is removed from the Thermostatic Air Cleaner (THERMAC)
canister and consumed in the normal combustion
process when the engine is running. This system is The THERMAC system regulates heated air
through the air cleaner to provide uniform inlet air
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used on all engines and is not controlled by the ECM.

tem perature which gives good driveability under
Section 6 various climatic conditions. This system is not
Ignition/Electronic Spark Timing controlled by the ECM and is used on all engines.

This system is controlled by the ECM which SPECIAL TOOLS

controls ignition timing and is used on all engines.
Refer to Section 13 for special tools and equipment
Section 7 needed to diagnose the fuel control and emissions
Electronic Spark Control (ESC) systems.

This system uses a Knock Sensor in connection ABBREVIATIONS

with the ECM to control spark timing to allow the
engine to have maximum spark advance without Refer to Section 14 for abbreviations used in this
spark knock. This improves driveability and fuel manual.
economy and is used on all engines except the 2.5L &
7.4L.
 GENERAL INFORMATION 1-5

'M ' series r p o :LN 8 ENGINE CODElE 2.5L L4

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□ COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

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CONTROL SENSORS (NOT ECM CONTROLLED)

C1 Electronic Control Module (E.C.M.) A Manifold pressure (M.A.P.) N1 Crankcase vent (PCV) valve
C2 ALDL diagnostic connector B Exhaust oxygen N15 Fuel vapor canister
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C3 "SERVICE ENGINE SOON" light C Throttle position (T.P.S.)

C5 ECM harness ground D Coolant temperature
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C6 Fuse panel F Vehicle speed (V.S.S.)

C8 Fuel pump test connector T Manifold Air Temperature (M.A.T.)
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□ ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pump relay
5 Transmission Converter Clutch Connector
6 Electronic Spark Timing Distributor (E.S.T.)
8 Oil pressure switch
13 A/C relay
7S 3297
5-5-86
Figure 1-2 Component Locations - 2.5L (M Series)
1-6 GENERAL INFORMATION

'S/T' series rp o :LN 8 enginecode:E 2 .5L L4

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□ COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

CONTROL SENSORS (NOT ECM CONTROLLED)
C1 Electronic Control Module (E.C.M.) A Manifold pressure (M.A.P.) N1 Crankcase went valve (PCV)
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C2 ALDL diagnostic connector B Exhaust oxygen N17 Fuel Vapor Canister

C3 "SERVICE ENGINE SOON" light C Throttle position (T.P.S.)
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C5 ECM harness ground D Coolant temperature

C6 Fuse panel F Vehicle speed (V.S.S.)
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C8 Fuel pump test connector G Power Steering Pressure

T Manifold Air Temperature (M.A.T.)
1 ECM CONTROLLED
COMPONENTS
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1 Fuel injector
2 Idle air control
3 Fuel Pump relay
5 Transmission Converter Clutch Connector
6 Electronic Spark Timing Distributor (E.S.T.)
13 A/C relay
7S3310
5-5-86
Figure 1-3 Component Locations - 2.5L (ST Series)
 GENERAL INFORMATION 1-7

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□ COMPUTER COMMAND Q ECM INFORMATION f i EMISSION COMPONENTS

CONTROL SENSORS (NOT ECM CONTROLLED)
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C1 Electronic Control Module (E.C.M.) A Manifold Absolute Pressure (M.A.P.) N1 Crankcase vent valve (PCV)
C2 ALDL diagnostic connector B1 Exhaust oxygen (Federal) N9 Air Pump
C3 "SERVICE ENGINE SOON" light B2 Exhaust Oxygen (California) N15 Fuel Vapor Canister
C5 ECM harness ground C Throttle position (T.P.S.)
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C6 Fuse panel D Coolant temperature

C8 Fuel pump test connector F Vehicle speed (V.S.S.)
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C9 Elapsed Timer Module J Electronic Spark Control Knock (E.S.C.)

□ COMPONENTS U EGR vacuum diagnostic switch

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ECM CONTROLLED
1 Fuel injector
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2 Idle air control

3 Fuel pump relay
5 Transmission Converter Clutch Connector
6 Electronic Spark Timing Distributor (E.S.T.)
6a Remote ignition coil
7 Electronic Spark Control module (E.S.C.)
8 Oil pressure switch
9 Electric Air Control solenoid (E.A.C.)
12 Exhaust Gas Recirculation Vacuum Solenoid
7S3298
13 A/C Relay 4-23-86
Figure 1-4 Component Locations - 2.8L (ST Series)
1-8 GENERAL INFORMATION

'C/K' series rpo:LB4 e n g i n e c o d e :Z 4.3L V6

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□ COMPUTER COMMAND O ECM in f o r m a t io n ; EMISSION COMPONENTS

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CONTROL SENSORS (NOT ECM CONTROLLED)

C1 Electronic Control Module (E.C.M.) A Manifold Absolute Pressure (M.A.P.) N1 Crankcase vent valve (PCV)
C2 ALDL diagnostic connector B Exhaust oxygen N9 Air Pump
C3 "SERVICE ENGINE SOON" light C Throttle position (T.P.S.) N15 Fuel Vapor Canister
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C5 ECM harness ground D Coolant temperature

C6 Fuse panel F Vehicle speed (V.S.S.)
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C8 Fuel pump test connector J Electronic Spark Control Knock (E.S.C.)

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□ ECM CONTROLLED
COMPONENTS
1 Fuel injector
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2 Idle air control

3 Fuel pump relay
5 Transmission Converter Clutch Connector
6 Electronic Spark Timing Distributor (E.S.T.)
6a Remote ignition coil
7 Electronic Spark Control module (E.S.C.)
8 Oil pressure switch
9 Electric Air Control solenoid (E.A.C.)
12 Exhaust Gas Recirculation Vacuum Solenoid 7S3300
4-23-86

Figure 1-5 Component Locations - 4.3L (CK Series)

 GENERAL INFORMATION 1-9

' G ' series r p o :LB 4 engin e c o d e :Z 4 .3 L V 6

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□ COMPUTER COMMAND O ECM INFORMATION □ EMISSION COMPONENTS

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CONTROL SENSORS (NOT ECM CONTROLLED)

C1 Electronic Control Module (E.C.M.) A Manifold Absolute Pressure (M.A.P.) N1 Crankcase vent valve (PCV)
C2 ALDL diagnostic connector B Exhaust oxygen N9 Air Pump
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C3 "SERVICE ENGINE SOON" light c Throttle position (T.P.S.) N15 Fuel Vapor Canister
C5 ECM harness ground D Coolant temperature
C6 Fuse panel F Vehicle speed (V.S.S.)
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C8 Fuel pump test connector J Electronic Spark Control Knock (E.S.C.)

1 ECM CONTROLLED
COMPONENTS
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1 Fuel injector
2 Idle air control
3 Fuel pump relay
5 Transmission Converter Clutch Connector
6 Electronic Spark Timing Distributor (E.S.T.)
6a Remote ignition coil
7 Electronic Spark Control module (E.S.C.)
8 Oil pressure switch
9 Electric Air Control solenoid (E.A.C.) 7S3301
12 Exhaust Gas Recirculation Vacuum Solenoid 5-5-86

Figure 1-6 Component Locations - 4.3L (G Series)

1-10 GENERAL INFORMATION

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O ECM INFORMATION
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□ COMPUTER COMMAND f i EMISSION COMPONENTS

CONTROL SENSORS (NOT ECM CONTROLLED)
C1 Electronic Control Module (E.C.M.) A Manifold Absolute Pressure (M.A.P.) N1 Crankcase vent valve (PCV)
C2 ALDL diagnostic connector B Exhaust oxygen N9 Air Pump
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C3 "SERVICE ENGINE SOON" light C Throttle position (T.P.S.) N15 Fuel Vapor Canister
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C5 ECM harness ground D Coolant temperature

C6 Fuse panel F Vehicle speed (V.S.S.)
C8 Fuel pump test connector J Electronic Spark Control Knock (E.S.C.)
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□ ECM CONTROLLED
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COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pump relay
5 Transmission Converter Clutch Connector
6 Electronic Spark Timing Distributor (E.S.T.)
6a Remote ignition coil
7 Electronic Spark Control module (E.S.C.)
8 Oil pressure switch
9 Electric Air Control solenoid (E.A.C.)
12 Exhaust Gas Recirculation Vacuum Solenoid

Figure 1-7 Component Locations - 4.3L (M Series)

 GENERAL INFORMATION 1-11

'R/V' SERIES rpo :LB4 ENGINE CODE:Z 4.3L V6

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□ COMPUTER COMMAND O ECM INFORMATION "" EMISSION COMPONENTS

CONTROL SENSORS (NOT ECM CONTROLLED)
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C1 Electronic Control Module (E.C.M.) A Manifold Absolute Pressure (M.A.P.) N1 Crankcase vent vaIve (PCV)
C2 ALOL diagnostic connector B Exhaust oxygen N9 Air Pump
C3 "SERVICE ENGINE SOON" light C Throttle position (T.P.S.) N15 Fuel Vapor Canister
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C5 ECM harness ground D Coolant temperature

C6 Fuse panel F Vehicle speed (V.S.S.)
C8 Fuel pump test connector J Electronic Spark Control Knock (E.S.C.)
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] ECM CONTROLLED
COMPONENTS
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1 Fuel injector
2 Idle air control
3 Fuel pump relay
5 Transmission Converter Clutch Connector
6 Electronic Spark Timing Distributor (E.S.T.)
6a Remote ignition coil
7 Electronic Spark Control module (E.S.C.)
8 Oil pressure switch
9 Electric Air Control solenoid (E.A.C.) 7 S 3302
12 Exhaust Gas Recirculation Vacuum Solenoid 4-14-86

Figure 1-8 Component Locations - 4.3L (RV Series)

1-12 GENERAL INFORMATION

'C/K' s e r ie s rpo:L03/L05 e n g in e c o d e : H/K 5.0/5.7L V8

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□ COMPUTER COMMAND Q ECM INFORMATION f"i EMISSION COMPONENTS

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CONTROL SENSORS (NOT ECM CONTROLLED)

C1 Electronic Control Module (E.C.M.) A Manifold Absolute Pressure (M.A.P.) N1 Crankcase vent valve (PCV)
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C2 ALDL diagnostic connector B Exhaust oxygen N2 Fuel Module (5.7L H.D. only)
C3 "SERVICE ENGINE SOON" light C Throttle position (T.P.S.) N3 Downshift Relay (THM 400 only)
C5 ECM harness ground D Coolant temperature N9 Air Pump
C6 Fuse panel F Vehicle speed (V.S.S.) N15 Fuel Vapor Canister
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C8 Fuel pump test connector J Electronic Spark Control Knock (E.S.C.)

□ COMPONENTS
ECM CONTROLLED
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1 Fuel injector
2 Idle air control
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3 Fuel pump relay

5 Transmission Converter Clutch Connector
6 Electronic Spark Timing Distributor (E.S.T.)
6a Remote ignition coil
7 Electronic Spai'k Control module (E.S.C.)
8 Oil pressure switch
9 Electric Air Control solenoid (E.A.C.) 7 S 3303
12 Exhaust Gas Recirculation Vacuum Solenoid 7-24-86

Figure 1-9 - Component Locations - 5.0L/5.7L (CK Series)

 GENERAL INFORMATION 1-13

'G ' s e r ie s rpo:L03/L05 e n g in e c o d e :H /K 5.0/5.7L V 8

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EMISSION COMPONENTS
CONTROL SENSORS (NOT ECM CONTROLL
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C1 Electronic Control Module (E.C.M.) A Manifold Absolute Pressure (M.A.P.) N1 Crankcase vent valve (PCV)
C2 ALDL diagnostic connector B Exhaust oxygen N2 Fuel Module
C3 "SERVICE ENGINE SOON" light C Throttle position (T.P.S.) N3 Downshift Relay (THM 400 only)
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C5 ECM harness ground D Coolant temperature N9 Air Pump

C6 Fuse panel F Vehicle speed (V.S.S.) N15 Fuel Vapor Canister
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C8 Fuel pump test connector J Electronic Spark Control Knock (E.S.C.)

] ECM CONTROLLED
COMPONENTS
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1 Fuel injector
2 Idle air control
3 Fuel pump relay
5 Transmission Converter Clutch Connector
6 Electronic Spark Timing Distributor (E.S.T.)
6a Remote ignition coil
7 Electronic Spark Control module (E.S.C.)
8 Oil pressure switch
9 Electric Air Control solenoid (E.A.C.) 7S 3304
12 Exhaust Gas Recirculation Vacuum Solenoid 7-24-86

Figure 1-10 - Component Locations - 5.0L/5.7L (G Series)

1-14 GENERAL INFORMATION

'R/V' s e r ie s rpo:L03/L05 e n g in e c o d e : H/K 5.0/5. 7L V8

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□ COMPUTER COMMAND O ECM INFORMATION n EMISSION COMPONENTS

CONTROL SENSORS (NOT ECM CONTROLLED)
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C1 Electronic Control Module (E.C.M.) A Manifold Absolute Pressure (M.A.P.) N1 Crankcase vent valve (PCV)
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C2 ALDL diagnostic connector B Exhaust oxygen N2 Fuel Module (5.7L H.D. only)
C3 "SERVICE ENGINE SOON" light C Throttle position (T.P.S.) N9 Air Pump
C5 ECM harness ground D Coolant temperature N15 Fuel Vapor Canister
C6 Fuse panel F Vehicle speed (V.S.S.)
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C8 Fuel pump test connector J Electronic Spark Control Knock (E.S.C.)

ECM CONTROLLED
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□
COMPONENTS
1 Fuel injector
2 Idle air control
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3 Fuel pump relay

5 Transmission Converter Clutch Connector
6 Electronic Spark Timing Distributor (E.S.T.)
6a Remote ignition coil
7 Electronic Spark Control module (E.S.C.)
8 Oil pressure switch
9 Electric Air Control solenoid (E.A.C.) * 7S3305
12 Exhaust Gas Recirculation Vacuum Solenoid 7-25-86
Figure 1-11- Component Locations - 5.0L/5.7L (RV Series)
 GENERAL INFORMATION 1-15

'P' SERIES r po :L05 ENGINE CODE:K 5.7L V8

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□ COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

CONTROL SENSORS (NOT ECM CONTROLLED)
C1 Electronic Control Module (E.C.M.) A Manifold Absolute Pressure (M.A.P.) N1 Crankcase vent valve (PCV)
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C2 ALDL diagnostic connector B Exhaust oxygen N3 Downshift Relay (THM 400 Only)
C3 "SERVICE ENGINE SOON" light C Throttle position (T.P.S.) N9 Air Pump
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C5 ECM harness ground D Coolant temperature N15 Fuel Vapor Canister

C6 Fuse panel F Vehicle speed (V.S.S.)
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C8 Fuel pump test connector J Electronic Spark Control Knock (E.S.C.)

□ ECM CONTROLLED
COMPONENTS
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1 Fuel injector
2 Idle air control
3 Fuel pump relay
5 Transmission Converter Clutch Connector
6 Electronic Spark Timing Distributor (E.S.T.)
6a Remote ignition coil
7 Electronic Spark Control module (E.S.C.)
8 Oil pressure switch
9 Electric Air Control solenoid (E.A.C.)
7S 3307-6E
12 Exhaust Gas Recirculation Vacuum Solenoid
5-5-86
Figure 1-12 Component Locations - 5.7L (P Series)
1-16 GENERAL INFORMATION

'C/K & RV' series rpo:L19 e n g i n e c o d e :N 7.4L V8

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O ECM INFORMATION
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□ COMPUTER COMMAND EMISSION COMPONENTS

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CONTROL SENSORS (NOT ECM CONTROLLED)

C1 Electronic Control Module (E.C.M.) A Manifold Absolute Pressure (M.A.P.) N1 Crankcase vent valve (PCV)
C2 ALDL diagnostic connector B Exhaust oxygen N2 Fuel Module
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C3 "SERVICE ENGINE SOON" light C Throttle position (T.P.S.) N3 Downshift Relay (THM 400 only)
C5 ECM harness ground D Coolant temperature N9 Air Pump
C6 Fuse panel F Vehicle speed (V.S.S.) N15 Fuel Vapor Canister
s

C8 Fuel pump test connector

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□ ECM CONTROLLED
COMPONENTS
1 Fuel injector
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2 Idle air control

3 Fuel pump relay
6 Electronic Spark Timing Distributor (E.S.T.)
6a Remote ignition coil
8 Oil pressure switch
9 Electric Air Control solenoid (E.A.C.)
12 Exhaust Gas Recirculation Vacuum Solenoid 7S3306
7-24-86

Figure 1-13- Component Locations - 7.4L (CK & RV Series)

 DRIVEABILITY SYMPTOMS 2-1

SECTION 2
DRIVEABILITY SYMPTOMS
TABLE OF CONTENTS
Before Startin g ................................................................................................................................... Page 2-1
Poor Fuel Econom y............................................................................................................................. Page 2-1
ECM Intermittent Codes or Perform ance.......................................................................................... Page 2-2
Dieseling, Run-O n............................................................................................................................... Page 2-2
Backfire................................................................................................................................................ Page 2-2
Rough, Unstable, or Incorrect Idle, Stalling ..................................................................................... Page 2-3
Above Normal Emissions (O dors)....................................................................................................... Page 2-3
Hard S ta rt............................................................................................................................................

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Page 2-4
Surges and/ or Chuggle...................................................................................................................... Page 2-4
Lack of Power, Sluggish, or S p o n g y .................................................................................................. Page 2-5
Detonation /Spark K n o c k .................................................................................................................. Page 2-5

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Hesitation, Sag, Stumble .................................................................................................................. Page 2-6
Cuts Out, Misses................................................................................................................................... Page 2-6

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Before using this section, you should have
BEFORE STARTINGar • Air leaks at throttle body mounting and intake
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performed the DIAGNOSTIC CIRCUIT CHECK in manifold.
Section 3 Diagnosis. • Ignition wires for cracking, hardness, proper
routing, and carbon tracking.
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Verify the customer complaint, and locate the

correct SYMPTOM below. Check the item s • Wiring for proper connections, pinches, and
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indicated under that symptom. cuts.

If the ENGINE CRANKS BUT WILL NOT The im p o rta n c e of th is s te p c a n n o t be
RUN, see CHART A-3, in Section 3. stressed too strongly - it can lead to correcting
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a problem w ithout fu rth er checks and can save

Careful Visual Check valuable time.
Several of the following symptom procedures The following symptoms cover several engines.
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call for a careful visual (physical) check. This check To determine if a particular system or component is
should include: used, refer to the ECM w iring diag ram s for
• Vacuum hoses for splits, kinks, and proper application.
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connections, as shown on Vehicle Emission

Control Information label.
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POOR FUEL ECONOMY

Definition: Fuel economy, as measured by an actual road test, is
noticeably lower than expected. Also, economy is noticeably lower than it
was on this vehicle at one time, as previously shown by an actual road test.

• CHECK:
- Engine thermostat for faulty part (always open) - Ignition timing. See Vehicle Emission Control
or for wrong heat range. Information label for procedure.
- Fuel Pressure. See CHART A-5 in Section 3. - TCC for proper operation. See Section 10.
2-2 DRIVEABILITY SYMPTOMS

ECM INTERMITTENT CODES OR PERFORMANCE

Problem may or may not turn "ON” the "Service Engine Soon” light, or store a code.

The ECM code charts, in Section 3, determine if > Loss of code memory: To check, disconnect TPS,
there is a fault with a circuit, or, if there is an and idle engine until "Service Engine Soon" light
intermittent problem. An intermitent means that a comes "ON”. Code 22 should be stored, and kept
code is stored in the ECM memory, but the circuit is in memory when ignition is turned "OFF”, for at
OK. least 10 seconds. If not, the ECM is faulty.
• Most intermittent problems are caused by faulty ► CHECK:
electrical connections or wiring. Perform careful
check of the suspected circuits for: - Electrical system interference caused by a
Poor mating of the connector halves, or defective relay, ECM driven solenoid, or switch.
terminals, not fully seated in the connector They can cause a sharp electrical surge.
body (backed out). Normally, the problem will occur when the

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Improperly formed or damaged terminals. faulty component is operated.
All connector term inals, in a problem - Improper installation of electrical options, such
circuit, should be carefully reformed to as lights, 2-way radios, etc.
increase contact tension. - EST wires should be kept away from spark plug
wires, distributor wires, distributor housing, coil,

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Poor term inal to wire connection. This
requires removing the terminal from the and generator. Wire from CKT 453 to distributor
connector body as outlined in Section 3. should have a good contact to ground.

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• If a visual (physical) check does not find the - Ignition secondary shorted to ground.
- CKT’s 419 and 451 interm ittently shorted to
cause of the problem, the vehicle can be driven
with a voltm eter connected to a suspected
circuit. An abnormal voltage reading, when the
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ground.
- ECM power grounds.
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problem occurs, indicates the problem may be in
that circuit.
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DIESELING, RUN-ON
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Definition: Engine continues to run, after key is turned

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"OFF”, but runs very roughly. If engine runs smoothly, check

ignition switch and adjustment.

• Check injector(s) for leaking. Apply 12 volts to Visually check injector and TBI assembly for
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fuel pump test terminal to turn on fuel pump and fuel leakage,
pressurize fuel system.
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BACKFIRE
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Definition: Fuel ignites in intake manifold, or in

exhaust system, making a loud popping noise.

• CHECK:
EGR operation, for being open all the time. See Engine tim ing - See Vehicle E m ission
EGR diagnosis. Control Information label.
Output voltage of ignition coil. For faulty spark plugs and/or plug wires or
For crossfire between spark plugs (distributor boots.
cap, spark plug wires, and proper routing of plug For proper valve timing.
wires). Perform a compression check - look for sticking
For intermittent condition in primary ignition or leaking valves.
system.
 DRIVEABILITY SYMPTOMS 2-3

ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING

Definition: The engine runs unevenly at idle. If bad enough, the vehicle
may shake. Also, the idle may vary in rpm (called "hunting"). Either condition
may be severe enough to cause stalling. Engine idles at incorrect speed.

• CHECK: - Power Steering - ECM should compensate for

- Ignition timing. See Vehicle Emission Control Power Steering loads. Loss of this signal would
Information label. be most noticable when parking and steering
- P/N switch circuit. See ECM diagnosis. loads are high. See ECM diagnosis.
- For injector leaking. Check Fuel Pressure in - MAP Sensor - Ignition "ON”, engine stopped.
CHART A-5, Section 3 Diagnosis. Compare MAP voltage with known good vehicle.
- Injectors - Too rich or lean. Voltage should be the same ± 400 mv (.4 volts).
• If ROUGH IDLE only occurs HOT, perform these or

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additional checks: S tart and idle engine. Disconnect sensor
- Vacuum Leaks - Block idle air passage using J- electrical connector. If idle improves substitute
33047 plug or equivalent. If closed throttle a known good sensor and recheck.

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engine speed is above 650 rpm, locate and correct - A/C compressor or relay. If inoperative, refer to
A/C diagnosis in Section 3.

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vacuum leak such as a disconnected thermae or
cruise control hose. - A/C Refrigerant Pressure too high. Check for
- Park/Neutral Switch (Automatic Transmission overcharge or faulty cycling switch.

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Only). See ECM diagnosis. - Check PCV valve for proper operation by
- Sticking throttle shaft or binding linkage causes placing finger over inlet hole in valve end
a high TPS Voltage (open throttle indication). several times. Valve should snap back. If not,
ra replace valve.
The ECM will not control idle. Monitor TPS
voltage. "Scan” and/or Voltmeter should read - Run a cylinder compression check.
- Inspect Oxygen sensor for silicon
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less than 1.2 volts, with throttle closed.
- EGR "ON”, while idling, will cause roughness, contamination from fuel, or use of improper
stoppage, and hard starting. See EGR diagnosis. RTV sealant. The sensor will have a white,
- Battery cables and ground straps should be clean powdery coating, and will result in a high, but
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and secure. Erratic voltage will cause IAC to false, signal voltage (rich exhaust indication).
change its position, resulting in poor idle The ECM will, then, reduce the amount of fuel
quality. delivered to the engine, causing a severe
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- IAC valve will not move, if system voltage is driveability problem.

below 9 or greater than 17.8 volts. • Check A/C signal. See A/C diagnosis in Section
3.
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• Check air management system for intermittent

air to ports while in "Closed Loop.”
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ABOVE NORMAL EMISSIONS (ODORS)

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• If test shows higher than normal CO and HC, - Canister for fuel loading.
(also has excessive odors), check items that will - For stuck PCV valve or blocked PCV hose. See
cause engine to run rich: PCV diagnosis.
• CHECK: - Condition of spark plugs, plug w ires, and
distributor cap.
For high fuel pressure. See CHART A-5, in - For lead contamination of catalytic converter
Section 3. (look for removal of fuel filler neck restrictor).
For incorrect timing. See Vehicle Emission
Control Information Label.
2-4 DRIVEABILITY SYMPTOMS

HARD START
Definition: Engine cranks OK, but does not start for a long
time. Does eventually run, or may start but immediately dies.

• CHECK: 4. Connect a radiator test pump to the line

For water contaminated fuel. and apply 103 kPa (15 psi) pressure. If
Fuel pressure. See Section 3. the pressure will hold for 60 seconds, the
TPS for sticking or binding. check valve is OK.
EGR operation. See Section 9. • Check ignition system for:
Fuel pump relay (ST & M) - Connect test light Proper Output with J 26792 (ST-125).
between pump test terminal and ground. Light Worn shaft.
should be "ON”, for 2 seconds, following ignition Bare and shorted wires.
"ON”. Pickup coil resistance and connections.

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On 7.4L, and some 5.7L engines, a fuel module Loose ignition coil ground.
circuit will run the fuel pump for 20 seconds, Moisture in distributor cap.
following ignition "ON”. If this circuit is not Spark plugs, wet plugs, cracks, w ear,

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functioning, this may cause a hot, hard start improper gap, burned electrodes, or heavy
condition. deposits.
For a faulty in-tank fuel pump, check valve, • If engine starts, but then, immediately stalls,

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which would allow the fuel in the lines to drain open distributor bypass line. If engine then
back to the tank after the engine is stopped. To starts, and runs OK, replace distributor pickup
check for this condition: coil.
1. Ignition "OFF”.
2. Disconnect fuel line at the filter.
• ar Hard start, with engine at normal operating
temperature. See Crank Signal Diagnosis, in
Section 3.
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3. Remove the tank filler cap .
• On vehicle, between 8,500 and 10,000 lb. GVW
with a 5.7L or 7.4L engine, check fuel pump cycle
system.
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SURGES AND/OR CHUGGLE

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Definition: Engine power variation under steady throttle or

cruise. Feels like the vehicle speeds up and slows down with no
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change in the accelerator pedal.

• If a tool is available which plugs in to the ALDL Inspect Oxygen sensor for silicon contamination
connector, make sure reading of VSS matches from fuel, or use of improper RTV sealant. The
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vehicle speedometer. sensor may have a white, powdery coating and

• CHECK: result in a high but false signal voltage (rich
exhaust indication). The ECM will then reduce
- For intermittent EGR at idle. See Section 9. the amount of fuel delivered to the engine,
- Ignition timing. See Vehicle Emission Control causing a severe driveability problem.
Information label. • Remove spark plugs. Check for cracks, wear,
- Inline fuel filter for dirt or restriction. improper gap, burned electrodes, or heavy
- Fuel pressure. See Section 3. deposits. Also, check condition of distributor
- Generator output voltage. Repair, if less than 9 cap, rotor, and spark plug wires.
volts or more than 16 volts
- TCC Operation.
 DRIVEABILITY SYMPTOMS 2-5

LACK OF POWER, SLUGGISH, OR SPONGY

Definition: Engine delivers less than expected power. Little or
no increase in speed when accelerator pedal is pushed down part way.

• Compare customer’s vehicle to similar unit. Check Exhaust system for restriction:
Make sure the customer’s vehicle has an actual 1. W ith engine a t n o rm a l o p e ra tin g
problem. temperature, connect a vacuum gage to any
• Remove air cleaner and check air filter for dirt, convenient vacuum port on intake manifold.
or for being plugged. Replace as necessary. 2. D isconnect EGR solenoid e le c tr ic a l
• CHECK: connector or connect EGR valve directly to
vacuum source bypassing any switches or
- Ignition timing. See Vehicle Emission Control solenoids.
Information label. 3. Run engine at 1000 rpm and record vacuum
- For restricted fuel filter, contaminated fuel or

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reading.
improper fuel pressure. See CHART A-5 in 4. Increase rpm slowly to 2500 rpm. Note
Section 3. vacuum reading at steady 2500 rpm.

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- ECM Grounds. 5. If vacuum at 2500 rpm decreases more than
- EGR operation for being open or partly open all 3", from reading at 1000 rpm, the exhaust
the time. See Section 9. system should be inspected for restrictions.
- Generator output voltage. Repair if less than 9

.
6. Disconnect exhaust pipe from engine and
or more than 16 volts.

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repeat steps 3 & 4. If vacuum still drops,
- Engine valve timing and compression. more than 3" with exhaust disconnected,
- Engine for proper or worn camshaft. check valve timing.
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DETONATION / SPARK KNOCK
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Definition: A mild to severe ping, usually worse under acceleration.

The engine makes sharp metallic knocks that change with throttle opening.
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> Check for obvious overheating problems. Check EGR system for not opening. See Section 9.
- Low coolant. For proper transmission shift points and TCC
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- Loose water pump belt. operation.

- Restricted air flow to radiator, or restricted For incorrect basic engine parts such as cam,
water flow thru radiator. heads, pistons, etc.
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> CHECK: Remove carbon with top engine cleaner.

Follow instructions on can.
- For poor fuel quality, proper octane rating.
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On vehicles with 7.4L or 5.7L (over 8500 GVW)

- For correct PROM. (See Service Bulletins). engine and a dual catalytic converter system,
- THERMAC for staying closed. check for an exhaust restriction in the rear
- Ignition timing. See Vehicle Emission Control converter area.
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Information label.
- Fuel system for low pressure. See CHART A-5
in Section 3.
2-6 DRIVEABILITY SYMPTOMS

HESITATION, SAG, STUMBLE

Definition: Momentary lack of response, as the accelerator is
pushed down, can occur at all vehicle speeds. Usually, most severe,
when first trying to make the vehicle move, as from a stop sign.
May cause the engine to stall, if severe enough.

• Perform careful visual (physical) check as - Fuel pump cycle system.

described at start of Section 2. - TPS for binding or sticking.
• CHECK: - Generator output voltage. Repair if less than 9 or
more than 16 volts.
- Fuel pressure. See CHART A-5 in Section 3. - For open HEI ground, CKT 453.
- Water contaminated fuel. - Canister purge system for proper operation. See
- Ignition timing. See Vehicle Emission Control Section 5.

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Information label. - EGR valve operation. See Section 9.

CUTS OUT, MISSES

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Definition: Steady pulsation or jerking that follows engine
speed, usually more pronounced as engine load increases. The

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exhaust has a steady spitting sound at idle or low speed.

• Check for missing cylinder by: • CHECK:

1. Disconnecting IAC motor. Start engine.
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- Spark plug wires by connecting ohmmeter to
Remove one spark plug wire at a time using ends of each wire in question. If meter reads
insulated pliers. over 30,000 ohms, replace wire(s).
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2. If there is an rpm drop on all cylinders - Ignition coil and secondary voltage using spark
(equal to within 50 rpm), go to "ROUGH, tester J-26792 (ST-125), or equivalent.
UNSTABLE, OR INCORRECT IDLE, - For restricted fuel filter. Also check fuel tank for
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STALLING” symptom. Reconnect IAC water.

motor. - For low fuel pressure. See CHART A-5 in Section
3. If there is no rpm drop on one or more 3.
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cylinders, or excessive variation in drop, - Check for proper valve timing.

check for spark on the suspected cylinder(s) • Perform compression check on questionable
with J 26792 (ST-125) Spark Gap Tool or cylinder(s) found above. If compression is low,
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equivalent. If no spark, see Ignition Section repair as necessary.

6. If there is spark, remove spark plug(s) in • Visually check distributor cap and rotor for
those cylinders and check for:
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moisture, dust, cracks, burns, etc. Spray cap and

Cracks plug wires with fine water mist to check for
Wear shorts.
Improper Gap • Remove rocker covers. Check for bent pushrods,
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Burned Electrodes worn rocker arms, broken valve springs, worn

Heavy Deposits camshaft lobes.
 COMPUTER COMMAND CONTROL 3-1

SECTION 3
COMPUTER COMMAND CONTROL
TABLE OF CONTENTS
GENERAL DESCRIPTION................................. 3-2 THROTTLE POSITION SENSOR.................... 3-9
ALDL Connector...................................... 3-2 VEHICLE SPEED SEN SO R............................. 3-9
Wiring Harness and Connectors........... 3-2 MAT SEN SO R............................................... 3-9
Information Sensors............................... 3-3 EGR SYSTEM ............................................... 3-9
ELECTRONIC CONTROL MODULE .............. 3-3 IDLE SPEED................................................... 3-9
MEM-CAL................................................ 3-4 ELECTRONIC SPARK TIM IN G ...................... 3-9
PROM ..................................................... 3-4 ELECTRONIC SPARK CO N TR O L.................. 3-9
C A LP A K ................................................... 3-4 PARK/NEUTRAL SW ITCH............................. 3-9

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INPUT INFORMATION................................. 3-4 CRANK SIGNAL............................................ 3-10
Coolant Sensor........................................ 3-4 POWER STEERING PRESSURE SW ITC H ___ 3-10
MAP Sensor............................................ 3-4 DISTRIBUTOR REFERENCE SIGNAL..............3-10

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Oxygen Sensor........................................ 3-5 A/C CLUTCH CO NTROL............................... 3-10
Throttle Position Sensor......................... 3-5 A/C "ON" SIGNAL........................................ 3-10
Manifold Air Temperature Sensor......... 3-5 EXHAUST S Y S T E M ...................................... 3-10

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E-Cell....................................................... 3-6 ON-VEHICLE SERVICE...................................... 3-85
Vehicle Speed Sensor............................. 3-6 WIRE HARNESS............................................ 3-85
Knock Sensor.......................................... 3-6
Park/Neutral Switch S ig n a l.................... 3-6
Crank Signal............................................ 3-6
ar CONNECTORS AND TERM IN ALS................ 3-85
Micro-Pack............................................... 3-86
Metri-Pack............................................... 3-86
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Distributor Reference Sign al.................. 3-6 W eather-Pack........................................ 3-86
Power Steering Pressure Switch Signal . 3-6 Compact Three........................................ 3-87
A/C Control Signal................................... 3-6 Wiring Diagram - 2.5L ........................... 3-88
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Transmission Gear Position Signal . . . . 3-6 Wiring Diagram - 2.8L ........................... 3-91
D IA G N O SIS..................................................... 3-6 Wiring Diagram - 4.3L & V8.................... 3-94
BULB CHECK .............................................. 3-6 ELECTRONIC CONTROL M O D U LE..............3-87
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SYSTEM C H E C K .......................................... 3-6 ECM Connector Terminals - 2.5 L ........... 3-98

Engine Does Not Start ........................... 3-7 ECM Connector Terminals-2.8 L ........... 3-99
"Scan" T o o l............................................ 3-7 ECM Connector Terminals - 4.3L & V8 . . 3-100
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Diagnostic M o d e ................................... 3-7 COOLANT SEN SO R...................................... 3-104

Field Service M ode................................. 3-8 MAP SEN SO R............................................... 3-104
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Code System .......................................... 3-8 OXYGEN SENSOR........................................ 3-106

Clear C o d e s............................................ 3-8 THROTTLE POSITION SENSOR.................... 3-108
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ELECTRONIC CONTROL MODULE .............. 3-8 MAT SEN SO R............................................... 3-109

PROM ..................................................... 3-9 E-C E LL.......................................................... 3-109
MEM-CAL................................................. 3-9 VEHICLE SPEED SEN SO R............................. 3-109
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CA LP A K ................................................... 3-9 KNOCK SEN SO R.......................................... 3-109

FUEL PUMP CIRCUIT................................... 3-9 PARK/NEUTRAL SW ITCH............................. 3-109
COOLANT SEN SO R...................................... 3-9 POWER STEERING PRESSURE SW ITCH ___ 3-110
MAP SEN SO R.............................................. 3-9 PARTS INFORMATION .................................... 3-110
OXYGEN SENSOR........................................ 3-9
3-2 COMPUTER COMMAND CONTROL

GENERAL DESCRIPTION
The Computer Command Control System has a ■ -
computer (Electronic Control Module) to control the
fuel delivery, ignition timing, some emission control o G
F E D C B A
H M
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system s and engagem ent of the tran sm issio n TERMINAL IDENTIFICATION
converter clutch, downshift control or the manual
transmission shift light. 0 GROUND
0 T.C.C. (IF USED)
The system, through the electronic control module 0 DIAGNOSTIC TERMINAL
0 FUEL PUMP (IF USED)
(ECM), monitors a number of engine and vehicle 0 A.I.R. (IF USED)
functions (Figure 3-1) and controls the following
0
SERVICE ENGINE 0 BRAKE SENSE
SPEED INPUT

0
operations: SOON LAM P-IF USED
SERIAL DATA (L4)
Fuel Control
Ignition/Electronic Spark Timing 0 SERIAL DATA
(SEE SPECIAL TOOLS)
(SEE SPECIAL TOOLS)
6-5-86 *7S 3541-6E

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Electronic Spark Control
Air Management Figure 3-2 ALDL Connector
Exhaust Gas Recirculation
Transm ission C onverter C lutch, Downshift Wiring Harness and Connectors
Control or Manual Transmission Shift Light

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A wiring harness electrically connects the ECM to
ALDL Connector various sensor, solenoid and relays within the system.

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Many connectors in the engine com partment are
The Assembly Line Diagnostic Link (ALDL) is environmentally protected because of the systems low
wired to the ECM and is located under the instrument voltages and current levels.
panel.
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This connector has term inals that are used to
diagnose the system either with jumper wires or a
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"Scan” tool.
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* OPERATING CONDITIONS SENSED * SYSTEMS CONTROLLED

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• A/C “On" or “Off "

• Air Management
• Engine Coolant "Temperature
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• Exhaust Gas Recirculation (EGR)

• Engine Crank Signal
• Electronic Spark Timing (EST)
• Exhaust 0 xyge n (02) Sensor
• Fuel Control
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• Distributor Reference
• Idle Air Control (IAC)
• Crankshaft Position
• Electric Fuel Pump
• Engine Speed (RPM)
• Transmission Converter Clutch (TCC),
• Manifold Absolute Pressure (MAP) ELECTRONIC
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(ENGINE) Downshift Control or Manual

• Park Neutral Switch (P/N) Position
CONTROL Transmission Shift Light
• System Voltage
• Air Conditioning
• Throttle Position (TPS) MODULE
(ECM) • Diagnostics
• Tra nsm ission Gea r Position
• "Service Engine Soon" Light
• Vehicle Speed (VSS)
• Diagnostic Terminal (ALDL)
• Fuel Pump Voltage
• Data Output (ALDL)
• Power Steering Pressure
• Electronic Spark Control (ESC)
• EGR Vacuum
• E-Cell - 2.8L
• Engine Knock (ESC)
• Manifold Air Temperature (MAT) *All systems not used on all engines.
6 - 10-86
*7S 3537-6E

Figure 3-1 Computer Command Control System

 COMPUTER COMMAND CONTROL 3-3

Information Sensors
In addition to the ECM, the Computer Command
Control System has the following information sensors:
• Oxygen sensor
• Coolant sensor
• Throttle position sensor
• Manifold absolute pressure sensor
• Vehicle speed sensor
• Manifold temperature sensor
• Knock sensor
and the following input signals:
• Park/neutral switch signal
• Crank signal
• Distributor reference signal

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• Power steering pressure switch signal
• A/C control signal
• Transmission gear position signal
• EGR vacuum signal output, therefore, if the one input failed it could effect

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more than one system operations.
ELECTRONIC CONTROL MODULE The ECM has a "learning” ability which allows it
(Figure 3-3 or 3-4) to make corrections for minor variations in the fuel

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The Electronic Control Module (ECM) is located in system to improve driveability. If the battery is
the passenger compartment and is the control center disconnected to clear codes, or for re p a ir, the
of the Computer Command Control System.
The ECM constantly looks at the information from
various sensors, and controls the systems that affect
ar "learning” process has to begin all over again. A
change may be noted in the vehicle’s performance. To
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"teach” the vehicle, make sure the engine is at
vehicle perform ance. The ECM perform s the operating temperature, and drive at part throttle,
diagnostic function of the system. It can recognize with moderate acceleration and idle conditions, until
operational problems, alert the driver through the
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normal performance returns.

"Service Engine Soon” light, and store a code or codes
which identify the problem areas to aid the technician NOTICE: The ECM m ust be m ain tain ed a t a
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in making repairs. See Diagnosis section for more tem perature below 185°F (85°C) at all
information. times. This most essential if the vehicle is
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The ECM is designed to process the various input put through a paint baking process. The
information (Figure 3-1) and then sends the necessary ECM will become in o p erativ e if its
electrical responses to control fuel delivery, spark te m p e ra tu re exceeds 185°F (85°C).
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timing and other emission control systems. The input T herefore, it is recom m ended th a t
information has an interrelation to more than one temporary insulation be placed around the
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ECM during the time the vehicle is in a

paint oven or other high tem perature
process.
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There are two type of ECM’s used in light duty

trucks.
A vehicle equipped with a 4 cylinder engine has an
ECM (referred to as GMP4) with two parts for service.
A controller (an ECM without a MEM-CAL) and a
MEM-CAL (Memory and Calibration unit).
All vehicles with a V6 or V8 cylinder engine have
an ECM (referred to as GMCM) with three parts for
service. A controller (an ECM without a PROM), a
PROM with specific program inform ation for an
engine and vehicle and a CALPAK with specific
calibration information.

Figure 3-3 Electronic Control Module (L4)

3-4 COMPUTER COMMAND CONTROL

MEM-CAL (L4) the voltage, the ECM knows the engine coolant
(Figure 3-3) temperature. Engine coolant temperature affects
This assembly contains both the functions of the most systems the ECM controls.
PROM and CALPAK. Like the PROM, it contains the
calibrations needed for a specific vehicle as well as the
back-up fuel control circuitry required if the rest of the
ECM becomes damaged or faulty.

PROM (V6& V8)

(Figure 3-5)
Information for specific engine and vehicle is
programmed using an integrated circuit called a
PROM, (Programmable Read-Only Memory). In the
parts book, it is listed as a calibrator. This allows one
model of controller to be used for many different

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vehicles. The PROM is located inside the ECM and
has information on the vehicle’s weight, engine,
transmission, axle ratio, and several others. While

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one ECM part number can be used by many vehicle
lines, a PROM is very specific and must be used for the MAP Sensor
right vehicle. For this reason, it is very important to (Figure 3-7)

y.
check the latest parts book and Service B ulletin The Manifold Absolute Pressure (MAP) sensor
information for the correct p a rt num ber when m easures the changes in the in tak e m anifold
replacing a PROM. pressure, which result from engine load and speed

CALPAK (V6 & V8)

(Figure 3-5)
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changes, and converts this to a voltage output.
A closed throttle on engine coastdown will produce
a relatively low MAP output, while a wide-open
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A CALPAK is used to allow fuel delivery if other throttle will produce a high output. This high output
parts of the ECM are damaged. If the CALPAK is is produced because the pressure inside the manifold
is the same as outside the manifold, so 100% of the
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missing, it will result in a no start and run condition.

outside air pressure is measured. The MAP sensor
reading is the opposite of what you would measure on
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a vacuum gage. When manifold pressure is high,

vacuum is low. The MAP sensor is also used to
m easu re b a ro m e tric p re s su re u n d er c e rta in
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conditions, which allows the ECM to automatically

adjust for different altitudes.
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The ECM sends a 5 volt reference signal to the

MAP sensor. As the manifold pressure changes, the
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electrical resistance of the sensor also changes. By

[T] ECM QT] PROM C A R R IE R
{jT j PROM (ENGINE C A LIB R A T O R ) [ T ] C A LPA K
4S 1217-6E
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Figure 3-5 PROM and CALPAK (V6 & V8)

INPUT INFORMATION
Coolant Sensor
(Figure 3-6)
The coolant sensor is a therm istor (a resistor
which changes value based on temperature mounted
in the engine coolant s tre a m . Low coo lan t
temperature produces a high resistance (100,0000
ohms at -40°C/-40°F) while high temperature causes
low resistance (70 ohms at 130°C/266°F).
The ECM supplies a 5 volt signal to the coolant
sensor through a resistor in the ECM and measures
the voltage. The voltage will be high when the engine
is cold, and low when the engine is hot. By measuring
 COMPUTER COMMAND CONTROL 3-5

monitoring the sensor output voltage, the ECM knows

the manifold pressure. A higher pressure, low
vacuum (high voltage) requires more fuel, while a
lower pressure, higher vacuum (low voltage) requires
less fuel.
The ECM uses the MAP sensor to control fuel
delivery and ignition timing.

Oxygen (O 2) Sensor
(Figure 3-8)
The exhaust oxygen (O2 ) sensor is mounted in the
exhaust system where it can monitor the oxygen m THROTTLE BODY ASSEM BLY
content of the exhaust gas stream . The oxygen m THROTTLE POSITION SENSOR - NON-ADJUSTABLE
content in the exhaust reacts with the oxygen sensor I 3 [ THROTTLE POSITION SENSOR - NON-ADJUSTABLE
to produce a voltage output. This voltage ranges from m THROTTLE POSITION SENSOR - ADJUSTABLE
m SCREW ASSEM BLY

om
approximately .1 volts (high O2 - lean mixture) to .9
I 6 t RETAINER 7S3652-6E
volts (low O2 - rich mixture).
By monitoring the voltage output of the O2 sensor, Figure 3-9 Throttle Position Sensor
the ECM will know what fuel mixture command to
give to the injector (lean mixture-low voltage-rich Manifold Air Temperature (MAT) Sensor

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command, rich mixture-high voltage-lean command). (Figure 3-10)
The Manifold Air Temperature (MAT) Sensor is a
thermistor (a resistor which changes value based on

ry
tem perature) mounted on a 2.5L engine in the
m anifold. Low te m p e ratu re produces a hig h
ra resistance (100,000 ohms at -40°C/-40°F) while high
tem perature causes low resistance (70 ohms at
130°C/266°F).
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The ECM supplies a 5 volt signal to the sensor
through a resistor in the ECM and measures the
voltage. The voltage will be high when the manifold
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air is cold, and low when the air is hot. By measuring

the voltage, the ECM knows the m anifold a ir
temperature.
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The MAT sensor signal is used by the ECM to

delay EGR until the manifold air temperature reaches
about 5°C (40°F).
!~ n EXH A U ST O XYG EN
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(0 2) SENSOR 4S 0619-6E
The ECM uses the signal to slightly retard the
timing during high ambient air temperatures.
Figure 3-8 Oxygen Sensor
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Throttle Position Sensor

(Figure 3-9)
The Throttle Position Sensor (TPS) is connected to
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the th ro ttle shaft on the TBI u n it. It is a

potentiometer with one end connected to 5 volts from
the ECM and the other to ground. A third wire is
connected to the ECM to measure the voltage from the
TPS. As the th ro ttle valve angle is changed
(accelerator pedal moved), the output of the TPS also
changes. At a closed throttle position, the output of
the TPS is low (approximately .5 volts). As the
throttle valve opens, the output increases so that, at
rn MANIFOLD AIR TEMPERATURE (MAT) SENSOR
wide-open throttle, the output voltage should be
m ENGINE INTAKE MANIFOLD
approximately 5 volts.
By monitoring the output voltage from the TPS,
7S 3545-6E
the ECM can determine fuel delivery based on throttle
valve angle (driver demand). Figure 3-10 MAT Sensor
3-6 COMPUTER COMMAND CONTROL

E-Cell -2.8L Crank Signal

(Federal Only)
The E-Cell located next to the ECM, is also known The ECM uses this signal to tell when the vehicle
as an elapsed timer module or a cold start program is in the STARTING mode.
modifier. The E-Cell is an emission device that is an
enrichment signal to the ECM for about 4 seconds Distributor Reference Signal
during cold start. After an elapsed time of operating
hours, the signal is no longer required and becomes The distributor sends a signal to the ECM to
inoperative. indicate both engine RPM and crankshaft position.
See Section 6 for further information.
Vehicle Speed Sensor
Power Steering Pressure Switch Signal
The Vehicle Speed Sensor (VSS) located behind
the speedometer sends a pulsing voltage signal to the Located near the power steering gear. When
ECM, which the ECM converts to miles per hour. This steering is to the extreme left or right, the switch is

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sensor mainly controls the operation of the TCC closed and this signal will increase the idle air rate
system, shift light, and cruise control. and retard the spark for a stable idle.

Knock Sensor A/C Control Signal

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Located in the engine block, it retards ignition This signal indicates that the A/C control switch is
timing during a spark knock condition to allow the turned "ON” and the pressure switch is closed. The

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ECM to maintain maximum timing advance under ECM uses this signal to adjust the idle speed and on
most conditions. some systems engage the A/C compressor clutch.
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Park/Neutral Switch Signal Transmission Gear Position Signal
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The Park/Neutral (P/N) switch, located on the A sw itch , lo cated in s id e th e a u to m a tic
steering column is used on an automatic transmission transmission, opens when the transmission shifts to
vehicle to indicate to the ECM when the transmission high gear. This sig n a l is used for d elay ed
is in Park or Neutral. This information is used to disengagement of the transmission converter clutch.
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control the operation of the transmission converter

and idle air control.
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DIAGNOSIS
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The Computer Command Control System has a When the engine is started, the light will turn
diagnostic system built into the ECM to indicate a "OFF”. If the light remains "ON” refer to System
failed circuit. An amber "Service Engine Soon” light Check.
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on the instrument panel will illuminate if a problem

ha~ been detected when the engine and vehicle are SYSTEM CHECK
running. This light is also used for a bulb and system (Figure 3-11)
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check. The system check is perform ed through the

The system requires an ALDL read-out "Scan” twelve term inal Assembly Line Diagnostic Link
tool, tachom eter, test light, ohmmeter, d ig ital (ALDL) connector (Figure 3-2) under the instrument
voltmeter with 10 megohms impedance (J-29125A), panel in the passenger compartment. The following
vacuum gage and jumper wires for diagnosis. Refer terminals are used:
to Section 13 for additional information about special A - This terminal provides a ground circuit to other
tools. terminals.
B - This terminal is the "diagnostic term inal” for
Bulb Check the ECM. When grounded to "A” terminal, the
"Service Engine Soon” light will flash codes (key
With the ignition "ON” and engine not running, "O N ” and en g in e "O F F ”) e n te r in g th e
the lamp should be illustrated which indicates that Diagnostic Mode or flashes a Field Service Mode
the ECM has completed the circuit to turn "ON” the (engine running) to determine if system is in a
light. "Closed” or "Open” Loop operation.
If the "Service Engine Soon” light is not "ON”,
refer to CHART A-l for diagnosis.
 COMPUTER COMMAND CONTROL 3-7

M - This terminal is the serial data line for the 2.5L

engines and is used by the ”Scan” tool to read
various system data information.
With the key "ON” and the engine "OFF”, jumper
ALDL terminals "B” to "A”. The "Service Engine
Soon” light will flash Code 12 to indicate th at the
diagnostic system is working. Code 12 consists of "one
flash” followed by a pause and then "two flashes”. The
code will repeat for a total of three times and will
continue to repeat if there are no other codes stored.
If Code 12 does not display, refer to CHART A-2.

Engine Does Not Start

If the engine cranks but will not start, refer to

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CHART A-3 through A-5 to determine if it is a fuel or
ignition problem.

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"Scan" Tool
A "Scan” tool is designed to interface with the

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Computer Command Control System. It supplies a
visual reading of most inputs to the ECM and some
outputs. Review the tool instruction m anual to
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understand its operation and limitations.
When the tool is connected to the ALDL and
cigarette/cigar lighter connector or 12 volts, there
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should be a visual instruction displayed. If there is no
display or tool reads "No DATA or No ALDL” with
ignition "ON”, refer to CHART A-2.
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With the tool in the code position, the display

window will indicate any code stored in the ECM
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6-5-86
memory (Figure 3-12). Referring to the applicable
*7S 3538-6E code chart, the tool will ’’Scan” an input to determine
if a specific circuit is operating properly. If there are
Figure 3-11 System Check
no codes, the System Check is completed. Additional
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C - This terminal, on some air management systems information on "Scan” tools is in Section 13.
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is wired to the ground side of the electric air If there are additional driveability symptoms,
control valve. It can be used to diagnose the air refer to Section 2.
management system. Refer to Section 8. If there are additional codes, refer to applicable
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D - This terminal, on some systems, can be used to code chart.

diagnose the "Service Engine Soon” light. Refer
to CHART A-1. Diagnostic Mode
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E - This terminal is the serial data line on all

engines except 2.5L and is used by a "Scan” tool If the Diagnostic terminal is grounded with the
to read various system data information. ignition "ON” and the engine stopped, the system will
F - This terminal is used to diagnose the TCC enter the Diagnostic Mode. In this mode the ECM
system and is wired to the ground side of the TCC will:
Solenoid. Refer to Section 10. 1. Display a Code 12 by flashing the "Service Engine
G - This terminal is used to diagnose the fuel pump Soon” light (indicating the system is operating). A
circuit on a 4.3L or V8 engine. On other engines Code 12 consists of one flash, followed by a short
the fuel pump te st lead is in the engine pause, then two flashes in quick succession. This
compartment near the fuel pump relay. Refer to code will be flashed three times. If no other codes
CHART A-5. are stored, Code 12 will continue to flash until the
H - This terminal is used to diagnose the brake Diagnostic terminal is ungrounded.
system on CK trucks. Refer to CK Light Duty
Codes can only be obtained with the engine
Service Manual for additional information.
stopped. Grounding the Diagnostic terminal with
the engine running gives the "field service mode”.
3-8 COMPUTER COMMAND CONTROL

2. Display any stored trouble codes by flashing the Clearing Codes

"Service Engine Soon” light. Each code will be
flashed three times, then Code 12 will be flashed When the ECM sets a code, the "Service Engine
again. If a trouble code is displayed, a Diagnostic Soon” light will come "ON” and a code will be stored in
Code Chart is to used to find the problem. The memory. If the problem is intermittent, the light will
chart will determine if the problem exists (hard go out after 10 seconds, when the fault goes away.
failure), or is intermittent. However, the code will stay in the ECM memory for 50
3. Energize all ECM controlled relays and solenoids starts or until the battery voltage to the ECM is
except fuel Pump Relay . removed. Removing battery voltage for 30 seconds
4. The IAC valve also moves to the fully extended will clear all stored codes.
position. Codes should be cleared after repairs have been
completed. Also, some Diagnostic Charts will tell you
Field Service Mode to clear the codes before using the chart. This allows
the ECM to set the code while going through the chart,
If the Diagnostic terminal is grounded with the which will help to find the cause of the problem more

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engine running, the system will enter the Field quickly.
Service mode. In this mode, the "Service Engine
Soon” light will show whether the system is in Open or NOTICE :To prevent ECM damage, the key must be

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Closed Loop. "OFF” when disconnecting or reconnecting
In "Open Loop” the "Service Engine Soon” light power to ECM (for example battery cable,
flashes two and one-half times per second. ECM pigtail, ECM fuse, jumper cables, etc.)

y.
In "Closed Loop”, the light flashes once per second:
Also, in "Closed Loop”, the light will stay OUT most of ELECTRONIC CONTROL MODULE
the time if the system is too lean. It will stay ON most
of the time if the system is too rich.
While the system is in Field Service Mode, the
ar The diagnosis of the electronic control module
(ECM) starts with the system check. The code system
indicates a failure of a specific circuit and diagnosis
ECM will be in the following mode:
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1. New trouble codes cannot be stored in the ECM. may indicate replacement of the ECM. A Code 55
2. The "Closed Loop” timer is bypassed. indicates th a t the ECM has failed and m ust be
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replaced.
Code System If the ECM has been replaced and the condition
(Figure 3-12) was not corrected, the following information may be
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The ECM is equipped with a self-diagnosis system the cause:

which detects system failure and aids the technician • An incorrect ECM or PROM / MEM-CAL
the circuit at fault via a code. application may cause a malfunction and may
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The ECM is really a computer. It uses sensors to or may not set a code.
look at many engine operating conditions. It has a • If the connector at the ECM is the possible
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memory and it knows what a certain sensor readings problem, the terminal may have to be removed
should be under certain conditions. These conditions from the connectors in order to properly check
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are described on the facing page of each Code Chart. If them.

a sensor reading is not what the ECM thinks it should • Although the PROM / MEM-CAL rarely fails, it
be, the ECM will turn on the "Service Engine Soon” operates as part of the ECM, therefore, it could
light on the instrument panel, and will store a code in be the cause of the problem.
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the memory. The code tells which CIRCUIT the • Although a rare condition, the replacement
trouble is in. A circuit consists of a sensor (such as ECM may be faulty.
coolant temperature), the wiring and connectors to it, • In the case of an intermittent problem, refer to
and the ECM. Section 2 and make a c a re fu l p h y sica l
An "intermittent” code is one which does not reset inspection of the system involved.
itself, and is not present while you are working on the • A shorted solenoid, relay coil or harness may
vehicle. This is often caused by a loose connection. cause an ECM to fail and a replacement ECM to
The facing page of a code chart will contain diagnostic fail when it is installed. Use a short tester
aids to help in detecting intermittents. J34636, BT 8405, or equivalent as a fast,
A "hard” code is one which is present when you are accurate means of checking for a short circuit.
working on the vehicle and the condition still exists
while working on the vehicle. The chart with the
stored code number will lead you to the cause of the
problem.
 COMPUTER COMMAND CONTROL 3-9

PROM MAP SENSOR

A PROM th a t has failed or was in sta lled Code 33 or Code 34 indicates a failure in the MAP
improperly will generally set a Code 51. sensor circuit. Also refer to MAP output check
diagnosis to check the MAP sensor if there is no code.
MEM-CAL
OXYGEN SENSOR
A MEM-CAL that has failed or was installed
improperly will set a Code 51. Code 13 indicates an open in the oxygen sensor
circuit. Code 44 indicates a shorted oxygen sensor
CALPAK circuit. Code 45 indicates a high voltage in the oxygen
sensor circuit. If a code is set, the engine will always
A no start and run condition will result if the run in the "Open Loop” mode. The oxygen sensor
CALPAK is not installed in the ECM. A CALPAK voltage output can be m easured with a d ig ita l
that is removed will set a Code 52. voltmeter having at least a 10 meg ohms input

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impedance. Use of a standard shop type voltmeter will
FUEL PUMP CIRCUIT result in an inaccurate reading.
Normal "Scan” voltage varies between 100 mv to

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Code 54 indicates a failure in the fuel pump 999 mv (.1 and 1.0 volt) while in "Closed Loop”. Code
circuit. 13 sets in one minute if voltage remains between .35
Two types of fuel pump relays are used on light and .55 volts, but the system will go "Open Loop” in

y.
duty trucks. The S,T and M series use one type and C, about 15 seconds.
K, R, V, G and P series use the other type. Both relays Using the "Scan”, observe the block learn values
have the same function, but terminals arrangement is at different rpm and air flow conditions. The "Scan”

pump operation, this is either a separate terminal

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different. Both relays have a terminal to test the fuel also displays the block cells, so the block learn values
can be checked in each of the cells to determine when
Code 44 or Code 45 may have been set. If the condition
located near the relay or along the ECM harness or at
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terminal "G” in the ALDL connector. By applying for Code 44 exists, the block learn values will be
voltage at this terminal, it can be determined if the around 150. If the condition for Code 45 exists, the
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fuel pump will operate. This terminal will also prime block learn values will be around 115.
the fuel line to the TBI unit.
THROTTLE POSITION SENSOR
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FUEL MODULE
Code 21 indicates that there is a shorted TPS
A fuel module is used on all 7.4L and some 5.7L circuit. Code 22 indicates that there is an open in the
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engines to correct a hot restart (vapor lock) during a TPS circuit. When a code is set, the ECM will use an
high ambient condition. It is designed to override the artificial value for throttle position and some engine
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ECM 2 second pump operation and will run the fuel performance will return.
pump for 20 seconds at initial ignition "ON”. A broken TPS can cause interm ittent bursts of
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An inoperative fuel module may be the cause of a fuel from the injector(s) and an unstable idle because
hot stall/no start condition. Check for power and the ECM thinks the throttle is moving.
ground circuit to the fuel module and a complete A "Scan” tool reads throttle position in volts.
circuit to the pump from terminal "A”. If OK and the Should read about .763 volts (2.5L), .45 volts (2.8L),
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pump does not run for the specified 20 seconds at .60 volts (4.3L & V8) + .75 volts with throttle closed
initial ignition "ON”, replace the Fuel Module. and ignition "ON” or at idle, voltage should increase
at a steady rate as throttle is moved toward WOT.
COOLANT SENSOR "Scan” TPS while depressing accelerator pedal
with engine stopped and ignition "ON”, display
Code 14 or Code 15 indicates a failures in the should vary from below 2.5 volts (2500 mv) when
coolant sensor circuit. throttle was closed, to over 4.5 volts (4500 mv) when
A "Scan” tool displays engine temperature in throttle is held at wide open throttle position.
degrees centigrade. After engine is started, the
temperature should rise steadily to about 90°C then VEHICLE SPEED SENSOR
stabilize when thermostat opens.
The vehicle speed sensor circuit diagnosis is in
Code 24 chart.
"Scan” read in g should closely m atch w ith
speedometer reading, with drive wheels turning.
3-10 COMPUTER COMMAND CONTROL

MAT SENSOR If the EST line is grounded, the Ignition Module

will switch to EST, but because the line is grounded
Code 23 indicates that there is an open in the MAT there will be no EST signal. A Code 42 will be set.
circuit. Code 25 indicates that there is a short to Code 42 sets if there is an open or a short to ground
ground in the MAT circuit. in the EST or by-pass circuit.
A "Scan” tool reads tem perature of the a ir
entering the engine and should read close to ambient ELECTRONIC SPARK CONTROL
air temperature when engine is cold, and rises as
underhood temperature increases. Code 43 sets if there is an open or short to ground
in the ESC circuit.
EGR SYSTEM If the conditions for a Code 43 are present, the
"Scan” will always display "yes”. There should not be
Code 32 indicates that there is a failure in the a knock at idle unless an internal engine problem, or a
EGR system circuit. system problem exists.

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IDLE SPEED PARK/NEUTRAL SWITCH
Code 35 sets when there is an idle speed error on a Diagnosis of the park/neutral switch is on page 3-

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2.5L engine. Refer to diagnosis in Section 4 for idle air 70 of this section.
control valve check for other engines.
• System too lean. (High air/fuel ratio) CRANK SIGNAL

y.
Idle speed may be too high or too low. Engine
speed may vary up and down, disconnecting IAC The crank signal diagnosis procedure is at the end
does not help. May set Code 44. of this section. If there is no crank signal to the ECM,
"Scan” and/or voltmeter will read an oxygen
sensor output less than 300 mv (.3 volts). Check
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the engine may be hard to start.

POWER STEERING PRESSURE SWITCH

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for low regulated fuel pressure or water in fuel, a
lean exhaust with an oxygen sensor output fixed
above 800 mv (.8 volts) will be a contaminated The diagnosis of the power steering pressure
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sensor, usually silicone. This may also set a Code switch is covered on page 3-72 of this section.
45.
• System too rich (Low air/fuel ratio) DISTRIBUTOR REFERENCE SIGNAL
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Idle speed too low. "Scan” counts usually above

80. System obviously rich and may exhibit black The distributor reference signal is covered in
smoke exhaust. Section 6 of the ignition system and electronic spark
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"Scan” tool and/or voltmeter will read an oxygen control.

sensor signal fixed above 800 mv (.8 volts).
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A/C CLUTCH CONTROL

ELECTRONIC SPARK TIMING
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The diagnosis of the A/C clutch control on a 2.5L

When the system is running on the Ignition engine is covered on page 3-76 of this section.
Module, that is, no voltage on the by-pass line, the
Ignition Module grounds the EST signal. The ECM A/C "ON" SIGNAL
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expects to see no voltage on the EST line during this

condition. If it sees a voltage, it sets Code 42 and will The diagnosis of the A/C "ON” signal on all
not go into the EST mode. engines other than 2.5L is covered on page 3-80 of this
When the rpm for EST is reached (about 400 rpm), section.
and by-pass voltage applied, the EST should no longer
be grounded in the ignition module so the EST voltage EXHAUST SYSTEM
should be varying.
If the by-pass line is open or grounded, the Refer to Figure 3-13 for diagnosis of a restricted
Ignition Module will not switch to EST mode so the exhaust system.
EST voltage will be low and Code 42 will be set.
 COMPUTER COMMAND CONTROL 3-11

CODE IDENTIFICATION
The ’’Service Engine Soon” light will only be "ON” if the malfunction exists under the conditions listed
below. If the malfunction clears, the light will go out and the code will be stored in the ECM. Any codes
stored will be erased if no problem reoccurs within 50 engine starts.

CODE AND CIRCUIT PROBABLE CAUSE CODE AND CIRCUIT PROBABLE CAUSE
Code 13-02 Sensor Indicates that the Code 33 - MAP Sensor MAP sensor output to
Open Oxygen Sensor oxygen sensor circuit or Low Vacuum high for 5 seconds or
Circuit sensor was open for one an Open signal circuit.
minute while off idle.
Code 14 - Coolant Sensor Sets if the sensor or Code 34 - MAP Sensor Low or no output from
High Vacuum sensor with engine

om
High Temperature signal line becomes
Indication grounded for 3 seconds. running.

Code 15 - Coolant Sensor Sets if the sensor, Code 35 - IAC IAC error
Low Temperature connections, or wires

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Indication open for 3 seconds. Code 42 - EST ECM has seen an open
or grounded EST or
Bypass circuit.

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Code 21 - TPS TPS voltage greater
Signal Voltage High than 2.5 volts for 3 Code 43 - ESC Signal to the ECM has
seconds with less than remained low for too
ra long or the system has
1200 rpm.
failed a functional
Code 22 - TPS A shorted to ground or check.
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Signal Voltage Low open signal circuit will
set code in 3 seconds. Code 44 Sets if oxygen sensor
Lean Exhaust Indication voltage remains below
.2 volts for about 20
r

Code 23 - MAT Sets if the sensor,

Low Temperature seconds.
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connections, or wires
Indication open for 3 seconds.
Code 45 Sets if oxygen sensor
Code 2 4 -VSS No vehicle speed present Rich Exhaust Indication voltage remains above
.7 volts for about 1
ic

No Vehicle Speed during a road load decel.

Indication minute.
s

Code 25 - MAT Sets if the sensor or Code 51 Faulty MEM-CAL,

High Temperature signal line becomes Prom, or ECM.
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Indication grounded for 3 seconds.

Code 52 Fuel CALPAK
missing or faulty.
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Code 32 - EGR Vacuum switch shorted

to ground on start up Code 54 - Fuel Pump Sets when the fuel
OR Low voltage pump voltage is less
Switch not closed after than 2 volts when
the ECM has reference pulses are
commanded EGR for a being received.
specified period of time.
OR Code 55 Faulty ECM
EGR solenoid circuit
open for a specified
period of time.

7-12-85
7S 3337-6E
Figure 3 -12 - ECM Code System
3-12 COMPUTER COMMAND CONTROL

om
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CHART A-1
NO "SERVICE ENGINE SOON" LIGHT
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ALL ENGINES
Circuit Description:
There should always be a steady "Service Engine Soon” light when the ignition is "ON” and engine stopped.
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Battery ignition voltage is supplied to the light bulb. The Electronic Control Module (ECM) will control the
light and turn it on by providing a ground path through CKT 419 to the ECM.
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Test Description: Step numbers refer to step Diagnostic Aids:

numbers on diagnostic chart.
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1. If the fuse in holder is blown, refer to facing page If the engine runs ok, check:
of Code 54 for complete circuit. • Faulty light bulb.
2. Using a test light connected to 12 volts, probe each • CKT 419 open.
of the system ground circuits to be sure a good • Gage fuse blown. This will result in no stop
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ground is present. See ECM terminal end view in lights, oil or g en erato r lig h ts, sea t b elt
front of this section for ECM pin locations of reminder, etc.
ground circuits. If the engine cranks but will not run, check:
• Continuous battery-fuse or fusible link open.
• ECM ignition fuse open.
• Battery CKT 340 to ECM open.
• Ignition CKT 439 to ECM open.
• Poor connection to ECM.
 COMPUTER COMMAND CONTROL 3-13

CHART A-1
NO "SERVICE ENGINE SOON"LIGHT
ALL ENGINES

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7S 3687
CLEAR CODES AND CONFIRM "CLOSED LOOP " OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. n oc
3-14 COMPUTER COMMAND CONTROL

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CHART A-2
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NO ALDL DATA OR WONT FLASH CODE 12

"SERVICE ENGINE SOON" LIGHT ON STEADY
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ALL ENGINES
Circuit Description:
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There should always be a steady "Service Engine Soon” light when the ignition is "ON” and engine stopped.
Battery ignition voltage is supplied to the light bulb. The Electronic Control Module (ECM) will turn the light
on by grounding CKT 419 at the ECM.
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With the diagnostic terminal grounded, the light should flash a Code 12, followed by any trouble code(s)
stored in memory.
A steady light suggests a short to ground in the light control CKT 419, or an open in diagnostic CKT 451.
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Test Description: Step numbers refer to step At this point the "Service Engine Soon” light
numbers on diagnostic chart. wiring is OK. The problem is a faulty ECM or
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1. If there is a problem with the ECM that causes a PROM/Mem-Cal. If Code 12 does not flash, the
"Scan” tool to not read Serial data then the ECM ECM should be replaced using the o rig in al
should not flash a Code 12. If Code 12 does flash, PROM/Mem-Cal. Replace the PROM/Mem-Cal
be sure that the "Scan” tool is working properly on only a fte r try in g an ECM, as a defective
another vehicle. If the "Scan” is functioning PROM/Mem-Cal is an unlikely cause of the
properly and CKT 461 is OK, the PROM/Mem-Cal problem.
or ECM may be at fault for the NO ALDL
symptom.
2. If the light goes "OFF” when the ECM connector is
disconnected, then CKT 419 is not shorted to
ground.
3. This step will check for an open diagnostic CKT
451.
 COMPUTER COMMAND CONTROL 3-15

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3-16 COMPUTER COMMAND CONTROL

ECM
439 PNK/BLK TO ECM
ECM 1
12V 439 PNK/BLK 439 RED 467 LTBLU
IGN 10A TBI UNIT
AB INJECTOR

A '
7S 3774-6E
8-11-87 7-23-86

CHART A-3

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ENGINE CRANKS BUT WILL NOT RUN
2.5L ENGINE
Circuit Description:

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This chart assumes that battery condition and engine cranking speed are OK, and there is adequate fuel in
the tank. This chart should be used on engines using the Model 700 throttle body.

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Test Description: Step numbers refer to step 4. Use an injector test light like J34730, BT8329A or
numbers on diagnostic chart. equivalent, to test injector circuit. A blinking
1. A "Service Engine Soon” light "ON” is a basic test light indicates the ECM is controlling the injector.
to determine if there is a 12 volt supply and
ignition 12 volts to ECM. No ALDL may be due to
an ECM problem and CHART A-2 will diagnose
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5. This test will determine if there is fuel pressure at
the injector and that the injector is operating.
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the ECM. If TPS is over 2.5 volts the engine may Diagnostic Aids:
be in the clear flood mode which will cause
If no trouble is found in the ECM, fuel pump and
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starting problems. If coolant sensor is below -30°C,

the ECM will provide fuel for this extremely cold ignition systems, check for:
temperature which will severely flood the engine. • Fouled spark plugs
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2. Voltage at the spark plug is checked using Spark • EGR valve stuck open
Tester tool ST125 (J26792) or equivalent. No • Low fuel pressure. See CHART A-6.
spark indicates a basic ignition problem.
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3. While cranking engine there should be no fuel

spray with injector disconnected. Replace an
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injector if it sprays fuel or drips like a leaking

water faucet.
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 COMPUTER COMMAND CONTROL 3-17

IF CODE 54 IS STORED, USE THAT CHART FIRST

© • IGN "ON" - IF S.E.S. LIGHT IS OFF, SEE CHART A-1.

CHART A-3
• INSTALL "SCAN" TOOL - IF "NO ALDL", SEE CHART A-2.
• CHECK THE FOLLOWING: ENGINE CRANKS BUT WILL NOT RUN
• TPS - IF OVER 2.5V AT CLOSED THROTTLE, SEE CODE 22. 2.5L ENGINE
• COOLANT - IF BELOW -30°C, SEE CODE 15.
• APPLY 12V TO FUEL PUMP TEST TERMINAL AND LISTEN
FOR PUMP TO RUN. DOES IT?

YES NO
~r~
• PROBE FUEL PUMP TEST TERMINAL
WITH A TEST LIGHT TO 12V.
• TEST LIGHT WILL LIGHT.
• IGN "OFF" FOR 10 SECONDS.
• IGN "ON". TEST LIGHT SHOULD GO

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OUT FOR 2 SEC. DOES IT?

YES NO

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CRANK ENGINE AND CHECK FOR J SEE FUEL PUMP RELAY
© SPARK WITH ST-125. i CIRCUIT CHART A-5
CHECK ONE WIRE. LEAVE THE OTHER

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WIRES CONNECTED TO THE SPARK
PLUGS DURING CRANKING.
IS THERE SPARK?

YES
ar NO
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i—
I T---------------------------------------------1
• DISCONNECT INJECTOR CONNECTOR. J SEE IGNITION SYSTEM j
© • CRANK ENGINE. i CHECK IN SECTION 6 t
IS THERE FUEL SPRAY FROM INJECTOR?
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NO YES
I
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• CONNECT INJECTOR TEST LIGHT FAULTY INJECTOR

© TO HARNESS CONNECTOR. SEAL OR INJECTOR
• CRANK ENGINE.
DOES TEST LIGHT BLINK?
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NO
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i--"----------------------- 1
RECONNECT INJECTOR CONNECTOR. I SEE INJECTOR CIRCUIT J
CRANK ENGINE. i DIAGNOSIS CHART A-4 i
IS THERE FUEL SPRAY FROM INJECTOR?
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NO
I
NO TROUBLE FOUND. • IGN "OFF:
• INSTALL FUEL PRESSURE GAGE AS OUTLINED IN SECTION 4.
SEE DIAGNOSTIC AIDS
• IGN "ON".
ON FACING PAGE. • FUEL PRESSURE SHOULD BE 62-90 KPa (9-13 psi)
IS IT?

NO

FAULTY INJECTOR j SEE FUEL SYSTEM j

7S3775
i DIAGNOSIS CHART A-6 i 7-23-86
3-18 COMPUTER COMMAND CONTROL

468 LT GRN

482 WHT —| 481 RED 467 LTBLU

TBI220 UNIT
INJECTORS

. ECM 1 2.8L(S,T SERIES)

12V 439 PNK/BLK TO ECM 4.3L & V-8 (P, R & V SERIES)
IGN 10A

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ECM
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468 LT GRN D14

482 WHT 481 RED 467 LTBLU D16

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TBI 220 UNIT
INJECTORS

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4.3L & V-8 (C, K, G & M SERIES)
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12V
IGN 7S3777-6E
8- 11-86
7-23-86
a

CHART A-3
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ENGINE CRANKS BUT WILL NOT RUN

ALL ENGINES EXCEPT 2.5L
Circuit Description:
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This chart assumes that battery condition and engine cranking speed are OK, and there is adequate fuel in
the tank. This chart should be used on engines using the Model 220 throttle body.
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Test Description: Step numbers refer to step 4. Use an injector te st lig h t like BT8320, or
numbers on diagnostic chart. equivalent, to test each injector circuit. A
1. A "Service Engine Soon” light "ON” is a basic test blinking light indicates the ECM is controlling
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to determine if there is a 12 volt supply and the injectors.

ignition 12 volts to ECM. No ALDL may be due to 5. This test will determine if there is fuel pressure at
an ECM problem and CHART A-2 will diagnose the injectors and that the injectors are operating.
the ECM. If TPS is over 2.5 volts the engine may
be in the clear flood mode which will cause Diagnostic Aids:
starting problems. If coolant sensor is below -30°C,
the ECM will provide fuel for this extremely cold If no trouble is found in the ECM, fuel pump and
temperature which will severely flood the engine. ignition systems, check for:
2. Voltage at the spark plug is checked using Spark • Fouled spark plugs
Tester tool ST125 (J26792) or equivalent. No • EGR valve stuck open
spark indicates a basic ignition problem. • Low fuel pressure. See CHART A-6.
3. While cranking engine there should be no fuel
spray with injectors disconnected. Replace an
injector if it sprays fuel or drips like a leaking
water faucet.
 COMPUTER COMMAND CONTROL 3-19

IF CODE 54 IS STORED, USE THAT CHART FIRST

© •• IGN "O N "- IF S.E.S. LIGHT IS OFF. SEE CHART A-1. CHART A-3
INSTALL "SCAN” TOOL - IF "NO ALDL", SEE CHART A-2.
• CHECK THE FOLLOWING: ENGINE CRANKS BUT WILL NOT RUN
• TPS - IF OVER 2.5V AT CLOSED THROTTLE. SEE CODE 22. ALL ENGINES EXCEPT 2.5L
• COOLANT - IF BELOW -30°C, SEE CODE 15.
• APPLY 12V TO FUEL PUMP TEST TERMINAL AND LISTEN
FOR PUMP TO RUN. DOES IT?

YES NO
HZ
• PROBE FUEL PUMP TEST TERMINAL
WITH A TEST LIGHT TO 12V.
• TEST LIGHT WILL LIGHT.
• IGN "OFF" FOR 10 SECONDS.
• IGN "ON". TEST LIGHT SHOULD GO

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OUT FOR 2* SEC. DOES IT?

YES NO

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CRANK ENGINE AND CHECK FOR i SEE FUEL PUMP RELAY
© SPARK WITH ST-125. ! CIRCUIT CHART A-5
i_______________________
CHECK ONE WIRE. LEAVE THE OTHER

.
WIRES CONNECTED TO THE SPARK

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PLUGS DURING CRANKING.
IS THERE SPARK? ra
NO
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I-------------------------1
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• DISCONNECT INJECTOR CONNECTORS. j SEE IGNITION SYSTEM j
• CRANK ENGINE. i CHECKIN SECTION 6 i
IS THERE FUEL SPRAY FROM ONE OR BOTH INJECTORS? i________________________ ._i
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• CONNECT INJECTOR TEST LIGHT TO ONE HARNESS CONNECTOR. FAULTY INJECTOR

• CRANK ENGINE. SEAL OR INJECTOR
• REPEAT TEST ON OTHER CONNECTOR
DOES TEST LIGHT BLINK ON BOTH TESTS?
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YES NO
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HZ X
© • RECONNECT INJECTOR CONNECTORS.
• CRANK ENGINE.
| SEE INJECTOR CIRCUIT
i DIAGNOSIS CHART A-4
IS THERE FUEL SPRAY FROM INJECTORS?
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ONE ONLY NO

NO TROUBLE FOUND. FAULTY INJECTOR • IGN "OFF:.

• INSTALL FUEL PRESSURE GAGE AS OUTLINED IN SECTION 4.
SEE DIAGNOSTIC AIDS
• IGN "ON".
ON FACING PAGE. • FUEL PRESSURE SHOULD BE 62-90 KPa (9-13 psi)
IS IT?

1
YES NO
ON SOME VEHICLES THE PUMP WILL RUN =E=
FAULTY INJECTORS SEE FUEL SYSTEM
FOR APPROXIMATELY 20 SECONDS. 7S3778
i DIAGNOSIS CHART A-6 7-23-86
3-20 COMPUTER COMMAND CONTROL

ECM
439 PNK/BLK TO ECM
ECM 1
12V 439 PNK/BLK 439 RED 467 LTBLU
IGN 10A TBI UNIT
AB INJECTOR

7S 3774-6E
8 - 11-86 7-23-86

CHART A-4

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INJECTOR CIRCUIT DIAGNOSIS
2.5L ENGINE
Circuit Description:

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This chart should only be used if diagnosis in CHART A-3 indicated an injector circuit problem.

Test Description: Step numbers refer to step

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numbers on diagnostic chart.
1. This step tests for 12 volts to the injector. It will
also determine if there is a short to voltage on the
ECM side of the circuit.
2. This test checks for continuity to the ECM.
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 COMPUTER COMMAND CONTROL 3-21

CHART A-4
INJECTOR CIRCUIT DIAGNOSIS
2.5L ENGINE

: fro m ]
: CHART A-3 :

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CLEAR CODES AND CONFIRM "CLOSED LOOP " OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. / s ,/ '1
7-25-86
3-22 COMPUTER COMMAND CONTROL

ECM
y
468 LTGRN

482 WHT I - 481 RED 467 LTBLU

1
A B TBI220 UNIT
INJECTORS

. ECM 1 2.8L(S,T SERIES)

12V 439 PNK/BLK TO ECM 4.3L & V-8 (P, R & V SERIES)
IGN 10A

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ECM

468 LTGRN D14 |

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482 WHT 481 RED 467 LTBLU D16 |
TBI 220 UNIT
1

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INJECTORS

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4.3L & V-8 (C, K, G & M SERIES)
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12V
IGN 7S 3777-6E
8 - 11-86
7-23-86
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CHART A-4
INJECTOR CIRCUIT DIAGNOSIS
ic

ALL ENGINES EXCEPT 2.5L

Circuit Description:
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This chart should ony be used if diagnosis in CHART A-3 indicated an injector circuit problem. If both
injector circuits fail to blink when tested, diagnose one injector circuit at a time.
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Test Description: Step numbers refer to step

numbers on diagnostic chart.
1. This step tests for 12 volts to the injector. It will
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also determine if there is a short to voltage on the

ECM side of the circuit.
2. This test checks for continuity to the ECM.
 COMPUTER COMMAND CONTROL 3-23

CHART A-4
INJECTOR CIRCUIT DIAGNOSIS
ALL ENGINES EXCEPT 2.5L

: FROM
: CHART A-3 :

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CLEAR CODES AND CONFIRM "CLOSED LOOP " OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
7-25-86
3-24 COMPUTER COMMAND CONTROL

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CHART A-5
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FUEL PUMP RELAY CIRCUIT

S , T&M SERIES
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Circuit Description:
When the ignition switch is turned "ON”, the Electronic Control Module (ECM) will turn "ON” the in-tank
cc

fuel pump. It will remain "ON” as long as the engine is cranking or running, and the ECM is receiving
distributor reference pulses. If there are no reference pulses, the ECM will shut "OFF” the fuel pump within 2
seconds after ignition "ON” or engine stops.
si

The pump will deliver fuel to the TBI unit where the system pressure is controlled to about 62 to 90 kPa (9 to
13 psi). Excess fuel is then returned to the fuel tank.
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Test Description: Step numbers refer to step 3. Determines if ECM can control the relay.
numbers on diagnostic chart. 4. The oil pressure switch serves as a backup for the
1. Turns "ON” the fuel pump if CKT 120 wiring is fuel pump relay to help prevent a no s ta r t
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OK. If the pump runs, it maybe a fuel pump relay situation. If the fuel pump relay was found to be
circuit problem, which the following steps will inoperative, the oil pressure switch circuit should
locate. also be tested to determine why it did not operate
2. The next two steps check for power and ground the fuel pump.
circuits to the relay.
 COMPUTER COMMAND CONTROL 3-25

THIS CHART ASSUMES NO CODE 54 STORED CHART A-5

•
•
APPLY 12V TO FUEL PUMP TEST TERMINAL
LISTEN FOR IN TANK FUEL PUMP. DOES IT RUN?
FUEL PUMP RELAY CIRCUIT
S , T&M SERIES
1
YES NO
□ c HI
• REMOVE 12V FROM TEST TERMINAL OPEN IN CKT 120 OR CKT 150 TO
• IGNITION "OFF" FOR TEN SECONDS. THE FUEL PUMP OR FAULY PUMP.
• IGNITION "ON". LISTEN FOR IN TANK FUEL
PUMP. PUMP SHOULD RUN FOR 2 SECONDS
AFTER IGNITION ON. DOES IT?

NO YES
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© • DISCONNECT PUMP RELAY. NO TROUBLE FOUND

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• IGNITION "ON" ENGINE STOPPED.
• PROBE RELAY HARNESS-CONNECTOR TERMINAL
CKT 440 WITH A TEST LIGHT TO GROUND.

LIGHT" OFF'

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LIGHT" ON'
T
CONNECT A TEST LIGHT BETWEEN REPAIR OPEN
HARNESS CONNECTOR TERMINAL CKT 440.

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CKTS450 AND 440.
1

LIGHT" ON"
1
LIGHT" OFF"
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CONNECT TEST LIGHT BETWEEN REPAIR OPEN
TERMINAL CKT 465 AND GND. GROUND
IGNITION "OFF" FOR 10 CKT 450.
SECONDS.
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IGNITION "ON". TEST LIGHT

SHOULD LIGHT FOR 2 SECONDS.
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DOES IT?
cc

YES NO
Z JZ I
FAULTY CONNECTION AT RELAY TERMINAL "B" OPEN OR SHORT TO
OR FAULTY RELAY. GROUND IN CKT 465
IF ORIGINAL SYMPTOM WAS "ENGINE CRANKS OR FAULTY ECM.
si

BUT WILL NOT RUN", CONTINUE TESTING OF OIL

PRESSURE SWITCH.
ENGINE AT NORMAL OPERATING TEMPERATURE.
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OIL PRESSURE NORMAL.

DISCONNECT FUEL PUMP RELAY. ENGINE
SHOULD CONTINUE TO RUN. DOES IT?
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YES NO
HE I
• RECONNECT FUEL PUMP OPEN IN CKT 440 OR 120 TO
RELAY. THE OIL PRESSURE SWITCH OR
• IGNITION "OFF". FAULTY OIL PRESSURE SWITCH
• PROBE FUEL PUMP TEST
TERMINAL WITH A TEST
LIGHT TO GROUND.

NO LIGHT LIGHT
X ----- r
NO TROUBLE FOUND FAULTY OIL
PRESSURE SWITCH

CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S3803
7-28-86
3-26 COMPUTER COMMAND CONTROL

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CHART A-5
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FUEL PUMP RELAY CIRCUIT

C, K, R, V, G & P SERIES
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Circuit Description:
When the ignition switch is turned "ON”, the Electronic Control Module (ECM) will turn "ON” the in-tank
fuel pump. It will remain "ON” as long as the engine is cranking or running, and the ECM is receiving
distributor reference pulses. If there are no reference pulses, the ECM will shut "OFF” the fuel pump within 2
c

seconds after ignition "ON” or engine stops.

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The pump will deliver fuel to the TBI unit where the system pressure is controlled to about 62 to 90 kPa (9 to
13 psi). Excess fuel is then returned to the fuel tank.
A fuel module is used on all 7.4L and some 5.7L engines to correct a hot restart (vapor lock) during a high
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ambient condition. It is designed to over-ride the ECM 2 second pump operation and will run the fuel pump for
20 seconds at initial ignition "ON”.
Test Description: Step numbers refer to step Diagnostic Aids:
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numbers on diagnostic chart.

1. Turns "ON” the fuel pump if CKT 120 wiring is • An inoperative fuel module may be the cause of a
OK. If the pump runs, it maybe a fuel pump relay hot stall/no start condition. Check for power and
circuit problem, which the following steps will ground circuit to the fuel module and a complete
locate. circuit to the pump from terminal "A”. If OK, and
2. The next two steps check for power and ground the pump does not run for the specified 20 seconds
circuits to the relay. at initial ignition "ON”, replace the Fuel Module.
3. Determines if ECM can control the relay.
4. The oil pressure switch serves as a backup for the
fuel pump relay to help prevent a no s ta r t
situation. If the fuel pump relay was found to be
inoperative, the oil pressure switch circuit should
also be tested to determine why it did not operate
the fuel pump.
 COMPUTER COMMAND CONTROL 3-27

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3-28 COMPUTER COMMAND CONTROL

TBI
INJECTOR
THROTTLE BODY MODEL 700 TBI
PRESSURE REGULATOR
FUEL RETURN LINE

l z i:
/
IN-LINE
FUEL FILTER
f
FLEX HOSE FUEL PRESSURE LINE IN-TANK PUMP

FUEL PRESSURE
GAGE TEST

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FUEL V
TANK I PUMP INLET FILTER — \

TBI UNIT THROTTLE BODY MODEL 220 TBI

INJECTORS PRESSURE REGULATOR

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FUEL RETURN LINE

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FLEX HOSE FUEL PRESSURE LINE FUEL CAP
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IN-TANK FUEL PUMP
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FUEL PRESSURE
PUMP INLET FILTER 7S 3806-6E
8 - 11-86 GAGE TEST POINT - S
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7-29-86

CHART A-6
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FUEL SYSTEM PRESSURE TEST

Circuit Description: ALL ENGINES
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When the fuel pump is running, fuel is delivered to the injector(s) and then to the regulator where the
system pressure is controlled to about 62 to 90 kPa (9 to 13 psi). Excess fuel is then returned to the fuel tank.
Test Description: Step numbers refer to step pressure). When battery voltage is applied to the
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numbers on diagnostic chart. pump test connector, pressure should be from 90 to

1. Pressure but less than 62 kPa (9 psi) falls into two 124 kPa (13 to 18 psi).
areas: 3. This test determines if the high fuel pressure is
• Regulated pressure but less than 62 kPa (9 psi) - due to a restricted fuel return line or a throttle
Amount of fuel to injector OK but pressure is too body pressure regulator problem.
low. System will be lean running and may set
Code 44. Also, hard starting cold and poor overall Diagnostic Aids:
performance.
• Restricted flow causing pressure drop - Normally, • If the vehicle is equipped with a fuel module, the
a vehicle with a fuel pressure of less than 62 kPa module must be disconnected before performing
(9 psi) at idle will not be driveable. However, if the fuel system pressure test. Refer to Section 4.
the pressure drop occurs only while driving, the • Fuel system is under pressure. To avoid fuel
engine will normally surge then stop as pressure spillage, refer to procedures in Section 4 for
begins to drop rapidly. testing or making repairs requiring disassembly
2. Restricting the fuel return line allows the fuel of fuel lines or fittings.
pump to develop its maximum pressure (dead head
 COMPUTER COMMAND CONTROL 3-29

CHART A-6
FUEL SYSTEM PRESSURE TEST
SEE "DIAGNOSTIC AIDS" BEFORE BEGINNING
ALL ENGINES
• IGNITION "OFF" FOR TEN SECONDS.
• IGNITION "ON". LISTEN FOR IN TANK FUEL
PUMP. PUMP SHOULD RUN FOR 2 SECONDS
AFTER IGNITION ON. DOES IT?

1
YES NO
~JZ
• IGNITION "OFF" ! SEE FUEL PUMP RELAY !
• FUEL TANK QUANTITY OK. | CIRCUIT CHART A-5
• INSTALL PRESSURE GAGE AS OUTLINED IN SECTION 4

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• IGNITION "ON", NOTE PRESSURE.

FUEL PRESSURE IS BELOW 62 kPa (9 psi) FUEL PRESSURE IS

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OR ABOVE 89 kPa (13 psi). 62-90 kPa (9-13 psi)
I ,.,_ z
NO PROBLEM FOUND

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(? ) LESS THAN 62 kPa (9 psi) ABOVE 89 kPa (13 psi)
X
INSTALL PRESSURE GAGE ON INLET SIDE OF FUEL
ra • DISCONNECT INJECTOR CONNECTOR.
FILTER AND REINSTALL FILTER OUTLET LINE. • DISCONNECT FUEL RETURN LINE FLEXIBLE HOSE.
APPLY 12V TO TEST TERMINAL • ATTACH 5/16 I.D. FLEX HOSE TO THROTTLE BODY
NOTE PRESSURE SIDE OF RETURN LINE. INSERT THE OTHER END IN
lib
AN APPROVED GASOLINE CONTAINER.
• NOTE FUEL PRESSURE WITHIN 2 SECONDS AFTER
IGNITION "ON".
LESS THAN 62 kPa (9 psi) ABOVE 62 kPa (9 psi)
ar

ABOVE 89 kPa (13 psi) 62-89 kPa (9-13 psi)

IGNITION "OFF". REPLACE FILTER
DISCONNECT INJECTOR. AND RECHECK.
BLOCK FUEL RETURN LINE BY
cc

CHECK FOR RESTRICTED FUEL LOCATE AND CORRECT

PINCHING FLEXIBLE HOSE. LINE BETWEEN GAGE AND RESTRICTED FUEL
APPLY 12 VOLTS TO FUEL RETURN LINE FLEXIBLE HOSE RETURN LINE TO TANK
PUMP TEST CONNECTOR
AND NOTE PRESSURE.
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IF LINE OK, REPLACE

FUEL METER COVER.
ABOVE 89 kPa (13 psi) PRESSURE. BUT LESS
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THAN 62 kPa (9 psi)

REPLACE FUEL CHECK FOR RESTRICTED FUEL

METER COVER. LINE FROM FUEL TANK TO
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GAGE OR FAULTY IN-TANK

- FUEL PUMP
- COUPLING HOSE
- PUMP INLET FILTER
- WRONG FUEL PUMP

7S3807
7-29-86
3-30 COMPUTER COMMAND CONTROL

ECM
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PPL 412 ------ D7 0 2 SENSOR

SIGNAL

D6
0 2 GROUND
CIRCUIT

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4S 0790-6E
8 - 11-86
S ' 4-16-86

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CODE 13
OPEN OXYGEN SENSOR CIRCUIT
ALL ENGINES

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Circuit Description:
The ECM supplies a voltage of about .45 volt between terminals "D7” and "E15”.(If measured with a 10
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megohm digital voltmeter, this may read as low as .32 volts.) The O2 sensor varies the voltage within a range of
about 1 volt if the exhaust is rich, down through about .10 volt if exhaust is lean.
The sensor is like an open circuit and produces no voltage when it is below 315° C (600°F). An open sensor
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circuit or cold sensor causes "Open Loop” operation.
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Test Description: Step numbers refer to step Diagnostic Aids:

numbers on diagnostic chart.
Normal "Scan” voltage varies between 100 mv to
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1. Code 13 WILL SET:

999 mv (.1 and 1.0 volt) while in closed loop. Code 13
• Engine at normal operating temperature
sets in one minute if voltage remains between .35 and
• At least 2 minutes engine time after start.
.55 volts, but the system will go "Open Loop” in about
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• Oxygen sensor signal voltage steady between

15 seconds. Refer to ECM "Intermittents” in Section
.35 and .55 volts .
2.
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• Throttle position sensor signal above 4% .

• All conditions m ust be met for about 60
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seconds.
If the conditions for a Code 13 exist, the
system will not go "Closed Loop”.
2. This will determine if the sensor is at fault or the
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wiring or ECM is the cause of Code 13.

3 In doing this test, use only a high impedence digital
volt ohm meter. This test checks the continuity of
CKT’s 412 and 413 because if CKT 413 is open the
ECM voltage on CKT 412 will be over .6 volts
(600 mv).
 COMPUTER COMMAND CONTROL 3-31

'SCAN" DIAGNOSTICS
CODE 13
OPEN OXYGEN SENSOR CIRCUIT
ALL ENGINES

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5-7-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. *7S3054-6E
3-32 COMPUTER COMMAND CONTROL

COOLANT TEMPERATURE
SENSOR

ECM

-COOLANT SENSOR
SIGNAL

5V
410 YEL {cTTJ- ■m a t
2.5L, 4.3L M & G VAN 452 BLK f^ T
ALL EXCEPT ABOVE * 452 BLK
{H }

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7S 3690-6E
8 - 11-86 7-9-86

CODE 14

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COOLANT TEMPERATURE SENSOR
(HIGH TEMPERATURE INDICATED)

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ALL ENGINES
Circuit Description:
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The Coolant Temperature Sensor uses a thermistor to control the signal voltage to the ECM. The ECM
applies a voltage on CKT 410 to the sensor. When the engine is cold the sensor (thermistor) resistance is high,
therefore the ECM will see high signal voltage.
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As the engine warms, the sensor resistance becomes less, and the voltage drops. At normal engine
operating temperature (85°C to 95°C) the voltage will measure about 1.5 to 2.0 volts.
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Test Description: Step numbers refer to step Diagnostic Aids:

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numbers on diagnostic chart.

1. Code 14 will set if: Check harness routing for a potential short to
• Signal v o ltag e in d ic a te s a c o o lan t ground in CKT 410.
tem perature above 130°C (266°F) for 3 "Scan” tool displays engine temp, in degrees
ic

seconds. centigrade. After engine is started, the temperature

2. This test will determine if CKT 410 is shorted to should rise steadily to about 90°C then stabilize when
s

ground which will cause the conditions for Code thermostat opens.
14. See "ECM Intermittent Codes or Performance” in
as

Section 2.
The "Temperature to Resistance Value” scale at
the right may be used to test the coolant sensor at
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various temperature levels to evaluate the possibility

of a "slewed” (mis-scaled) sensor. A "slewed” sensor
could result in poor driveability complaints.
 COMPUTER COMMAND CONTROL 3-33

'SCAN" DIAGNOSTICS
CODE 14
COOLANT TEMPERATURE SENSOR
(HIGH TEMPERATURE INDICATED)
ALL ENGINES

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DIAGNOSTIC AID
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COOLANT SENSOR
TEMPERATURE TO RESISTANCE VALUES
(APPROXIMATE)
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°F °C OHMS
210 100 185
160 70 450
100 38 1,800
70 20 3,400
40 4 7,500
20 -7 13,500
0 -18 25,000
-40 -40 100,700

3-5-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. *7S 3055
3-34 COMPUTER COMMAND CONTROL

COOLANT TEMPERATURE
U IL SENSOR

U ECM

-COOLANT SENSOR
SIGNAL

410 YEL " M aat

5V

2.5L, 4.3L M & G VAN 452 BLK - — E l h

© ALL EXCEPT ABOVE “ 452 BLK

iH } 7 S 3690

m
8 - 11-86 7-9-86

CODE 15

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COOLANT TEMPERATURE SENSOR
(LOWTEMPERATURE INDICATED)

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ALL ENGINES
Circuit Description:
ar
The Coolant Temperature Sensor uses a thermistor to control the signal voltage to the ECM. The ECM
applies a voltage on CKT 410 to the sensor. When the engine is cold the sensor (thermistor) resistance is high,
therefore the ECM will see high signal voltage.
br
As the engine warms, the sensor resistance becomes less, and the voltage drops. At normal engine
operating temperature (85°C to 95°C) the voltage will measure about 1.5 to 2.0 volts.
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Test Description: Step numbers refer to step Diagnostic Aids:

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numbers on diagnostic chart.

1. Code 15 will set if: A "Scan” tool reads engine temperature in degrees
• S ig n al v o ltag e in d ic a te s a c o o la n t centigrade. After engine is started, the temperature
tem perature less than -44°C (-47°F) for 3 should rise steadily to about 90°C then stabilize when
c

seconds. thermostat opens.

2. This test sim ulates a Code 14. If the ECM A faulty connection, or an open in CKT 410 or 452
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recognizes the low signal voltage, (high temp.) and will results in a Code 15.
the "Scan” reads 130°C or above, the ECM and See "ECM Intermittent Codes on Performance” in
as

wiring are OK. Section 2.

3. This test will determine if CKT 410 is open. There The "Temperature To Resistance Value” scale at
should be 5 volts present at sensor connector if the right may be used to test the coolant sensor at
cl

measured with a DVOM. various temperature levels to evaluate the possibility

of a "slewed” (mis-scaled) sensor. A "slewed” sensor
could result in poor driveability complaints.
 COMPUTER COMMAND CONTROL 3-35

'SCAN'' DIAGNOSTICS
CODE 15
COOLANT SENSOR CIRCUIT
(LOW TEMPERATURE INDICATED)
ALL ENGINES

© DOES "SCAN" DISPLAY COOLANT -30°C OR COLDER?

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YES NO

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© •
•
DISCONNECT SENSOR
JUMPER HARNESS TERMINALS TOGETHER
CODE 15 IS INTERMITTENT. IF NO
ADDITIONAL CODES WERE STORED, REFER

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• "SCAN" SHOULD DISPLAY 130°C OR MORE. TO DIAGNOSTIC AIDS ON FACING PAGE.
DOES IT?

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YES NO
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FAULTY CONNECTION OR SENSOR. © • JUMPER CIRCUIT 410 TO GROUND.

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• "SCAN" SHOULD DISPLAY OVER 130°C.

DOES IT?
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DIAGNOSTIC AID YES NO

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COOLANT SENSOR
TEMPERATURE TO RESISTANCE VALUES OPEN CIRCUIT452, OPEN CIRCUIT 410, FAULTY
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(APPROXIMATE) FAULTY CONNECTION CONNECTION AT ECM, OR

°F °C OHMS OR FAULTY ECM. FAULTY ECM.
210 100 185
160 70 450
100 38 1,800
70 20 3,400
40 4 7,500
20 -7 13,500
0 -18 25,000
-40 -40 100,700

3-19-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. *7S 3261
3-36 COMPUTER COMMAND CONTROL

ECM
y
C14
-^ W ^ E F E R E N C E
THROTTLE
POSITION C13 TPS SIGNAL
SENSOR
A11 5V RETURN

ECM

C14 V
v v REFERENCE
THROTTLE

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POSITION C13 TPS SIGNAL
SENSOR
A11 5V RETURN

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D2 5V RETURN
7S3691
9-4-86

y.
CODE 21
THROTTLE POSITION SENSORar
(SIGNAL VOLTAGE HIGH)
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ALL ENGINES
Circuit Description:
The Throttle Position Sensor (TPS) provides a voltage signal that changes relative to the throttle blade
rli

angle. Signal voltage will vary from about .5 volts at idle to about 5 volts at wide open throttle.
The TPS signal is one of the most important inputs used by the ECM for fuel control and for most of the
ca

ECM control outputs.

Test Description: Step numbers refer to step Diagnostic Aids:

numbers on diagnostic chart.
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1. Code 21, will set if: A "Scan” tool reads throttle position in volts.
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• Engine running Should read about .73 volts (2.5L), .45 volts (2.8L), .60
• TPS signal voltage is greater than about 3.5 volts (4.3L & V8) ± .75 volts with throttle closed and
volts ignition on or at idle. Voltage should increase at a
as

• All conditions met for 5 seconds. steady rate as throttle is moved toward WOT.
OR Also some "Scan” tools will read throttle angle.0%
• TPS signal voltage over 4.5 volts with ignition = closed throttle 100% = WOT.
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"ON”. Refer to Section 2 for "ECM Intermittent Codes or

With throttle closed, the TPS should read less Performance”.
than .70 volts. If it doesn’t, check adjustment. "Scan” TPS while depressing accelerator pedal
2. With the TPS sensor disconnected, the TPS with engine stopped and ignition "ON”. Display
voltage should go low if the ECM and wiring is should vary from below 2.5 volts (2500 mv) when
OK. throttle was closed, to over 4.5 volts (4500 mv) when
3. Probing CKT 452 with a test light checks the 5 throttle is held at wide open throttle position.
volts return CKT, because a faulty 5 volts return
will cause a Code 21.
 COMPUTER COMMAND CONTROL 3-37

'SCAN " DIAGNOSTICS

CODE 21
THROTTLE POSITION SENSOR
(SIGNAL VOLTAGE HIGH)
ALL ENGINES

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3-5-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. *7S 3057
3-38 COMPUTER COMMAND CONTROL

ECM
✓
C14
THROTTLE
POSITION C13 TPS SIGNAL
SENSOR
A11 5V RETURN

ECM
✓
C14
v v REFERENCE
THROTTLE

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POSITION C13 TPS SIGNAL
SENSOR
A11 5V RETURN

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02 5V RETURN
7S3691-6E
9-3-86 7-10-86

y.
CODE 22
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THROTTLE POSITION SENSOR
(SIGNAL VOLTAGE LOW)
ALL ENGINES
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Circuit Description:
The Throttle Position Sensor (TPS) provides a voltage signal that changes relative to the throttle blade.
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Signal voltage will vary from about .5 at idle to about 5 volts at wide open throttle.
The TPS signal is one of the most important inputs used by the ECM for fuel control and for most of the
ECM control outputs.
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Test Description: Step numbers refer to step Diagnostic Aids:

numbers on diagnostic chart.
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1. Code 22, will set if: A "Scan” tool reads throttle position in volts.
• Engine running Should read about .73 volts (2.5L), .48 volts (2.8L), .60
s

• TPS signal voltage is less than about .2 volt for volts (4.3L & V8) ± .08 volts with throttle closed and
3 seconds. ignition on or at idle. Voltage should increase at a
as

2. Simulates Code 21: (high voltage) If the ECM steady rate as throttle is moved toward WOT.
recognizes the high signal voltage the ECM and An open or short to ground in CKTs 416 or 417
wiring are OK. will result in a Code 22.
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3. TPS adjustment: (2.8L) With throttle closed, the Refer to Section 2 for "ECM Intermittent Codes or
TPS voltage reading should be .48 volts ± .06 volts. Performance”.
4. This simulates a high signal voltage to check for "Scan” TPS while depressing accelerator pedal
an open in CKT 417. with engine stopped and ignition "ON”. Display
should vary from below 2.5 volts (2500 mv) when
throttle was closed, to over 4.5 volts (4500 mv) when
throttle is held at wide open throttle position.
 COMPUTER COMMAND CONTROL 3-39

'SCAN" DIAGNOSTICS
CODE 22
THROTTLE POSITION SENSOR
(SIGNAL VOLTAGE LOW)
ALL ENGINES

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4-24-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. *7S 3365
3-40 COMPUTER COMMAND CONTROL

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CODE 23

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MANIFOLD AIR TEMPERATURE SENSOR
(LOW TEMPERATURE INDICATED)
2.5L ENGINE

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Circuit Description:
The Manifold Air Temperature (MAT) Sensor uses a thermistor to control the signal voltage to the ECM.
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The ECM applies a voltage (4-6 volts) on CKT 472 to the sensor. When the air is cold, the sensor (thermistor)
resistance is high, therefore the ECM will see a high signal voltage. If the air is warm, the sensor resistance is
low therefore the ECM will see a low voltage.
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Test Description: Step numbers refer to step Diagnostic Aids:

numbers on diagnostic chart.
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1. Code 23 will set if all conditions are met: A "Scan” tool reads tem perature of the a ir
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• A signal voltage indicates a manifold air entering the engine and should read close to ambient
tem perature below -30°C (-22°F) for 12 air temperature when engine is cold, and rises as
seconds. underhood temperature increases.
Carefully check harness and connections for
ic

• Time since engine start is 1 minute or longer.

• No VSS (vehicle not moving) possible open CKT 472 or 452.
2. A Code 23 will set, due to an open sensor, wire, or Refer to Section 2 for "ECM Intermittent Codes or
s

connection. This test will determine if the wiring Performance.

The "Temperature to Resistance Value” scale at
as

and ECM are OK.

3. This will determine if the signal CKT 472 or the the right may be used to test the MAT sensor at
5V return CKT 452 is open. various temperature levels to evaluate the possibility
of a "slewed” (mis-scaled) sensor. A "slewed” sensor
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could result in poor driveability complaints.

 COMPUTER COMMAND CONTROL 3-41

'SCAN " DIAGNOSTICS

CODE 23
MANIFOLD AIR TEMPERATURE SENSOR
(LOW TEMPERATURE INDICATED)
2.5L ENGINE

© • DOES "SCAN" TOOL DISPLAY MAT -30°C OR COLDER?

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YES NO

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• DISCONNECT SENSOR. CODE 23 IS INTERMITTENT. IF NO
©
• JUMPER HARNESS TERMINALS TOGETHER. ADDITIONAL CODES WERE STORED,

.
• "SCAN" SHOULD DISPLAY TEMPERATURE OVER 130°C. REFER TO DIAGNOSTIC AIDS ON

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DOES IT? FACING PAGE.
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YES NO
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FAULTY CONNECTION OR SENSOR.

© •
•
JUMPER CIRCUIT 452 TO GROUND.
"SCAN" SHOULD DISPLAY TEMP.
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OVER 130°C.
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DOES IT?
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si

YES NO

DIAGNOSTIC AID I I
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MAT SENSOR OPEN CIRCUIT 452, OPEN CIRCUIT 472,

TEMPERATURE TO RESISTANCE VALUES FAULTY CONNECTION FAULTY CONNECTION
(APPROXIMATE OR FAULTY ECM. OR FAULTY ECM.
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°F °C OHMS
210 100 185
160 70 450
100 38 1,800
70 20 3,400
40 4 7,500
20 -7 13,500
0 -18 25,000
-40 -40 100,700

4-2-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. *7S 3285
3-42 COMPUTER COMMAND CONTROL

ECM ^

** VEHICLE SPEED SIGNAL < -------------------------------437 BRN A10 - A A / v ~ 12V

P/N SWITCH

I---- 450 BLK/WHT ---- 434 ORN/BLK — B10 - ^ V W - 12V

CLOSED IN
PARK OR NEUTRAL
7S 3693

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8-11-86 7-9-86

CODE 24

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VSS CIRCUIT FAULT
ALL ENGINES

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Circuit Description:
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The ECM applies and monitors 12 volts on CKT 437. CKT 437 connects to the Vehicle Speed Sensor (VSS)
which alternately grounds CKT 437 when drive wheels are turning. This pulsing action takes place about 2000
times per mile and the ECM will calculate vehicle speed based on the time between "pulses”.
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A "Scan” tool reading should closely match with speedometer reading with drive wheels turning.
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Test Description: Step numbers refer to step 3. A steady 8-12 volts a t the ECM connector
numbers on diagnostic chart. indicates CKT 437 is open or a faulty Vehicle
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Code 24 will set if: Speed Sensor.

• CKT 437 voltage is constant. 4. This is normal voltage which indicates a possible
• Engine speed between 900 and 4400 rpm. intermittent condition.
cc

• Less than 2% throttle opening.

• Low load condition (low air flow). Diagnostic Aids:
• Not in park or neutral.
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• All conditions must be met for 3 seconds. 1. "Scan” read in g should closely m atch w ith
These conditions are met during a road load speedometer reading, with drive wheels turning.
2. Check park/neutral switch diagnosis ch art if
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deceleration.
1. This test monitors the ECM voltage on CKT 437. vehicle equipped with automatic transmission.
With the wheels turning, the pulsing action will 3. If park /n eu tral switch is OK, refer to ECM
result in a varying voltage. The variation will be Intermittent codes in Section 2.
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greater at low wheel speeds to an average of 4-6

volts at about 20 mph (32 km/h).
2. A voltage of less than 1 volt at the ECM connector
indicates that the CKT 437 wire is shorted to
ground. Disconnect CKT 437 at the Vehicle Speed
Sensor. If voltage now reads above 10 volts, the
Vehicle Speed Sensor is faulty. If voltage remains
less than 10 volt, then CKT 437 wire is grounded.
If 437 is not grounded, check for a faulty ECM
connector or ECM.
 COMPUTER COMMAND CONTROL 3-43

"SCAN" DIAGNOSTICS
CODE 24
VSS CIRCUIT FAULT
DISREGARD CODE 24 IF SET WHILE DRIVE WHEELS ARE NOT TURNING.
ALL ENGINES
• ASSUMES SPEEDOMETER IS WORKING OK.
• CRUISE CONTROL "OFF".
• RAISE DRIVE WHEELS.
• WITH ENGINE IDLING IN GEAR, "SCAN" SHOULD DISPLAY MPH
ABOVE 0.
DOES IT?

NO YES

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BACK PROBE ECM CONNECTOR, CKT 437,
© WITH VOLTMETER TO GROUND AND

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DRIVE WHEELS STILL TURNING.

© LESS THAN 1 VOLT

© ©

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8 TO 12 VOLTS. NOT VARYING 0 TO 10 VOLTS
1 AND VARYING
1 ......................
• DISCONNECT CONNECTOR - CHECK CONNECTIONS AT VSS.
AT VSS ASSY. RECHECK

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- CHECK FOR OPEN CKT 437.
VOLTAGE AT ECM.
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- CHECK FOR 12V AND GND AT VSS. CODE 24 IS INTERMITTENT. IF NO
-FAULTY VSS. ADDITIONAL CODES WERE STORED,
REFER TO DIAGNOSTIC AIDS ON
FACING PAGE.
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LESS THAN 1 VOLT

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DISCONNECT A-B ECM

CONNECTOR. WITH A TEST LIGHT
TO 12 VOLTS, PROBE CKT 437.
cc

IS THERE A LIGHT?

1
si

YES NO

X X
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CHECKCKT437 FOR ECM CONNECTIONS

SHORT TO GROUND, OR ECM.
INCLUDING WIRE TO
CRUISE CONTROL.
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7S 3694
CLEAR CODES AND CONFIRM "CLOSED LOOP " OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7-10-86
3-44 COMPUTER COMMAND CONTROL

MANIFOLD AIR ECM

TEMPERATURE
SENSOR

___ MAT SENSOR

SIGNAL

yJ = t 472 TAN - fc « l •AW'— 5 v

452 BLK
-[E h
TO TPS AND
COOLANT
TEMPERATURE 7S 3692

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SENSOR 7-9-86
8 - 11-86

CODE 25

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MANIFOLD AIR TEMPERATURE (MAT) SENSOR
(HIGH TEMPERATURE INDICATED)

y.
2.5L ENGINE
Circuit Description:
ar
The Manifold Air Temperature (MAT) Sensor uses a thermistor to control the signal voltage to the ECM.
The ECM applies a voltage (4-6 volts) on CKT 472 to the sensor. When the air is cold, the sensor (thermistor)
resistance is high, therefore the ECM will see a high signal voltage. As the air warms, the sensor resistance
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becomes less, and the voltage drops.

Test Description: Step numbers refer to step Diagnostic Aids:

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numbers on diagnostic chart.

1. Code 25 will set if: A "Scan” tool reads tem perature of the a ir
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• Signal voltage indicates a m anifold a ir entering the engine and should read close to ambient
tem perature below 150°C (302°F) for 2 air temperature when engine is cold, and rises as
seconds. underhood temperature increases.
• Time since engine start is 1 minute or longer. Check harness routing for possible short to ground
ic

• A vehicle speed is present. in CKT 472.

Refer to Section 2 for "ECM Intermittent Codes or
s

Performance.
The "Temperature to Resistance Value” scale at
as

the right may be used to test the MAT sensor at

various temperature levels to evaluate the possibility
of a "slewed” (mis-scaled) sensor. A "slewed” sensor
cl

could result in poor driveability complaints.

 COMPUTER COMMAND CONTROL 3-45

'SCAN" DIAGNOSTICS
CODE 25
MANIFOLD AIR TEMPERATURE
(MAT) SENSOR
(HIGH TEMPERATURE INDICATED)
2.5L ENGINE

m
©

. co
ry
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lib
ar
cc
si
as

DIAGNOSTIC AID
MAT SENSOR
TEMPERATURE TO RESISTANCE VALUES
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(APPROXIMATE)
°F °C OHMS
210 100 185
160 70 450
100 38 1,800
70 20 3,400
40 4 7,500
20 -7 13,500
0 -18 25,000
-40 -40 100,700

6-18-86
CLEAR CODES AND CONFIRM “CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. *7S 3190
3-46 COMPUTER COMMAND CONTROL

o m
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CODE 32

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EGR SYSTEM FAILURE
2.8L ENGINE
Circuit Description:
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The exhaust gas recirculation (EGR) valve is controlled by an ECM operated solenoid. The solenoid is
normally closed and the vacuum source is a ported signal. The ECM will turn the EGR "ON” and "OFF” (Duty
lib
Cycle) by grounding CKT 435. The duty cycle is calculated by the ECM based on information from the coolant
and MAP sensor and engine rpm. The duty cycle should be 0% (no EGR) when in Park or Neutral, TPS input
below a specified value, or TPS indicating WOT.
ar

Test Description: Step numbers refer to step 3. With the ignition "ON”, the solenoid should not be
numbers on diagnostic chart. energized and vacuum should not pass to the EGR
cc

1. Code 32 means that the EGR vacuum switch was valve.

closed during start-up, or that the switch was not 4. The EGR solenoid and valve are OK and the
detected closed under the following conditions. following check will check the vacuum switch
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• Coolant tem perature g re a te r th an 85°C portion of the system.

(185°F). 5. The switch should close at about 2” of vacuum.
as

• EGR duty cycle commanded by the ECM is With vacuum applied, the switch should close and
greater than 70%. resistance go to near zero ohms and the vacuum
• TPS less than half throttle, but not at idle. should hold.
• All conditions above m ust be m et for 5
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seconds. Diagnostic Aids:

If the switch is detected closed during start-up, or,
if the switch is detected open when the above With the ignition "ON”, engine stopped, the EGR
conditions are met, the "Service Engine Soon” solenoid is de-energized u n less the d iagnostic
light will remain "ON” unless the switch changes terminal is grounded.
state.
2. If the first step caused Code 32 to set, then the
ECM has recognized a closed vacuum switch on
start-up. This test will determine whether the
EGR control valve is the cause or, if the wiring or
the ECM is the cause.
 COMPUTER COMMAND CONTROL 3-47

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cc
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3-48 COMPUTER COMMAND CONTROL

TO EGR VALVE
MANIFOLD
M -------- = VACUUM

IGN EGR SOLENOID

N.C.

A B
GRY 435
— 39 _ —
PNK/BLK GRY 435

7S 3737-6E

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8-14-86 7-23-86

CODE 32
EGR SYSTEM FAILURE

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2.5L, 4.3L, 5.0L & 5.7L (UNDER 8500 GVW)
Circuit Description:

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The ECM operates a solenoid to control the Exhaust Gas Recirculation (EGR) valve. This solenoid is

to the EGR valve.

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normally closed. By providing a ground path, the ECM energizes the solenoid which then allows vacuum to pass

The ECM monitors EGR effectiveness by de-energizing the EGR control solenoid thereby shutting off
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vacuum to the EGR valve diaphragm. With the EGR valve closed, fuel integrator counts will be greater than
they were during normal EGR operation. If the change is not within the calibrated window, a Code 32 will be
set.
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The ECM will check EGR operation when:

• Vehicle speed is above 50 mph.
• Engine vacuum is between 40 and 51 kPa.
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• No change in throttle position while test is being run.

Test Description: Step numbers refer to step Diagnostic Aids:

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numbers on diagnostic chart.

1. Checks for solenoid stuck open. • Before replacing ECM, use an ohm meter and
s

2. Checks for solenoid always being energized. check the resistance of each ECM controlled relay
3. Grounding test terminal should energize solenoid and solenoid coil. See ECM wiring diagram for
as

and vacuum should drop. coil term. I.D. of solenoid(s) and relay(s) to be
4. Negative backpressure valve should hold vacuum checked. Replace any solenoid where resistance
with engine "OFF”. measures less than 20 ohms.
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5. When engine is started, exhaust backpressure

should cause vacuum to bleed off and valve to fully
close.
 COMPUTER COMMAND CONTROL 3-49

IF ANY OTHER CODES ARE STORED, DIAGNOSE THEM FIRST,

CODE 32
© • CHECK VACUUM SOURCE TO EGR

•
SOLENOID (IF NOT OK, REPAIR).
IGNITION "OFF” .
EGR SYSTEM FAILURE
• DISCONNECT EGR SOLENOID VACUUM 2.5L, 4.3L, 5.0L & 5.7L
HARNESS. (UNDER 8500 GVW)
• INSTALL HAND HELD VACUUM PUMP
ON MANIFOLD SIDE OF SOLENOID.
• APPLY VACUUM.
DOES SOLENOID HOLD VACUUM?

YES NO
m m
• IGNITION "ON", ENGINE STOPPED. FAULTY SOLENOID
©

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• DOES VACUUM DROP?

1
NO YES
X m

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© • GROUND DIAGNOSTIC TEST TERMINAL.
DOES VACUUM DROP?
CKT 435 SHORTED TO GROUND OR FAULTY ECM.
SEE DIAGNOSTIC AIDS.

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YES NO

©
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• REMOVE GROUND FROM DIAGNOSTIC TEST
TERMINAL.
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DISCONNECT SOLENOID ELECTRICAL CONNECTOR.
PROBE CKT 39 WITH A TEST LIGHT TO GROUND.
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• IGNITION "OFF".
• CONNECT A VACUUM PUMP TO EGR SIDE OF
VACUUM HARNESS. LIGHT "ON' LIGHT "OFF"
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• USING A MIRROR. OBSERVE EGR

DIAPHRAGM WHILE APPLYING VACUUM
CONNECT TEST LIGHT OPEN CKT 39
• DIAPHRAGM SHOULD MOVE FREELY AND
BETWEEN HARNESS
a

HOLD VACUUM FOR AT LEAST 20 SECONDS.

CONNECTOR TERMINALS.
■
cc

X 1 1
OK NOT OK LIGHT "ON" LIGHT "OFF"
m
si

CHECK VACUUM LINE TO VALVE. FAULTY SOLENOID OPEN CKT 435 OR FAULTY ECM.
IF OK. REPLACE EGR VALVE. SEE DIAGNOSTIC ADIS.
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© •
•
APPLY VACUUM TO EGR VALVE.
START ENGINE AND IMMEDIATELY OBSERVE
VACUUM AND VALVE POSITION.
• VALVE IS GOOD IF VALVE MOVES TO SEATED
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POSITION (VALVE CLOSED) AND VACUUM

DROPPED WHILE STARTING ENGINE.

OK NOT OK
X I
A/T CHECK P/N SWITCH REMOVE EGR VALVE AND CHECK
PASSAGES FOR BEING PLUGGED.
IF NOT PLUGGED REPLACE EGR VALVE.

OK NOT OK
X I
NO TROUBLE FOUND. REPAIR AS NECESSARY
SEE INTERMITTENTS
7S 3846
IN SECTION 2. CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 8-14-86
3-50 COMPUTER COMMAND CONTROL

IGN.

TO EGR VALVE PORTED

MANIFOLD 'ECM 1
10A<^ FUSE
VACUUM

&
EGR
SOLENOID 439 PNK/BLK -
N.C.
------- 435 GRY {77}

QD

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VENT FILTER CONTROL '
CIRCUITRY J
L ___________________________________________________________________ J
S '

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EVRV SOLENOID ASSY. 7S 3689-6E
8-14-86 7-9-86

CODE 32

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EGR SYSTEM FAILURE
7.4L & 5.7L (OVER 8500 GVW)
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Circuit Description:
The ECM operates a solenoid to control the Exhaust Gas Recirculation (EGR) valve. This solenoid is
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normally closed. By providing a ground path, the ECM energizes the solenoid which then allows vacuum to
pass to the EGR valve.
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The ECM monitors EGR effectiveness by de-energizing the EGR control solenoid thereby shutting off
vacuum to the EGR valve diaphragm. With the EGR valve closed, fuel integrator counts will be greater than
they were during normal EGR operation. If the change is not within the calibrated window, a Code 32 will be
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set.
The ECM will check EGR operation when:
• Vehicle speed is above 50 mph.
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• Engine vacuum is between 40 and 51 kPa.

• No change in throttle position while test is being run.
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Test Description: Step numbers refer to step Diagnostic Aids:

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numbers on diagnostic chart.

1. With the ignition "ON”, engine stopped, the • Before replacing ECM, use ohmmeter and check
solenoid should not be energized and vacuum the resistance of each ECM controlled relay and
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should not pass to the EGR valve. solenoid coil.

Grounding the diagnostic terminal will energize See ECM wiring diagram for coil te rm in a l
the solenoid and allow vacuum to pass to valve. identification of solenoid(s) and relay(s) to be
2. Checks for plugged EGR passages. If passages are checked.
plugged, the engine may have severe detonation Replace any relay or solenoid if the coil resistance
on acceleration. measures less than 20 ohms.
3. The EGR solenoid will not be energized in Park or
N eu tral. This test will d eterm in e if the
Park/Neutral switch input is being received by the
ECM.
 COMPUTER COMMAND CONTROL 3-51

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3-52 COMPUTER COMMAND CONTROL

MAP SENSOR

l- o
®©©.
I ECM
-f

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MANIFOLD
ABSOLUTE
416 GRY

432 LTGRN
— |c i « h

- E U -
5VREF

MAP SIGNAL

PRESSURE ALL EXCEPT 2.5L,4.3L M OR G VAN --- 455 PPL -{ A n }

(VACUUM)
----------- 2.5L ENGINE ------------- 469 BLK/ORN I 02 h
4.3L M OR G VAN ------ 455 PPL
-c E t
7S3697-6E

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8-7-86 7-9-86

CODE 33

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MAP SENSOR CIRCUIT
SIGNAL VOLTAGE HIGH

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(LOW VACUUM)
ALL ENGINES
Circuit Description: ar
The Manifold Absolute Pressure (MAP) Sensor responds to changes in manifold pressure (vacuum). The
ECM receives this information as a signal voltage that will vary from about 1 to 1.5 volts at idle to 4-4.5 volts at
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wide open throttle.

Test Description: Step numbers refer to step Diagnostic Aids:

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numbers on diagnostic chart.

1. Code 33 will set when: The "Altitude To Voltage” scale at the right may
• Signal is too high for a time greater than 6 be used to test the MAP sensor at a specific altitude
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seconds. level to evaluate the possibility of a "slewed” (mis-

Engine misfire or a low unstable idle may set scaled) sensor. A "slewed” sensor could result in poor
Code 33. driveability complaints.
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• Engine Running: Engine misfire or a low unstable idle may set Code
Manifold pressure greater than 75.3 kPa (A/C 33. Disconnect MAP sensor and system will go into
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"OFF”) 81.2 kPa (A/C "ON”) backup mode. If the misfire or idle condition remains,
Throttle angle less than 2% see Symptoms in Section 2.
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Conditions met for 2 seconds.

2. With the MAP sensor disconnect the ECM; should
see a low voltage if the ECM and wiring is OK.
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 COMPUTER COMMAND CONTROL 3-53

'SCAN" DIAGNOSTICS
CODE 33
MAP SENSOR CIRCUIT
SIGNAL VOLTAGE HIGH
(LOW VACUUM)
ALL ENGINES

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IGNITION "ON" ENGINE STOPPED VOLTAGES

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ALTITUDE VOLTAGE RANGE

Meters Feet
Below 305 Below 1,000 3.8—5.5V
305— 610 1,000 —2,000 3.6—5.3V
610— 914 2,000-3,000 3.5—5.1V
914-1219 3,000-4,000 3.3—5.0V
1219-1524 4,000-5,000 3.2—4.8V
1524-1829 5,000-6,000 3.0—4.6V
1829-2133 6,000-7,000 2.9—4.5V
2133-2438 7,000-8,000 2.8—4.3V
2438-2743 8,000-9,000 2.6—4.2V
2743-3048 9,000-10,000 2.5—4.0V
LOW ALTITUDE = HIGH PRESSURE = HIGH VOLTAGE
7S3698
CLEAR CODES ANDCONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7-9-86
3-54 COMPUTER COMMAND CONTROL

MAP SENSOR

£
®©©l
I ECM

t 416 GRY

432 LTGRN
-tZEJ
—|o i [
■ 5V REF

- MAP SIGNAL
MANIFOLD
ABSOLUTE
PRESSURE ALL EXCEPT 2.5L. 4.3L M OR G VAN --- 455 PPL —{TiT}
(VACUUM)
----------- 2.5L ENGINE ------------- 469 BLK/ORN H h
4 .3LM O R G VAN 455 PPL

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7S 3697
8-7-86 7-9-86

CODE 34

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MAP SENSOR CIRCUIT
SIGNAL VOLTAGE LOW

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(HIGH VACUUM)
ALL ENGINES
Circuit Description: ar
The Manifold Absolute Pressure (MAP) Sensor responds to changes in manifold pressure (vacuum). The
ECM receives this information as a signal voltage that will vary from about 1 to 1.5 volts at idle to 4-4.5 volts at
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wide open throttle.
If the MAP sensor fails the ECM will substitute a fixed MAP value and use the Throttle Position Sensor
(TPS) to control fuel delivery.
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Test Description: Step numbers refer to step Diagnostic Aids:

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numbers on diagnostic chart.

1. Code 34 will set when: An intermittent open in CKTs 416 will result in a
• When engine is less than 600 rpm. Code 34.
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• Manifold pressure reading less than 13 kPa, Refer to ECM intermittents in Section 2.
conditions met for 1 second The "Altitude to Voltage” scale at the right may
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or be used to test the MAP sensor at a specific altitude

• Engine is greater than 600 rpm. level to evaluate the possibility of a "slewed” (mis-
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• Throttle angle over 20%. scaled) sensor. A "slewed” sensor could result in poor
• manifold pressure less than 13 kPa conditions driveability complaints.
met for 1 second..
2. This tests to see if the sensor is at faulty for the
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low voltage or if there is a ECM or wiring problem.

3. This simulates a high signal voltage to check of an
open in CKT 432. if the test light is bright during
this test, CKT 432 is probable shorted to ground.
If "Scan” reads over 4 volts at this lest CKT 416
can be checked by m easuring the voltage at
terminal "C”. (should be 5 volts)
 COMPUTER COMMAND CONTROL 3-55

’SCA N " DIAGNOSTICS

CODE 34
MAP SENSOR CIRCUIT
SIGNAL VOLTAGE LOW
(HIGH VACUUM)
• IGNITION "OFF" FOR 10 SECONDS
ALL ENGINES
• START ENGINE AND IMMEDIATELY NOTE MAP
VALUE ON "SCAN” .
© DOES "SCAN" DISPLAY MAP BELOW .25 VOLTS?

YES NO

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© •
•
IGNITION "OFF".
DISCONNECT SENSOR ELECTRICAL CONNECTOR.
CODE 34 IS INTERMITTENT.
IF NO ADDITIONAL CODES WERE
STORED, REFER TO DIAGNOSTIC
• JUMPER HARNESS TERMINALS "B" TO "C".
AIDS ON FACING PAGE.

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• IGNITION "ON".
• MAP VOLTAGE SHOULD READ OVER 4 VOLTS.
DOES IT?

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NO
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FAULTY CONNECTION
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• IGNITION "OFF".
© • REMOVE JUMPER WIRE. OR SENSOR.
• PROBE TERMINAL "B" (CKT 432) WITH A
LIGHT TO 12 VOLTS.
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• IGNITION "ON".
• "SCAN" SHOULD READ OVER 4 VOLTS.
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DOES IT?
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YES NO
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CKT 416 OPEN OR SHORTED TO CIRCUIT 432 OPEN OR SHORTED TO

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GROUND OR FAULTY ECM. GROUND OR FAULTY ECM.

IGNITION "ON" ENGINE STOPPED VOLTAGES

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ALTITUDE VOLTAGE RANGE

Meters Feet
Below 305 Below 1,000 3.8—5.5V
305— 610 1,000-2,000 3.6—5.3V
610— 914 2,000-3,000 3.5—5.1V
914-1219 3,000-4,000 3.3—5.0V
1219-1524 4,000-5,000 3.2—4.8V
1524-1829 5,000-6,000 3.0—4.6V
1829-2133 6,000-7,000 2.9—4.5V
2133-2438 7,000-8,000 2.8—4.3V
2438-2743 8,000-9,000 2.6—4.2V
2743-3048 9,000-10,000 2.5—4.0V
LOW ALTITUDE = HIGH PRESSURE = HIGH VOLTAGE
7S 3699
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7-9-86
3-56 COMPUTER COMMAND CONTROL

TBI UNIT [=3

ir
AIR
FLOW
D C B A
ECM
IAC CONNECTOR
IAC COIL “A" HI
LT BLU/WHT 441 ~ C5

C6 IAC COIL "A" LO

LT BLU/BLK 442 —

LT GRN/WHT 443 - C4 IAC COIL "B" HI

LT GRN/BLK 444 — C3 IAC COIL "B"LO

IDLE AIR
■N *7S3852-6E
CONTROL (IAC)
8-18-86 8-18-86

CODE 35

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IDLE SPEED ERROR
2.5L ENGINE
Circuit Description:

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Code 35 will set when the closed throttle engine speed is 100 rpm above or below the correct idle speed for 45
seconds. Review General Description in Section 4.
Test Description: Step numbers refer to step System too lean. (High air/fuel ratio)

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numbers on diagnostic chart. Idle speed may be too high or too low. Engine speed
1. Continue with test even if engine will not idle. If may vary up and down, disconnecting IAC does not
idle is too low, "Scan” will display 80 or more
counts, or steps. If idle is high, it will display "0”
counts.
ar help. May set Code 44.
"Scan” and/or Voltmeter will read an oxygen sensor
output less than 300 mv (.3 volts). Check for low
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Occasionally, an erratic or unstable idle may occur. regulated fuel pressure or water in fuel. A lean
Engine speed may vary 200 rpm or more up and exhaust with an oxygen sensor output fixed above
down. Disconnect IAC. If the condition is 800 mv (.8 volts) will be a contaminated sensor,
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unchanged, the IAC is not at faulty, there is a usually silicone. This may also set a Code 45.
system problem. Proceed to paragraph three below. System too rich (Low air/fuel ratio)
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2. When the engine was stopped, the IAC valve Idle speed too low. "Scan” counts usually above 80.
retracted (more air) to a fixed Park” position for System obviously rich and may exhibit black smoke
increased air flow and idle speed during the next exhaust.
engine start. A "Scan” will display 100 or more "Scan” tool and/or voltmeter will read an oxygen
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counts. sensor signal fixed above 800 mv (.8 volts).

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3. Be sure to disconnect the IAC valve prior to this Check:

test. The test light will confirm the ECM signals by High fuel pressure
a steady or flashing light on all circuits. Injector leaking or sticking.
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4. There is a remote possibility that one of the circuits Throttle body.

is shorted to voltage which would have been Remove IAC and inspect bore for foreign material
indicated by a steady light. Disconnect ECM and or evidence of IAC valve dragging the bore.
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turn the ignition "ON” and probe term inals to A/C Compressor or relay failure.
check for this condition. See if A/C diagnosis circuit if shorted to ground. If
the relay is faulty, an idle problem may exist.
Diagnostic Aids: Refer to "Rough, U nstable, Incorrect Idle or
Stalling” in Symptoms in Section 2.
A slow unstable idle may be caused by a system
problem that cannot be overcome by the IAC. "Scan”
counts will be above 60 counts if too low and "0” counts
if too high.
If idle is too high, stop engine. Ignition "ON”.
Ground diagnostic terminal. Wait a few seconds for
IAC to seat, then disconnect IAC. Start engine. If idle
speed is above 800 ± 50 rpm, locate and correct
vacuum leak.
 COMPUTER COMMAND CONTROL 3-57

CODE 35
IDLE SPEED ERROR
2.5L ENGINE

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CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. * 7S 3151-6E
3-58 COMPUTER COMMAND CONTROL

PICK-UP COIL HALL

ECM
EFFECT
SWITCH

423 WHT - D4 EST

430 PPL/WHT - B5 REFERENCE
424 TAN/BLK - D5 BYPASS
453 BLK/RED ~ B3 GROUND

EST CONNECTOR

IGN 2.5L S/T TRUCK

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PICK-UP
COIL
IGNITION
EEH ECM
MODULE
DISTRIBUTOR
GBRE

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IGN.
uuuu DISTRIBUTOR 4 TERM.
CONNECTOR

IGN. COIL ' b GRY.

CONN.
ar — 423 WHT

430 PPL/WHT H B5
EST

REFERENCE
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424 TAN/BLK - H O - BY-PASS

CONNECTOR <EXCEPT 2-5LM VA N > ,------,

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--------------------------------- 453 BLK/RED ~\ B3 \

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TACH.LEAD
ALL EXCEPT 2.5L S/T TRUCK 7S 3700-6E
8 - 11-86 7-16-86
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CODE 42
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ELECTRONIC SPARK TIMING (EST)

ALL ENGINES
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Circuit Description
Refer to page 3-9 for EST and Code 42.
Test Description:
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Step numbers refer to step Selecting the 10-20,000 ohm s position w ill
numbers on diagnostic chart. indicate above 5000 ohms. The important thing is
1. Code 42 means the ECM has seen an open or short that the module "switched”.
to ground in the EST or bypass circuits. This test 4. The module did not switch and this step checks for:
confirms Code 42 and that the fault causing the • EST CKT 423 shorted to ground.
code is present. • Bypass CKT 424 open.
2. Checks for a normal EST ground path through the • Faulty ignition module connection or module.
ignition module. An EST CKT 423 shorted to 5. Confirms that Code 42 is a faulty ECM and not an
ground will also read less th a n 500 ohms; intermittent in CKTs 423 or 424.
however, this will be checked later.
Diagnostic Aids:
3. As the test light voltage touches CKT 424, the
module should switch causing the ohmmeter to The "Scan” tool does not have any ability to help
"overrange” if the meter is in the 100-200 ohms diagnose a Code 42 problem.
position. Refer to Section 2 for ECM Intermittent Code or
Performance.
 COMPUTER COMMAND CONTROL 3-59

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 3-60 COMPUTER COMMAND CONTROL

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CODE 43

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ELECTRONIC SPARK CONTROL (ESC) FAULT
ALL ENGINES EXCEPT 2.5L AND 7.4L

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Circuit Description:
Electronic spark control is accomplished with a module that sends a voltage signal to the ECM. As the
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knock sensor detects engine knock, the voltage from the ESC module to the ECM drops, and this signals the
ECM to retard timing. The ECM will retard the timing when knock is detected and rpm is above about 900
rpm.
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Code 43 means the ECM has been low voltage at CKT 485 terminal "B7” for longer than 5 seconds with the
engine running or the system has failed the functional check.
This system performs a functional check once per start-up to check the ESC system. To perform this test,
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the ECM will advance the spark when coolant is above 95°C and at a high load condition (near W.O.T.). The
ECM then checks the signal at "B7” to see if a knock is detected. The functional check is performed once per
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start-up and if knock is detected when coolant is below 95°C (194°F), the test has passed and the functional
check will not be run. If the functional check fails, the "Service Engine Soon” light will remain on until ignition
is turned "OFF” or until a knock signal is detected.
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Test Description:
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Test numbers refer to step 5. If CKT 496 is routed to close to secondary ignition
numbers on diagnostic chart. wires, the ESC module may see the interference as
1. If the conditions for a Code 43 are present, the a knock signal.
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"Scan” will always display "yes”. There should 6. This checks the ground circuit to the module. An
not be a knock at idle unless an internal engine open ground will cause the voltage on CKT 485 to
problem, or a system problem exists. be about 12 volts which would cause the Code 43
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2. This te st will determ ine if the system is functional test to fail.

functioning at this time. Usually a knock signal 7. Connecting CKT 496 with a test light to 12 volts
can be generated by tapping on the right exhaust should generate a knock signal. This will
manifold. If no knock signal is generated, try determ ine if the ESC m odule is o p eratin g
tapping on block close to the area of the sensor. correctly.
3. Because Code 43 sets when the signal voltage on
CKT 485 remains low, this test should cause the Diagnostic Aids:
signal on CKT 485 to go high. The 12 volts signal
should be seen by the ECM as "no knock” if the Code 43 can be caused by a faulty connection at
ECM and wiring are OK. the knock sensor at the ESC module or at the ECM.
4. This test will determine if the knock signal is Also check CKT 485 for possible open or short to
being detected on CKT 496 or if the ESC module is ground.
at fault. Refer to Section 2 for "ECM Intermittent Codes or
Performance”.
 COMPUTER COMMAND CONTROL 3-61

'SCAN" DIAGNOSTICS
CODE 43
ELECTRONIC SPARK CONTROL
© •
•
ENGINE IDLING.
"SCAN" SET ON KNOCK SIGNAL. (ESC) FAULT
IS THERE A KNOCK SIGNAL INDICATED?
ALL ENGINES EXCEPT
2.5L AND 7.4L
NO
X
© DISCONNECT ESC MODULE.
ENGINE IDLING.
•
•
ENGINE IDLING.
TAP ENGINE BLOCK IN AREA OF KNOCK SENSOR.
PROBE HARNESS TERMINAL "C" (CKT • IS A KNOCK SIGNAL INDICATED WHILE TAPPING
485) WITH A TEST LIGHT CONNECTED ON ENGINE?
TO 12 VOLTS.
AFTER 5 SECONDS, DOES "SCAN"
DISPLAY A KNOCK SIGNAL?

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• DISCONNECT ESC MODULE. CODE 43 IS INTERMITTENT. IF
1 • PROBE HARNESS TERM. "D" (CKT NO ADDITIONAL CODES WERE
NO YES STORED, REFER TO DIAGNOS­
486) WITH A TEST LIGHT TO 12 V.
X m TIC AIDS ON FACING PAGE.

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IGNITION "ON". CKT 485 OPEN,
PROBE TERM. "B" SHORTED TO
(CKT 439) WITH A GROUND, OR LIGHT "ON'

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TEST LIGHT TO FAULTY ECM.
GROUND.
© •
•
ra RECONNECT ESC MODULE.
DISCONNECT KNOCK SENSOR.
• ENGINE IDLING.
• MOMENTARILY TOUCH KNOCK
SENSOR HARNESS (CKT 496) WITH
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A TEST LIGHT TO 12V.
• EACH TIME THE TEST LIGHT
CONTACTS CKT 496, A KNOCK
SIGNAL SHOULD BE GENERATED.
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• IS A KNOCK SIGNAL INDICATED

WITH "SCAN"?
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IE
YES NO
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CKT 496 OPEN, SHORTED TO
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FAULTY CONNECTION AT SENSOR

OR FAULTY KNOCK SENSOR. GROUND, FAULTY CONNEC­
TION AT ESC MODULE. OR
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FAULTY ESC MODULE.

LIGHT "ON' LIGHT "OFF*
I....... X
• REMOVE CKT 496 FROM CONNECTOR. OPEN CKT 439
©
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• RECONNECT ESC MODULE.

• ENGINE IDLING.
IS THERE A KNOCK SIGNAL INDICATED?

YES NO
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FAULTY CONNECTION
OR ESC MODULE.
© IF AN AUDIBLE KNOCK CAN BE HEARD,
REPAIR INTERNAL ENGINE PROBLEM. IF OK,
CHECK FOR ROUTING OF WIRE FROM KNOCK
SENSOR TO ESC MODULE FOR PICKING UP
FALSE KNOCK SIGNALS FROM AN ADJACENT
WIRE. REROUTE AS NECESSARY. IF ROUTING
IS CORRECT, REPLACE KNOCK SENSOR.
7S 3292-6E
7-25-86
3-62 COMPUTER COMMAND CONTROL

ECM

PPL 412 ------ 07 0 2 SENSOR

SIGNAL

D6
0 2 GROUND
“ CIRCUIT

4S 0790
S '

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8 - 11-86 4-16-86

CODE 44

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LEAN EXHAUST INDICATED
ALL ENGINES

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Circuit Description:
The ECM supplies a voltage of about .45 volts between terminals "D6” and "D7”. (If measured with a 10
ar
meg ohm digital voltmeter, this may read as low as .32 volts.) The O2 sensor varies the voltage within a range
of about 1 volt if the exhaust is rich, down through about .10 volts if exhaust is lean.
The sensor is like an open circuit and produces no voltage when it is below about 315°C (600°F). An open
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sensor circuit or cold sensor causes "Open Loop” operation.

Test Description: Step numbers refer to step • Fuel C ontam ination. W ater, even in sm all
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numbers on diagnostic chart. amounts, near the in-tank fuel pump inlet, can be
1. Code 44 is set when the O2 sensor signal voltage delivered to the injectors. The water causes a lean
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on CKT 412: exhaust and can set a Code 44.

• Remains below .2 volts for 20 seconds. • Fuel Pressure. System will be lean if pressure is
• And the system is operating in "Closed Loop”. too low. It may be necessary to monitor fuel
pressure while driving the vehicle at various road
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Diagnostic Aids: speeds an/or loads to confirm. See Fuel System

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diagnosis.
Using the "Scan”, observe the block learn values • AIR System. Be sure air is not being directed to
at different rpm and air flow conditions. The "Scan” the exhaust ports while in "Closed Loop”. If the
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also displays the block cells, so the block learn values block learn value goes down while squeezing air
can be checked in each of the cells to determine when hose to left side of exhaust ports, refer to Section 8.
the Code 44 may have been set. If the conditions for If the above are OK, it is a faulty oxygen sensor.
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Code 44 exists, the block learn values will be around • CKT 413. If CKT 413 is open, the voltage at
150. terminal "D7” will be over one volt.
• O 9 Sensor W ire . S ensor p ig ta il may be • S ensor H a rn e s s . S ensor p ig ta il m ay be
m ispositioned and contacting the e x h a u st m ispositioned and co n tactin g the e x h a u s t
manifold. manifold.
• Check for intermittent ground in wire between
connector and sensor.
 COMPUTER COMMAND CONTROL 3-63

'SCAN" DIAGNOSTICS
CODE 44
LEAN EXHAUST INDICATED
ALL ENGINES

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3-6-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. *7S 3191
 3-64 COMPUTER COMMAND CONTROL

ECM
r '

D7 0 2 SENSOR
SIGNAL

D6
0 2 GROUND
CIRCUIT

S ' 4S 0790-6E

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4-16-86

CODE 45

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RICH EXHAUST INDICATED
ALL ENGINES

.
Circuit Description:

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The ECM supplies a voltage of about .45 volts between terminals "D6” and "D7”. (If measured with a 10
meg ohm digital voltmeter, this may read as low as .32 volts.) The O2 sensor varies the voltage within a range
of about 1 volt if the exhaust is rich, down through about .10 volts if exhaust is lean.
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The sensor is like an open circuit and produces no voltage when it is below about 315 °C (600°F). An open
sensor circuit or cold sensor causes "Open Loop” operation.
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Test Description: Step numbers refer to step • HEI Shielding. An open ground CKT 453
numbers on diagnostic chart. (ignition system reflow) may result in EMI, or
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1. Code 45 is set when the O2 sensor signal voltage or induced electrical "noise”. The ECM looks at this
CKT 412: "noise” as reference pulses. The additional pulses
• Remains above .7 volts for 50 seconds, and in result in a higher than actual engine speed
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"Closed Loop”. signal.The ECM then delivers too much fuel,

• Engine time after start is 1 minute or more. causing system to go rich. Engine tachometer will
• Throttle angle greater than 2% . (about .2 volts also show higher than actual engine speed which
above idle voltage) can help in diagnosing this problem.
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• Canister Purge. Check for fuel saturation. If full

Diagnostic Aids: of fuel, check canister control and hoses. See
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Evaporative Emission Control in Section 5.

Using the "Scan”, observe the block learn values • MAP Sensor. An output that causes the ECM to
at different rpm and air flow conditions. The "Scan” sensor a higher than normal manifold pressure
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also displays the block cells, so the block learn values (low vacuum) can cause the system to go rich.
can be checked in each of the cells to determine when Disconnecting the MAP sensor will allow the
the Code 45 may have been set. If the conditions for ECM to set a fixed value for the MAP sensor.
Code 45 exists, the block learn values will be around Substitute a different MAP sensor if the rich
115. condition is gone while the sensor is disconnected.
• Fuel Pressure. System will go rich if pressure is • Pressure R egulator. Check for leaking fuel
too high. The ECM can compensate for some pressure regulator diaphragm by checking for
increase. However, if it gets too high, a Code 45 presence of liquid fuel in the vacuum line to the
may be set. regulator.
See Fuel System diagnosis chart. • Check for leaking fuel p re ssu re re g u la to r
• Leaking Injector. See CHART A-4. diaphragm by checking vacuum line to regulator
• Check for fuel contaminated oil. for fuel.
• TPS. An intermittent TPS output will cause the
system to go rich, due to a false indication of the
engine accelerating.
 COMPUTER COMMAND CONTROL 3-65

"SCAN" DIAGNOSTICS
CODE 45
RICH EXHAUST INDICATED
ALL ENGINES

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3-6-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO 'SERVICE ENGINE SOON' LIGHT. *7S 3192
3-66 COMPUTER COMMAND CONTROL

ECM B FUSE
BATT 440 ORN ECM
10A
-f
FUEL PUMP
RELA 12 VOLT
A1 RELAY
DRIVE
OIL
PRESS.
RELAY SWITCH
HARNESS
CONNECTOR
rh
□
FUEL PUMP
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ENGINE
GROUND
B2

IN TANK
VOLTAGE
MONITOR

TEST CONNECTOR
FUEL PUMP
120 TAN/WHT
» M 1
S , T & M SERIES BULKHEAD CONNECTOR 150 BLK

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FUSE LINK (CK)
BATT-----1 |--- 440 ORN ---- ECM
12V
OR ECM B FUEL PUMP
✓

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FUSE (RVGP)
RELAY 12 VOLT
465 DK GRN/WHT A1 RELAY
«- DRIVE

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OIL
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FUEL PUMP
RELAY CONN.
) PRESS.
SWITCH
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TAN/WHT ^
SIGNAL

FUEL PUMP ) — 490 RED ----

TEST TERM. 120 TAN/WHT
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OR ALDL (CK) OR 920 PNK/BLK

FUEL PUMP
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(IN TANK)

TO FUEL MODULE
150
cc

BULKHEAD
CONNECTOR -L 8-15-86
C, K. R. V . G & P SERIES
~ 7S 3844-6E

CODE 54
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FUEL PUMP CIRCUIT

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(LOW VOLTAGE)
ALL ENGINES
Circuit Description
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The status of the fuel pump CKT 120 is monitored by the ECM at terminal "B2” and is used to compensate
fuel delivery based on system voltage. This signal is also used to store a trouble code if the fuel pump relay is
defective or fuel pump voltage is lost while the engine is running. There should be about 12 volts on CKT 120
for at least 2 seconds after the ignition is turned, or any time reference pulses are being received by the ECM.
Code 54 will set if the voltage at terminal "B2” is less than 2 volts for 1.5 seconds since the last reference
pulse was received. This code is designed to detect a faulty relay, causing extended crank time, and the code will
help the diagnosis of an engine that "Cranks But Will Not Run.”
If a fault is detected during start-up, the "Service Engine Soon” light will stay on until the ignition is cycled
"OFF”.
 COMPUTER COMMAND CONTROL 3-67

CODE 54
• IGN. "OFF" FOR 10 SECONDS
•
•
IGN. "ON"
LISTEN FOR IN-TANK FUEL PUMP.
FUEL PUMP CIRCUIT
• PUMP SHOULD RUN AFTER IGN. "ON' (LOW VOLTAGE)
DOES IT? ALL ENGINES
1
NO YES
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• IGN. "OFF". • CLEAR CODES.
• USING A FUSED JUMPER WIRE, CONNECT • START AND RUN ENGINE FOR 30
FUEL PUMP TEST CONN. TO 12 VOLTS. SECONDS OR UNTIL CODE 54 SETS.
• DOES PUMP RUN? DOES CODE SET?

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YES NO YES NO
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• IGN. "OFF". • DISCONNECT FUEL PUMP • BACK PROBE ECM TERM. CODE 54 IS INTER­
• DISCONNECT FUEL RELAY. B2 WITH A TEST LIGHT MITTENT. REFER TO

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PUMP RELAY. • USING THE FUSED TO GROUND. DIAGNOSTIC AIDS ON
• PROBE CKT 440 WITH A JUMPER WIRE, CONNECT • IGN. "OFF" FOR 10 SEC. FACING PAGE.
TEST LIGHT TO CKT 120 TO 12 VOLTS. • NOTE LIGHT AFTER IGN.
GROUND. DOES PUMP RUN? "ON".

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LIGHT LIGHT YES NO LIGHT "ON' LIGHT "OFF*
"ON" "OFF"
1
CONNECT TEST REPAIR FAULTY
raOPEN CKT 120, FAULTY CONNECTION OPEN CKT
LIGHT BETWEEN OPEN IN RELAY FAULTY IN-TANK AT ECM OR FAULTY 120 TO ECM.
CKTS 440 & 450 CKT440 PUMP OR FAULTY ECM.
PUMP GROUND.
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LIGHT "ON* LIGHT "OFF*

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• CONNECT TEST LIGHT BETWEEN REPAIR OPEN CKT 450
HARNESS CKT. 465 AND GND.
• IGN. "OFF" FOR 10 SECONDS.
• NOTE TEST LIGHT AFTER IGN.
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"ON".

1
LIGHT "ON* LIGHT "OFF*
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~ T ------------ ■
• FAULTY RELAY. CKT 465 OPEN. SHORTED TO
• IF ORIGINAL SYMPTOM WAS "ENGINE CRANKS BUT WILL
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GROUND, OR FAULTY ECM.

NOT RUN" CONTINUE TEST OF OIL PRESSURE SWITCH.
• ENGINE AT NORMAL OPERATING TEMPERATURE.
• OIL PRESSURE NORMAL.
• DISCONNECT FUEL PUMP RELAY. ENGINE SHOULD
CONTINUE TO RUN.
DOES IT?
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YES NO
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• RECONNECT FUEL PUMP RELAY. FAULTY OIL
• IGNITION "OFF". PRESSURE SWITCH
• PROBE FUEL PUMP TEST
TERMINAL WITH A TEST LIGHT
TO GROUND.

LIGHT "OFF" LIGHT "ON*

1 T
FUEL PUMP FAULTY OIL
CIRCUIT OK PRESSURE SWITCH
3-68 COMPUTER COMMAND CONTROL

CODE 51
CODE 52
CODE 55
CODE 51
FAULTY MEM-CAL
(2.5L ENGINE)
CHECK THAT ALL PINS ARE FULLY INSERTED IN THE SOCKET. IF OK. REPLACE MEM-
CAL, CLEAR MEMORY. AND RECHECK. IF CODE 51 REAPPEARS. REPLACE ECM.

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CODE 51
PROM PROBLEM

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(EXCEPT 2.5L ENGINE)
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CHECK THAT ALL PINS ARE FULLY INSERTED IN THE SOCKET. IF OK, REPLACE
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PROM. CLEAR MEMORY, AND RECHECK. IF CODE 51 REAPPEARS, REPLACE ECM.
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CODE 52
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FUEL CALPAK MISSING

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(EXCEPT 2.5L ENGINE)

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INSTALL MISSING OR FAULTY CALPAK.

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CODE 55
ALL ENGINES

BE SURE ECM GROUNDS ARE OK AND THAT MEM-CAL IS PROPERLY

LATCHED. IF OK REPLACE ELECTRONIC CONTROL MODULE (ECM).

7 S 3784
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
7-24-86
 COMPUTER COMMAND CONTROL 3-69

RESTRICTED EXHAUST SYSTEM CHECK

ALL ENGINES
Proper diagnosis for a restricted exhaust system is essential before any components are replaced. Either of
the following procedures may be used for diagnosis, depending upon engine or tool used:

CHECK AT A. I. R. PIPE: OR CHECK AT 02 SENSOR:

1. Remove the rubber hose at the exhaust 1. Carefully remove O2 sensor.
manifold A.I.R. pipe check valve. Remove 2. Install Borroughs Exhaust Backpressure
check valve. Tester (BT 8515 or BT 8603) or equivalent in
2. Connect a fuel pump pressure gauge to a hose place of O2 sensor (see illustration).
and nipple from a Propane Enrichm ent 3. After completing test described below, be

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Device (J26911) (see illustration). sure to coat threads of O2 sensor with anti-
3. Insert the nipple into the exhaust manifold seize compound P/N 5613695 or equivalent
A.I.R. pipe. prior to re-installation.

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DIAGNOSIS:
1. With the engine idling at normal operating temperature, observe the exhaust system backpressure
reading on the gauge. Reading should not exceed 1 i psi (8.6 kPa).
2. Accelerate engine to 2000 rpm and observe gauge. Reading should not exceed 3 psi (20.7 kPa).
3. If the backpressure, at either rpm, exceeds specification, a restricted exhaust system is indicated.
4. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler failure.
5. If there are no obvious reasons for the excessive backpressure, a restricted catalytic converter should be
suspected and replaced using current recommended procedures.
4-24-86 7S 3340-6E
Figure 3-13 Exhaust System Check
3-70 COMPUTER COMMAND CONTROL

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PARK/NEUTRAL SWITCH DIAGNOSIS

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ALL ENGINES
(AUTO TRANSMISSION ONLY)
Circuit Description:

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The Park/Neutral Switch contacts are closed to ground in park or neutral and open in drive ranges.
The ECM supplies ignition voltage, through a current limiting resistor, to CKT 434 and senses a closed
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switch, when the voltage on CKT 434 drops to less than one volt.
The ECM uses the P/N signal as one of the inputs to control:
Idle Air Control
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VSS Diagnostics
EGR
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Test Description: Step numbers refer to step Diagnostic Aids:

numbers on diagnostic chart.
1. Checks for a closed switch to ground in park If CKT 434 indicates P/N (grounded), while in
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position. Different makes of "Scan” tools will read drive range, the EGR would be inoperative, resulting
P/N differently. Refer to operators manual for in possible detonation.
type of display used for a specific tool. If CKT 434 always indicates drive (open), a drop in
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2. Checks for an open switch in drive or reverse the idle may exist when the gear selector is moved into
range. drive range.
3. Be sure "Scan” indicates drive, even while
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wiggling shifter to test for an interm ittent or

misadjusted switch in drive range.
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 COMPUTER COMMAND CONTROL 3-71

'SCA W" DIAGNOSTICS

PARK/NEUTRAL SWITCH DIAGNOSIS
ALL ENGINES
(AUTO TRANSMISSION ONLY)

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5-19-86
*7S 3161-6E
3-72 COMPUTER COMMAND CONTROL

N.O.

IGNITION 806 PPL/WHT

SWITCH MAN. TRANS.
CLUTCH START CRANK FUSE-3A
SWITCH OR
FUSE LINK (2.5L)
STARTER
SOLENOID

8- 11-86

CRANK SIGNAL DIAGNOSIS

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ALL ENGINES
Circuit Description:

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Crank signal is a 12 volts signal to the ECM during cranking to allow enrichment and cancel diagnostics
until engine is running or 12 volts is no longer on circuit.

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Test Description: Step numbers refer to step 2. Checks to determine if source of open fuse or fuse
numbers on diagnostic chart. link was a faulty ECM.
1. Checks for normal (cranking) voltage to terminal
"C9” of ECM. Test light should be "ON” during
cranking and then go "OFF” when engine is
running.
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 COMPUTER COMMAND CONTROL 3-73

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3-74 COMPUTER COMMAND CONTROL

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POWER STEERING (P/S) PRESSURE SWITCH CHECK

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2.5L ENGINE
Circuit Description: ar
The power steering pressure switch is normally open to ground, and CKT 495 will be near battery voltage.
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Turning the steering wheel increases power steering oil pressure and its load on an idling engine. The
pressure switch will close before the load can cause an idle problem.
Closing the switch causes CKT 495 to read less than 1 volt. The ECM will increase the idle air rate and
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retard the timing.

Test Description: Step numbers refer to step Diagnostic Aids:
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numbers on diagnostic chart.

1. Checks for ECM signal voltage on CKT 495 and A pressure switch that will not close, or an open
confirms that ground CKT 450 is OK. CKT 495 or 450, may cause the engine to stop when
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2. Maximum resistance, or infinity, indicates an power steering loads are high.

open switch. A switch that will not open, or a CKT 450 or 495,
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3. Less than 1 ohm indicates that the switch is closed

when the power steering pressure is high. Switch shorted to ground, will cause timing to retard at idle,
and may affect idle quality.
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is OK.
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 COMPUTER COMMAND CONTROL 3-75

POWER STEERING (P/S)

PRESSURE SWITCH CHECK
2.5L ENGINE

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CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON LIGHT.
7S 3707-6E
7-9-86
3-76 COMPUTER COMMAND CONTROL

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A/C CLUTCH CONTROL DIAGNOSIS
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(1 Of 2)
2.5L ENGINE
Circuit Description:
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ECM control of the A/C clutch improves idle quality and performance by;
• Delaying clutch apply until the idle air rate is increased.
• Releasing clutch when idle speed is too low.
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• Releasing clutch at wide open throttle.

• Smooths cycling of the compressor by providing additional fuel at the instant clutch is applied.
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Turning on air conditioning supplies CKT 459 battery voltage to the clutch control relay and terminal B8.
After a time delay of about 1/2 second the ECM will ground terminal "A4”, CKT 458, and close the control relay.
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A/C compressor clutch will engage.

Test Description: Step numbers refer to step 2. This and following tests check for faulty A/C
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numbers on diagnostic chart. control relay.

1. Checks for low refrigerant as cause for no A/C.
 COMPUTER COMMAND CONTROL 3-77

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3-78 COMPUTER COMMAND CONTROL

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A/C CLUTCH CONTROL DIAGNOSIS
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(2 of 2)
2.5L ENGINE
Circuit Description:
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ECM control of the A/C clutch improves idle quality and performance by;
• Delaying clutch apply until the idle air rate is increased.
• Releasing clutch when idle speed is too low.
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• Releasing clutch at wide open throttle.

• Smooths cycling of the compressor by providing additional fuel at the instant clutch is applied.
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Turning on air conditioning supplies CKT 459 battery voltage to the clutch control relay and terminal "B8”.
After a time delay of about 1/2 second, the ECM will ground terminal "A4”, CKT 458, and close the control
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relay. A/C compressor clutch will engage.

Test Description: Step numbers refer to step Diagnostic Aids:

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numbers on diagnostic chart.

3. Checks for faulty cycling switch. Before replacing ECM, use ohmmeter and check
• Solenoids and relays are turned "ON” or "OFF” by resistance of each ECM controlled relay or solenoid
the ECM, using internal electronic switches called coil. See ECM wiring diagram for coil term inal
"drivers”. Each driver is part of a group of four, identification for solenoids(s) and relay(s) to be
called "Quad-Drivers”. Failure of one driver can checked.
damage any other driver in the set. Replace any relay or solenoid that measures less
Solenoid and relay coil resistance must measure than 20 ohms.
more than 20 ohms. Less resistance will cause
early failure of the ECM "driver”. Using an
ohmmeter, check the coil resistance of the A/C
relay before replacing the ECM.
 COMPUTER COMMAND CONTROL 3-79

A/C CLUTCH CONTROL

DIAGNOSIS
(2 of 2)
FROM A/C CLUTCH
CONTROL DIAGNOSIS
2.5L ENGINE
CHART (PAGE 1 OF 2)

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7S 3850-6E
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 8-14-86
3-80 COMPUTER COMMAND CONTROL

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A/C CLUTCH CONTROL DIAGNOSIS
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(1 Of 2)
2.8L ENGINE
Circuit Description:
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ECM control of the A/C clutch improves idle quality and performance by;
• Delaying clutch apply until the idle air rate is increased.
• Releasing clutch when idle speed is too low.
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• Releasing clutch at wide open throttle.

• Smooths cycling of the compressor by providing additional fuel at the instant clutch is applied.
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Turning on air conditioning supplies CKT 59 battery voltage to the clutch control relay and terminal "B8” of
the ECM connector. After a time delay of about 1/2 second the ECM will ground terminal "A2” of the ECM
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connector, CKT 459, and close the control relay. A/C compressor clutch will engage.

Test Description: Step numbers refer to step 2. This and following tests check for faulty A/C
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numbers on diagnostic chart. control relay.

1. Checks for low refrigerant as cause for no A/C.
 COMPUTER COMMAND CONTROL 3-81

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3-82 COMPUTER COMMAND CONTROL

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A/C CLUTCH CONTROL DIAGNOSIS
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(2 of 2)
2.8L ENGINE
Circuit Description:
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ECM control of the A/C clutch improves idle quality and performance by;
• Delaying clutch apply until the idle air rate is increased.
• Releasing clutch when idle speed is too low.
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• Releasing clutch at wide open throttle.

• Smooths cycling of the compressor by providing additional fuel at the instant clutch is applied.
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Turning on air conditioning supplies CKT 59 battery voltage to the clutch control relay and terminal "B8” of
the ECM connector. After a time delay of about 1/2 second the ECM will ground terminal "A2” of the ECM
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connector, CKT 459, and close the control relay. A/C compressor clutch will engage.

Test Description: Step numbers refer to step Diagnostic Aids:

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numbers on diagnostic chart.

3. Checks for faulty cycling switch. Before replacing ECM, use ohmmeter and check
• Solenoids and relays are turned "ON” or "OFF” by resistance of each ECM controlled relay or solenoid
the ECM, using internal electronic switches called coil. See ECM wiring diagram for coil term inal
"drivers”. Each driver is part of a group of four, identification for solenoid(s) and relay(s) to be
called "Quad-Drivers”. Failure of one driver can checked.
damage any other driver in the set. Replace any relay or solenoid that measures less
Solenoid and relay coil resistance must measure than 20 ohms.
more than 20 ohms, less resistance will cause
early failure of the ECM "driver”. Using an
ohmmeter, check the coil resistance of the A/C
relay before replacing the ECM.
 COMPUTER COMMAND CONTROL 3-83

A/C CLUTCH CONTROL

DIAGNOSIS
(2 of 2)
FROM
CHART C-10B !
2.8L ENGINE
i
(1 of 2) i
_ J

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1 K
LIGHT OFF LIGHT ON

• PROBE HARNESS CONNECTOR • JUMPER BETWEEN HARNESS TERMINALS "B

TERMINAL "B" WITH A TEST & D". A/C CLUTCH SHOULD ENGAGE.

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LIGHT TO GROUND.
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NOT OK OK

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CHECK: FAULTY A/C
- OPEN CKT 959 TO CLUTCH RELAY

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- OPEN CLUTCH COIL
- OPEN HI PRESSURE SWITCH
- FAULTY GROUND
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LIGHT OFF LIGHT ON

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• DISCONNECT A/C PRESSURE • DISCONNECT WHITE ECM A-B CONNECTOR.

CYCLING SWITCH. • PROBE TERMINAL B8 WITH A TEST LIGHT TO GROUND.
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• PROBE BOTH HARNESS

TERMINALS WITH A
TEST LIGHT TO GROUND.
LIGHT ON LIGHT OFF
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FAULTY ECM CONNECTOR REPAIR OPEN IN

TERMINAL OR ECM. SEE FACING CKT 59 TO RELAY
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PAGE "DIAGNOSTIC AIDS"

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LIGHT ON ONE TERMINAL LIGHT OFF EITHER TERMINAL

CHECK FOR OPEN CKT 59 FROM CHECK FOR OPEN CKT 59

CYCLING SWITCH TO RELAY. IF OK, TO A/C CONTROL SWITCH
IT IS A FAULTY CYCLING SWITCH. OR FAULTY A/C SWITCH.

7S 3851-6E
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 8-14-86
3-84 COMPUTER COMMAND CONTROL

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4.3L AND V8 ENGINE

Circuit And Test Description:
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Turning on the air conditioning supplies CKT 59 battery voltage to the A/C compressor clutch and to
terminal "B8” of the ECM connector to increase idle air rate and maintain idle speed.
The ECM does not control the A/C compressor clutch, therefore, if A/C does not function, refer to the A/C
section of the service manual for diagnosis of the system.
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If A/C is operating properly and idle speed dips too low when the A/C compressor turns "ON” or flares too
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high when the A/C compressor turns "OFF”, check for an open CKT 59 to the ECM. If circuits is OK, it is a
faulty ECM connector terminal "B8” or ECM.
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 COMPUTER COMMAND CONTROL 3-85

ON-VEHICLE SERVICE
WIRE HARNESS

The ECM harness electrically connects the ECM term inal pair, it is possible to dam age c e rta in
to the various solenoids, switches, and sensors in components. Always use jum per wires between
vehicle engine and passenger compartment. connectors, for circuit checking. NEVER probe
Wire harnesses should be replaced with proper through the Weather-Pack seals. Use tachometer
part number harnesses. When signal wires are adapter J35812, or equivalent, which provides an easy
spliced, into a h a rn e ss, use w ire w ith high hook up of the tach. lead. The connector test adapter
temperature insulation only. kit J35616, or equivalent, contains an assortment of
With the low current and voltage levels found in flexible connectors, used to probe term inals during
the system, it is important that the best possible bond diagnosis. Fuse remover and test tool BT 8616, or
at all wire splices be made by soldering the splices, as equivalent, is used for removing a fuse and to adapt
shown in Figure 3-14. fuse holder, with a meter, for diagnosis.

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Molded on c o n n ec to rs r e q u ire c o m p lete When diagnosing, open circuits are often difficult
replacement of the connector. This means splicing a to locate by sight, because oxidation, or terminal mis­
new connector assembly into the harness. alignment are hidden by the connectors. Merely
Refer to Figure 3-17 through 3-28, for wiring wiggling a connector on a sensor, or in the wiring

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diagrams. harness, may correct the open circuit condition. This
Replacement connectors and terminals are listed should always be considered, when an open circuit, or
in Group 8.965, of the Standard Parts Catalog. failed sensor is indicated. Intermittent problems may,

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also, be caused by oxidized or loose connections.
CONNECTORS AND TERMINALS Before making a connector repair, be certain of the
ra type of connector. Weather-Pack and Compact Three
Use care, when probing a connector or replacing connectors look similar, but are serviced differently.
terminals in them. It is possible to short between
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opposite terminals. If this happens, to the wrong
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TWISTED/SHIELDED CABLE TWISTED LEADS

D RAIN WIRE
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Z O UTER JA C K E T

M YLA R
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1. REM OVE OUTER JA C K E T . 1. LO CATE DAMAGED WIRE.

2. UNWRAP ALUM INUM /M YLAR TAPE. DO NOT 2. REM OVE IN SU LATIO N AS REQ U IRED .
REM OVE M YLAR.
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SP LIC E & SO LD ER
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3. UNTWIST CONDUCTORS. STRIP IN SULATIO N AS 3. SP LIC E TWO W IRES TO G ETH ER USING SP LIC E
N EC ESSA R Y. C LIP S AND ROSIN CORE SO LD E R .

DRAIN WIRE

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4. SP LIC E W IRES USING SP LIC E C LIP S AND ROSIN CORE 4. CO V ER SP LIC E WITH TAPE TO IN SU LA TE
SO LD ER . WRAP EACH SPLIC E TO IN SU LA TE. FROM O THER W IRES.
5. WRAP WITH M YLA R AND D RAIN (U N IN SU LATED) W IRE. 5. RETW IST AS BEFO RE AND TAPE WITH
E L E C T R IC A L TAPE AND HOLD IN PLA CE.

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6. TAPE O V ER WHOLE BU NDLE TO SECU RE AS BEFO RE.
4S0570-6E
Figure 3-14 - Wire Harness Repair
3-86-COMPUTER COMMAND CONTROL

Micro-Pack To remove a terminal:

1. Slide the seal back on the wire.
Refer to Figure 3-15 ane repair procedure for 2. In se rt tool (3) BT-8518, or J35689, or
repolacement of a Micro-Pack terminal. equivalent, as shown in insert "A” and "B”, to
release the terminal locking tab (2).
Metri-Pack 3. Push the wire and terminal out through the
connector.
Some connectors use terminals called Metri-Pack If reusing the terminal, reshape the locking tang (2).
Series 150. (Figure 3-16). These may used at the
Coolant Sensor, as well as TBI units. Weather-Pack
They are, also, called "Pull-To-Seat” terminals,
because, to install a terminal on a wire, the wire is A Weather-Pack connector can be identified by a
first inserted through the seal (5) and connector (4). rubber seal, at the rear of the connector. This
The terminal is , then, crimped on the wire and the connector, which is used in the engine compartment,
terminal pulled back into the conector to seat it in protects against moisture and dirt, which could create

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place. oxidation and deposits on the tem rinals. This
protection is important, because of the very low
voltage and current levels found in the electronic
system.

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Repair of a Weather-Pack terminal is shown in
Figure 3-17. Use tool J28742, or BT8234-A, to remove
the pin and sleeve terminals.

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If removal is attempted with an ordinary pick,
there is a good chance that the terminal will be bent,
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or deformed. And, unlike standard blade type
terminals, these terminals cannot be straightened
once they are bent.
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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
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backup, or secondary, locking featu re for the

CABLE m LOCKING TANG
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m TERMINAL m TOOL J33095 BT8234-A

connector. They are used to improve the connector
reliability by retaining the term inals, if the small
7S 3548-6E terminal lock tangs are not positioned properly.
Figure 3-15 - Micro-Pack Connector Weather-Pack connections cannot be replaced
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with standard connections. Instructions are provided

with Weather-Pack connector and terminal packages.
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1. METRI-PACK SERIES 3. TOOL J35689 OR BT-8446

150 FEMALE TERMINAL 4. CONNECTOR BODY
2. LOCKING TANG 5. SEAL 4-18-86
♦7S3213-6E

Figure 3-16 - METRI-PACK SERIES 150 TERMINAL REMOVAL

 COMPUTER COMMAND CONTROL -3-87

1. OPEN SECONDARY LOCK HINGE ON CONNECTOR Important

FEMALE r s _______ .MALE When replacing a production ECM with a service
CO N N ECTO R^^^^ CONNECTOR
controller, tran sfer the b ro ad cast code and
production ECM part number to the controller
label. Do not record information on the access
^SECONDARY* cover.
LOCK HINGE
2. REMOVE TERMINAL USING TOOL NOTICE: The ig n itio n m ust be "O FF”, w hen
PUSH TO
RELEASE disconnecting or reconnecting the ECM
connector, to prevent internal damage to
TERMINAL TOOL J-28742/BT8234-A the ECM.
3. CUT WIRE IMMEDIATELY BEHIND CABLE SEAL
ECM Connector Terminal Voltages

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‘WIRE
Refer to Figure 3-28 through 3-30, for voltage
REPLACE TERMINAL charts, to aid in diagnosis.
A. SLIP NEW SEAL ONTO WIRE.
B. STRIP 5 mm (.2") OF INSULATION FROM WIRE. ECM Replacement - with Mem-Cal
C. CRIMP TERMINAL OVER WIRE AND SEAL.

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Figures 3-31 and 3-32
SEAL
«--► Remove or Disconnect

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5. PUSH TERMINAL AND CONNECTOR AND 1. Negative battery cable.
ENGAGE LOCKING TANGS.
6. CLOSE SECONDARY LOCK HINGE 2. Connectors from ECM.
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7S 3542-6E 4. ECM from passenger compartment.
Figure 3-17 - Weather-Pack Terminal Repair 5. ECM access cover (Figure 3-2).
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6. Mem-Cal removal (Figure 3-33).
Compact Three
Important
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The Compact Three connector, which looks similar Replacement ECM is supplied without a Mem-Cal,
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to a Weather-Pack connector, is not sealed and is used so, care should be used, when removing it from the
where resistance to the environment is not required. defective ECM, because it will be reused in the
This type of connector, most likely, is used at the air new ECM.
ic

control solenoid. Use the standard method, when

repairing a terminal. Do not use the Weather-Pack Using two fingers, push both retaining clips back
terminal tool J28742, or BT8234-A, as these will
s

away from the Mem-Cal. At the same time, grasp it at

damage the terminals. both ends and lift it up out of the socket. Do not
as

remove the cover of the Mem-Cal. Use of unapproved

ELECTRONIC CONTROL MODULE Mem-Cal removal methods may cause damage to the
Mem-Cal or socket.
Replacement of the Electronic Control Module
cl

(ECM) consists of a service controller, without a tfrl Inspect (Figure 3-34)

PROM/CALPAK, or Mem-Cal.
For alignm ent notches of the Mem-Cal and
If the diagnostic procedures required the ECM to
carefully set it aside. Do not open the Mem-Cal.
be replaced, the ECM, PROM, CALPAK, and Mem-
Cal should be checked for the correct part number. If
they are, remove the PROM and CALPAK, or Mem-
Cal, and install them in the service controller. The
service controller will not contain a PROM/CALPAK,
or Mem-Cal.
3-88 COMPUTER COMMAND CONTROL

ECM

I~mT ORN 461 A8 SERIAL DATA

A9 DIAGNOSTIC TEST
ALDL CONNECTOR < e * c n WHT/BLK 451

BLK/WHT 450 A12 SYSTEM GROUND

D1 SYSTEM GROUND
| TAN/WHT
= - ENGINE GND'S

PPL 412 OXYGEN SENSOR

D7

om
SIGNAL

OXYGEN SENSOR OXYGEN SENSOR

TAN 413 - D6 GROUND
ENGINE GND.

.c
V , A BLK/ORN 469 D2 5V RETURN--------1

ry
MAP SENSOR
B C11 MAP SIGNAL —
“ LT GRN 432
y ?
ra 24 PIN A-B
CONNECTOR
lib
_ GRY 416 C14 + 5V REFERENCE
A
TPS DKBLU417 C13 TPS SIGNAL
B
ar

-
C A11 5V RETURN
cc

COOLANT
TEMPERATURE COOLANT
SENSOR YEL 410 - CIO TEMPERATURE
SIGNAL
si
as

MAT
MANIFOLD AIR
cl

TAN 472 - C12 TEMPERATURE

SIGNAL
32 PIN C-D
EGR SOLENOID CONNECTOR

PNK/BLK 439 ------------1 V .* I------------- GRY 435 — A3 EGRCONTROL

ECM 1
IGN PNK/BLK 439 — A6 IGNITION
12 V 1QA
INJECTOR
RED ) ) J T ) f i r L ( (( (£ --------- LT BLU 467 D16 INJECTOR DRIVER

7S3265
7-12-86

Figure 3-18 - Wiring Diagram - 2.5L (1 of 3)

 COMPUTER COMMAND CONTROL 3-89

ECM

IAC
VALVE
ir
r_
n r r m _
D
r
B
LT BLU/WHT 441
LT BLU/BLK 442 -
C5
C6
LT GRN/WHT 443 “ C4
IAC COIL
IAC COIL
IAC COIL
"A" HI
“A “ LO
”B" HI
lJ U J U u IAC COIL "B" LO
A LT GRN/BLK 444 - C3

HALL EFFECT SWITCH

/ b\

D X. D BLK/RED 453 B3 REFERENCE LOW

C fp-l C TAN/BLK 424 D5 BY-PASS

om
B Lj B PPL/WHT 430 B5 REFERENCE HIGH
A r A ----- WHT 423 D4 EST

DISTRIBUTOR

.c
(2.5L ST TRUCK)
PICK-UP COIL

y
ar 24 PIN A-B
CONNECTOR
br
DISTRIBUTOR
(2.5L M VAN)
/£ l\ /D l\
li
ar

WHT423 — D4 EST
cc

PPL/WHT 430 B5 REFERENCE HIGH

TAN/BLK 424 D5 BY-PASS

PRIMARY COIL
si

BLK/RED 453 H B3 REFERENCE LOW

ECM B
as

12 V - 10A
----------- ORN 440 — B1 12V
----------- ORN 440 C16 12V
cl

DK GRN/WHT 465 ~ A1 FUEL PUMP RELAY

DRIVE (12V)
BLK/WHT
32 PINC-D
I CONNECTOR
D B ~ ENGINE GROUND
FUEL n T j

[J
PUMP
RELAY
m i TAN/WHT 120 — B2 FUEL PUMP SIGNAL
| FUEL PUMP
TEST CONNECTOR
TO
FUEL
PUMP a

SWITCH 7S3266
7-12-86
Figure 3-19 - Wiring Diagram - 2.5L (2 of 3)
3-90 COMPUTER COMMAND CONTROL

ECM
GAGE SERVICE ENGINE SOON
IGN PNK/BLK39 BRN/WHT 419 — A5
12V LIGHT CONTROL
20 A SES LAMP

BRAKE SWITCH
N.C. r t
- PPL 420 □
AUTOMATIC
TRANS. TCC
SOLENOID
TAN/BLK 422 A2 TCC CONTROL (A/T)

ALDL
CONN. B

m
AUTOMATIC TRANSMISSION
SHIFT LIGHT
m TAN/BLK 456 A2 (M/T)

co
MANUAL TRANS.
SHIFT LAMP

MANUAL TRANSMISSION
D10

.
ry
ra D9
lib
VEHICLE 24 PIN A-B
BUFFER BRN 437 ---- A10 SPEED CONNECTOR
SENSOR
VEHICLE SPEED SENSOR

A A
ar

BLK/WHT 450
A
cc

P/N
PARK
SWITCH I B ORN/BLK 434 — B10 NEUTRAL
SWITCH (A/T) :::
(12 V) — DCF--
si

□□
□□
□□
as

P/S □□
SWITCH
N.O. / B BLU/ORN 495 C8
POWER
STEERING
□□
PRESSURE
SWITCH
cx"
cl

'- - '- a

.—□IX-"
t:d=ii
IGN. 3
25A 32 PINC-D
PRESSURE CYCLING DK GRN/WHT 459 B8 A/C SIGNAL CONNECTOR

GAGE 20A

A4 A/C RELAY CONTROL

7S3267
7-24-86

Figure 3-20 - Wiring Diagram - 2.5L(3 of 3)

 COMPUTER COMMAND CONTROL 3-91

ECM

ORN 461 - A8 SERIAL DATA

y r C B
ALDL CONNECTOR WHT/BLK 451 - A9 DIAGNOSTIC TEST

BLK/WHT 450 - A12 SYSTEM GND

_5SL D1 SYSTEM GND

| TAN/WHT
= ENGINE GND'S

IGN SW.
N.O.
CRANK A A
START PPL/WHT 806 — C9 CRANK SIGNAL
MAN. TRANS.
CLUTCH START
SWITCH

m
START SOLENOID -=i=

co
PPL 412 - D7 OXYGEN SENSOR
SIGNAL
OXYGEN SENSOR
TAN 413 - D6 OXYGEN SENSOR

.
ENGINE GND GROUND

ry PPL 455 — A11

MAP SENSOR
ra MAPGROUND 24 PIN A-B
CONNECTOR
B
> — LT GRN 432 C11 MAP SIGNAL
lib

/£ i\ / d\
GRY 416
ar

L C14 + 5V REF
C13 TPS SIGNAL
B
cc

A
D2 5V RETURN
si

COOLANT
TEMPERATURE
SENSOR
C10 COOLANT TEMP
as

SIGNAL

IGN. 3
25A
cl

PRESSURE CYCLING DK GRN 59 B8 A/C SIGNAL

39 GAGE 20A 32 PIN C-D
h PNK/BLK ----- «3N CONNECTOR
DK GRN/WHT 459 A2 A/C RELAY
CONTROL

* 6S 2678-6E
8-18-86
Figure 3-21 - Wiring Diagram - 2.8L(1 of 3)
3-92 COMPUTER COMMAND CONTROL

_______ ECM

------- LT BLU/WHT 441

prrm _ A
B LT BLU/BLK 442 -
C5
C6
IAC COIL "A “ HI
IAC COIL "A" LO
IAC
i r LT GRN/WHT 443 C4 IAC COIL "B" HI
VALVE _ C
JUUUU— D
------- LT GRN/BLK 444 - C3 IAC COIL "B" LO

E-CELL

I + 12V --------- ORN 440 ----

B Ic I* ID
DK BLU/WHT 421 C12 E-CELL
A A
IGN + 1 2 V --------- PNK/BLK 439

m
ECM 1
IGN PNK/BLK ---- 439 A6 IGN.
1 2V 1QA
\ 481
\RED INJ.1

co
LT BLU 467 — D16 — INJECTOR
DRIVER

y.
PICK-UP COIL D14 INJECTOR
LTGRN ------ 468 DRIVER

ar 24 PIN A-B
CONNECTOR
br
rli

/c \ /D l\
ca

WHT ----- 423 - D4 EST

PPL7WHT ---- 430 — B5 REFERENCE

ic

SET TIMING CONNECTOR^ ____ TAN/BLK — 424 D5 BY-PASS

PRIMARY COIL
B3 REF. LOW
s

------------------------------------------------ BLK/RED — 453

ECM B
as

12 V ioa
---------- ORN 440 B1 12V
---------- ORN 440 C16 12V
cl

DK GRN/WHT 465 ~ A1 FUEL PUMP RELAY

DRIVE (12 V)
BLK/WHT
32 PIN C-D
r CONNECTOR
|E D |A C B |
FUEL ENG.GND
PUMP r r t .,5
RELAY

------------
TO
FUEL B2 FUEL PUMP SIGNAL
PUMP
OIL
FUEL PUMP
PRESS.
SWITCH
✓ a 1 ___I te st
CONNECTOR 6 S 2679
7-24-86
Figure 3-22 - Wiring Diagram - 2.8L (2 of 3)
 COMPUTER COMMAND CONTROL 3-93

ECM
GAGE SERVICE ENGINE SOON
IGN PNK/BLK39 BRN/WHT 419 — A5
12V LIGHT CONTROL
20 A SESLAMP

BRAKE SWITCH

- PPL 420 1
AUTOMATIC
TRANS. TCC
SOLENOID
TAN/BLK 422 — A7 A/T TCC CONTROL
ALDL
CONN.

m
MANUAL
TAN/BLK 456 — A7 TRANS.
SHIFT LAMP

co
MANUAL TRANS.
SHIFT LAMP

ALDL BLK/PNK421 — C1 EAC SOLENOID

CONN. & FED. ONLY

y.
A _ /w v w J L BRN 436 C2 EAC SOLENOID
EAC SOLENOID CALIF. ONLY
IGN
ECM 1

r
12V
ra PNK/BLK 439 A6
10 A

24 PIN A-B
lib
CONNECTOR
BRN 437 A10 VSS SIGNAL

A A
ar

BLK/WHT 450
A
cc

P/N PARK
SWITCH
r
I D ORN/BLK 434 B10 NEUTRAL
SWITCH (A/T)
si

KNOCK
SENSOR
«
as

BLK/WHT
450
cl

ESC SENSOR INPUT E 496 DK BLU

ELECTRONIC
SPARK ESC GROUND D 486 BRN — KNOCK
CONTROL SPARK RETARD C 485 BLK — B7 RETARD
MODULE SIGNAL (ESC) 32 PINC-D
12 V IGN. B CONNECTOR
A
PNK/BLK 439 — A6 12V IGN

« • EGR SOLENOID
± 1 __ A AA GRY 435 A4 EGR
* VACUUM CONTROL
i SWITCH
BLK/WHT 450 BRN 526 B9 EGR VACUUM
X EGRCONTROL
DIAGNOSTIC
SWITCH
SIGNAL 6S 2680
7-10-86
Figure 3-23 - Wiring Diagram - 2.8L (3 of 3)
3-94 COMPUTER COMMAND CONTROL

ECM

ORN ~ D ORN/GRN 461 A8 SERIAL DATA

ALDL B 1------------------------- WHT/BLK 451 A9 DIAGNOSTIC TEST

Na BLK/WHT 450 - A12

450 D1
SYSTEM GND

SYSTEM GND
/A l\ /b i \

| BLK/WHT
^ ENGINE GROUNDS
N.O. <2>
CRANK FUSE “
IGN SW.
START PPL/WHT 806 — C9 CRANK SIGNAL
MAN. TRANS. 5A
CLUTCH START

m
SWITCH
START SOLENOID -±=

co
■ PPL 412 - D7 OXYGEN SENSOR
SIGNAL

OXYGEN SENSOR 24 PIN A-B

CONNECTOR

y.
TAN 413 - D6 OXYGEN SENSOR
ENGINE GND. GROUND
PPL 455 MAP GROUND
D2 (4.3L M OR G VAN)
A

r PPL 455 A11 MAP GROUND

MAP SENSOR
ra (4.3L CK RV & V8)
B C11 MAP SIGNAL
LT GRN 432
r
lib

/^ l\ /D l\
ar

L GRY 416 - C14 + 5V REFERENCE

TPS DK BLU 417 - C13 TPS SIGNAL

v f ------------- B
cc

A
BLK 452 - A11 SENSORGROUND
(4.3LM ORG VAN)
si

COOLANT BLK 452 - D2 SENSORGROUND

TEMPERATURE (4.3L CK RV & V8))
SENSOR
YEL410 — C10 COOLANT TEMP.
as

SIGNAL
cl

A/C
IGN 3 LT GRN 66 DK GRN/WHT 59 - B8 A/C SIGNAL

PRESSURE CYCLING 32 PIN C-D

SWITCH CONNECTOR

A/C COMPRESSOR 7S3198

7-12-86

Figure 3-24 - Wiring Diagram - 4.3L & V8 (1 of 4)

 COMPUTER COMMAND CONTROL 3-95

ECM

A LT BLU/WHT 441 -
C5 IAC C O IL” A" HI
IAC I f B LT BLU/BLK 442 - C6 IAC COIL "A" LO
VALVE _ C LT GRN/WHT 443 “ C4 IAC COIL "B" HI
JUUUU— X D LT GRN/BLK 444 - C3 IAC COIL "B” LO

ECM B

ORN 440 — B1 12V

ORN 440 C16 12V
DK GRN/WHT 465 — A1 FUEL PUMP RELAY
DRIVE (12 V)

om
ENG. GND

TAN/WHT120 “1 B2 FUEL PUMP SIGNAL

.c
FUEL PUMP

□
TEST CONNECTOR

y
SWITCH
ar
FUEL PUMP RELAY CIRCUIT (M)
24 PIN A-B
CONNECTOR
li br
ECM FUSE LINK (CK)
BATT —• — J— RED 2C — • B1
ORN 440
ar

I— 12V
12 V JUNCTION BLOCK 0R ECM B
FUSE (RV G P)
OIL PRESS. SWITCH
----- ORN 440 ~ C16 12V
cc

CLOSES AT 4 PSI
DK GRN/WHT 465 — A1 FUEL PUMP RELAY
RED 490 BLK/WHT DRIVE (12 V)
E h
ALDL(CK) 7h
si

TERM. (RV G P)
C A
E l ENG GND
FUEL
PUMP
as

RELAY

PNK/BLK 920 OR TAN/WHT 120

cl

TAN/WHT 120 - B2 FUEL PUMP SIGNAL

32 PINC-D
CONNECTOR
FUEL A
PUMP
B
FUEL 20A
c - PNK/BLK 39 IGN 12 V
MODULE
BLK/WHT D
E
7.4L AND
r r SOME 5.7L

FUEL PUMP RELAY CIRCUIT (CK RV G P) 7S3199

8-14-86

Figure 3 - 25 Wiring Diagram - 4.3L & V8 (2 of 4)

3-96 COMPUTER COMMAND CONTROL

ECM
ECM/IGN SERVICE ENGINE SOON
IGN PNK/BLK 439 BRN/WHT 419 A5 LIGHT CONTROL
12V SESLAMP a -
10 A IP

BRAKE SWITCH

- PPL 420 □
AUTOMATIC LTBLU 446 — a HIGH GEAR SWITCH SIGNAL
TRANS. TCC
SOLENOID
TAN/BLK 422 A7 A/T TCC CONTROL
(GRD)
ALDL
THM 700 R4 TRANSMISSION

om
BRAKE / b\
SWITCH
420 PPL —1

BATT.
12V
2 RED
□

.c
FUSE
LINK

DOWNSHIFT

ry
CONTROL
RELAY A/T DOWNSHIFT
TAN/BLK 422 A7 CONTROL (GRD)
ra
— 55 ORN
.r\/w w
DOWNSHIFT SOLENOID
X
lib
24 PIN A-B
THM 400 TRANSMISSION (C & K) CONNECTOR

IGN. _ GAGE
ar

+ 12V ~ ^ \P ----------------------------------
20A
— PNK/BLK
cc

DOWNSHIFT
CONTROL
RELAY
[q TAN/BLK 422 A7
A/T DOWNSHIFT / \
CONTROL (GRD)
si

55 ORN
7 > /Y V W
X
as

DOWNSHIFT SOLENOID

THM 400 TRANSMISSION (G, P R & V)

MANUAL
m
cl

TAN/BLK 456 A7 TRANS.

MANUAL TRANS. OIP SHIFT LAMP
(GRD)
SHIFT LAMP

MANUAL TRANSMISSION
VEHICLE
BUFFER BRN 437 — A10 SPEED
SENSOR
VEHICLE SPEED SENSOR
32 PIN C-D
CONNECTOR
BLK/WHT 450

P/N
A
PARK NEUTRAL
SWITCH I B ORN/BLK 434 B10 SWITCH (A/T)
7S 3540
(12 V) 8-18-86
Figure 3-26 - Wiring Diagram - 4.3L & V8 (3 of 4)
 COMPUTER COMMAND CONTROL 3-97

ECM
INJ A 10A 481
IGN ( « GM 2_ RED
BLU 467 INJECTOR
1 2V ECM 110A
» DRIVER
(RVP)
INJECTOR
GRN468 — D14 DRIVER

ECM/IGN
439 ___ A y w W \ B _ GRY 435 A4 EGR SOLENOID
EGR SOLENOID 4.3L & 5.0L
10 A

A B GRY 435 A4 EVRV SOLENOID

5.7L & 7.4L

m
EVRV SOLENOID

BLK/WHT
Z L

co
ALDL
A A /W Y ll BRN 436 — C2 EAC SOLENOID
EAC SOLENOID

y.
PNK/BLK 439 — A 6 12V IGN

ELECTRONIC
ESC SENSOR INPUT
ESC GROUND 486 BRN
ar TO ENGINE GRD.
br
SPARK KNOCK
CONTROL SPARK RETARD 457 YEL/BLK OR YEL/RED OR BLK B7 RETARD 24 PIN A-B
MODULE SIGNAL (ESC) CONNECTOR
12 V IGN.
rli

A A
ca
ic

:-n D F -:
s
as
cl

WHT423 — D4 -EST
PPL/WHT 430 32 PIN C-D
B5 -REFERENCE CONNECTOR
TAN/BLK 424 D5 BY-PASS
BLK/RED 453 B3 - REF. LOW
PRIMARY COIL

7S 3200
7-24-86
Figure 3-27 - Wiring Diagram-4.3L&V8 (4 of 4)
3-98 COMPUTER COMMAND CONTROL

TBI FUEL INJECTION ECM CONNECTOR IDENTIFICATION

This ECM voltage chart is for use with a digital voltmeter to further aid in diagnosis. The voltages
you get may vary due to low battery charge or other reasons, but they should be very close.
THE FOLLOWING CONDITIONS MUST BE MET BEFORE TESTING:
• Engine at operating temperature • Engine idling in closed loop (for "Engine Run" column)
• Diagnostic terminal not grounded • ALDL tool not installed
VOl.TAGE VOLTAGE
KEY ENG. WIRE WIRE KEY ENG.
"ON ' RUN . CLRCU1L .PIN (COLOR /M \ /3 1 \ COLOR PIN CIRCUIT _ ....... I ON" RUN
DK GRN/ ORN B1 BATT.12.VOLTS 12 14
© 0 14 PULL PUMP REtAV A , WHT
SHIFT LIGHT (MT) TAN/ TAN/
1? 14 TCC CONTROL s'AT'; A? BLK WHT B2 FUEL PUMP SIGNAL 0 14 ©
BLK/
1A RED 83 EST REF LOW 0 0

m
1? FftR SOI FNOiD GRY
B4 NOT USED
12 14 A/C RELAY A4 BLU
"SERVICE ENGINE BRN/ PPL/ EST
0 WHT B5 REFERENCE HI 0 1.6

co
14 SOON” CONTROL A5 WHT
PNK/
12 , 14 . . IGN-ECM FUSE A6 BLK 36 . NOT USED ..........
B7 NOT USED
NOT USED A7

y.
DK GRN/
2-5 2-5 SERIAL DATA A8 ORN WHT A/C SIGNAL 0 0
WHT/
5 5 DIAG.TERM. A9 BLK B9 NOT USED

12
0
©
0
SPEED
t. SENSOR SIGNAL
MAT &
TPS GROUND
A10
A11
TAN
BLK
BLK/
ar
24 PIN A-B
CONNECTOR
ORN/
BLK B10
811
PARK/NEUTRAL
SW.SIGNAL
_ NQT USED . , _ _ .....
0 A ........
br
0 0 SYSTEM GROUND A12 WHT B12 NOT USED

TAN/
NOT USED C„1 WHT 01 SYSTEM GROUND 0 0
rli

BLK/
NOT U SED ............ . C2 ORN D2 5V RETURN 0 0
LT GRN/ /c \
NQTl, 5 EABLE IAC "B" LO ..... Q BLK DJ NOT USED ....... .......
ca

LT GRN/
NOT I .1EAEULL C4 WHT WHT D4 EST CONTROL .... 0 1.0
LT BLU/ TAN/
NOT I SEABLE IAC "A" HI C5 WHT BLK D5 EST BYPASS 0 4.75
LT BLU/
ic

NOT I Li a b le IAC "A" LO C6 BLK TAN D$ GRN 0 .( 0 ,) __ _____ p L .O _

NOT USED C7 PPL D7 _ 02 SENSOR SIGNAL 0 (3)

s

BLU/
12.3 12.3 . P/S SWITCH . CB YEL □a NOT USED ........
as

NOT USED C9 no NOT IK F D

COOLANT
© 1.9 . 1.7 TEMP. SIGNAL CIO YEL mo NOT USED

4.7 2.0 MAP SIGNAL Q1 1 LT GRN D11 NOT USED

cl

© 1.3 1.3 .. MAT SIGNAL C 12 TAN D1 2 NOT USED

© ,73 V ,73 V
TPS SIGNAL t l 3 DK BLU D ll N O TIISFH
5 VOLT
_ 5____ 5 REFERENCE Cr14 GRY 32 PINC-D D14 NOT USED
CONNECTOR
NOT USED Cl 5 015 n o tu sed

12 14 BATTERY 12 VOLTS C16 Q.m .... BLU D16 INJECTOR A 12 14

1 Varies from .60 to battery voltage depending on position of drive wheels. ENGINE 2.5L
2 Varies with temperature.
3 Varies. VEHICLE S/T TRUCK M VAN
4 12V First two seconds.
5 Measured between terminals C13 and A 1 1 ( ± 05V). 7S 3264
6 12-86
-

Figure 3-28 - ECM Connector Terminal End View-(2.5L)

 COMPUTER COMMAND CONTROL 3-99

TBI FUEL INJECTION ECM CONNECTOR IDENTIFICATION

This ECM voltage chart is for use with a digital voltmeter to further aid in diagnosis. The voltages
you get may vary due to low battery charge or other reasons, but they should be very close.
THE FOLLOWING CONDITIONS MUST BE MET BEFORE TESTING:
• Engine at operating temperature • Engine idling in closed loop (for "Engine Run" column)

VO LTAGE VOL1rAGE
KEY ENG. WIRE WIRE KEY ENG.
"ON * RUM CIRCUIT jpiN /COLOR A A COLOR PIN CIRCUIT ON" m u
>K GRN/ ORN B1 BATT.12.VOLTS 12 14
) 0 14 FUEL PUMP RELAY A1 WHT b A c k v ie w
A/C CLUTCH OF TAN/
)_ 1 Z_ .. 14..... CONTROL........ 4? nK RRN CO yiNECro R WHT _31 FUEL POMP SIGNAL 0 14 ©
BLK/
NOTilSFH A3 □ RED B3 EST REF LOW 0 0

m
□c \ B4 NOT USED
12 14 EGRCONTROL A4 GRY & 'D C
"SERVICE ENGINE BRN/ □C PPI7 EST
0 14 SOON"CONTROL A5 WHT □C WHT B5 REFERENCE HI 0 1.6

co
□C
12 14 IGN-ECMFUSE Aft BLK □C 56 NOT USED
SHIFT LIGHT OR TAN/ □C BLK B7 ESC SIGNAL 9 9
12 14 TCC CONTROL A7 BLK □C
ORN/ B8 A/C SIGNAL 0 0/ 12

y.
2-5 2.5 SERIAL DATA A8 GRN
□
□c ©
WHT/
5 5 DIAG. TERM. A9 BLK BRN B9 EGR SWITCH SIGNAL 12 12
SPEED 24 PIN A-B ORN/ PARK/NEUTRAL
©
0
0
0
SENSOR SIGNAL
MAPGROUND
A1Q
A11 i_W
BRN

Kf
PPL
ar
CONNECTOR BLK 81p
B11
SW.SIGNAL
NOT USED
0 0 ©
br
0 0 SYSTEM GROUND A12 WHT B12

BLK/ TAN/
0 0 EACSOL. (FED) C1 PNK WHT D1 SYSTEM GROUND 0 0
rli

>p c EAC SOL. (CALIF) C2 BRN

/a \ / d i\
BLK D2 5V RETURN 0 0
LT GRN/
NOT I SEABLE IAC "B" LO C3 BLK D3 NOT USED
ca

LT GRN/ BA4CK^VIBW
NOTL SEABLE IAC "B" HI C4 WHT WHT D4 ..ESJLCQNJRQL _ a 1.0
LT BLU/ CO*JNEyTOR TAN/
NOT I SEABLE IAC "A" HI WHT BLK D5 EST BYPASS 0 4.75
LT BLU/
:i=DO=::
c

NOT I. SEABLE IAC "A" LO C6 BLK TAN D6 GRN'D. (0,) 0 0

---n n ---
si

NOT USED a PPL D7 02 SENSOR SIGNAL 0 ®

□ □
□ □ o§ NOT USED
NOT USED C8 □ □
as

□ □
0 CRANK SIGNAL C9 PPL/WHT □ □ ... NOT USED...........
COOLANT
_La„ 1.7 TEMP. SIGNAL CIO YEL mmmm □ 10 NOT USED
4.9 2.0 MAP SIGNAL C 11LTGRN D11 NQ7 USED
cl

ELAPSED DK BLU/
— 1
.4 TIMER MODULE '--□ [ X -i D12 NOT USED
:4_ C12 WHT
© ,45 V . ,4 iY ... TPS SIGNAL C13 DK BLU D13 NOTUStD ...........
5 VOLT
5 5 REFERENCE C14 GRY 32 PINC-D LTGRN D14 INJECTOR B 12 14
CONNECTOR
NOT USED C15 D15 NOT USED

n 14 BATTERY 12 VOLTS 0 6 ORN BLU D16 INJECTOR A 12 14

1 Varies from .60 to battery voltage 5 Measured between terminals C13 and D2 ( ± ,05V).
ENGINE 2.8L LL2
depending on position of drive wheels. 6 12 V in gear
2 Varies with temperature. 7 0 V with A/C "on"
VEHICLE S/T TRUCK
3 Varies, (toggles) 8 12 V with A/C "on"
4 12V First two seconds. 9 12 Vwhen cold
6S 2819-6E
6-18-86

Figure 3-29 - ECM Connector Terminal End View- (2.8L)

3-100 COMPUTER COMMAND CONTROL

T B I F U E L IN JE C T IO N E C M C O N N E C T O R ID E N T IF IC A T IO N
T h is ECM v o lta g e ch a rt is fo r use w ith a d ig ita l vo ltm e te r to fu rth e r aid in d ia g n o s is . T h e v o lta g e s
yo u g e t m ay v a ry d ue to lo w b atte ry ch a rg e or o th er re aso n s, b ut th e y sh o u ld be v e ry close.
T H E F O LLO W IN G C O N D IT IO N S M U ST BE M ET B EFO R E TE ST IN G :
• E n g in e at o p e ra tin g te m p e ratu re • E n g in e id lin g in clo se d lo o p (fo r " E n g in e R u n " co lu m n )
• D ia q n o stic te rm in a l n ot g ro u n d e d • A L D L to o l not in stalled
VOL .T A G E V O LT A G E

KEY EN G . W IR E W IR E K E Y ENG.
"O N ' RUN PIN C O LO R
C IR C U IT CQLQR_ PIN C IR C U IT QN*’ RUN
A f a
>K GRN/ ORN B1 BATT.12.VOLTS 12 14
© 0 14 FUEL PUMP RELAY A1 WHT CK VIEW
OF TAN/
N D TIKFn A? co l iNECJ roR W ill,..... S2 JEUUPUMP..SIGNAL. _Q_ - 14..... ©
BLK/
NOT IKFO A3 RED_. _ S3 l QVV....... 0 0

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□c B4 NOT USED
12 14 EGRCONTROL A4 GRY □c
"SERVICE ENGINE BRN/ % □c
I PPL/ EST
0 14 SOON"CONTROL A5 WHT □c WHT B5 REFERENCE HI 0 1.6
- w □c
12 14 IGN-ECM FUSE Afi BLK < □c m ... N 0I UiLD. ...........
%

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SHIFT LIGHT OR TAN/ □c YEL/BLK B7 ESC SIGNAL 9 9
© 12 14 TCC CONTROL A7 BLK □c ©
DK GRN B8 A/C SIGNAL 0 0
2-5 2.5 SERIAL DATA Aft ORN □c

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WHT/ □ J C
5 5 DIAG. TERM. A9 BLK 69 _ iiQ IU it D ________
24 PIN A-B

© 0
(D
0
®
SPEED
SENSOR SIGNAL
5V RETURN
A1Q BRN
A11 BLK
CONNECTOR ar ORN/
JLL&.
B11
PARK/NEUTRAL
ft 10 .. .iaVlLSKiSAL. . ....... J L . .J l _ -
NOT USED
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0 0 SYSTEM GROUND A12 WHT B12
TAN/
NOT USED C1 WHT D1 SYSTEM GROUND 0 0
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0 0 EAC SOL. C? BRN PPL D2 MAPGROUND 0 0 ©

LT GRN/ / a \ / d i\
NOT I SEABLE IAC "B" LO BLK D3 NOT USED
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O BACK VIEW
LT GRN/
NOT I SEABLE IAC "B" HI C4 WHT \ OF/ WHT D4 _E5I£QNiaQk........ 0 1.Q
LT BLU/ CONNECTOR TAN/
NOT I SEABLE IAC "A" HI C5 WHT BLK D5 EST BYPASS 0 4.75
LT BLU/
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NOT I SEABLE IAC "A" LO C6 BLK TAN D6 GND(0?) 0 0

n a PPL D7 O2 SENSOR SIGNAL 0 <D
12 14 HI GEAR SWITCH C7 LT BLU □□
s

□□ D8 .. ._NjQI_USLQ_ ..... .....

NOT USED Cfl □□
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□□ D9 ...NQTJU5EO.________
0 0 CRANK SIGNAL C9 PPL/WHT % □□
COOLANT
© 1.9 1.7 TEMP. SIGNAL no YEL flfl Jmmm D10 NOT USED
4.9 2.0 MAP SIGNAL cm LT GRN □ 11 H Q JU S W ...............
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H
NOT USED D12 NOT USED
© .6 V .6 V TPS SIGNAL C13 DK BLU D13 ,. „N_QI U liD ........... _
5 VOLT
5 5 REFERENCE C14 GRY 32 PINC-D LT GRN D14 , , 1NJEC.TQR 8 ......... . 12 14
CONNECTOR
NOT USED C15 D15 NOT USED

12 14 8AITERY 12 VOLTS a s QRN____ BLU D16 INJECTOR A 12 14

1 Varies from .60 to battery voltage depending on position of drive wheels. ____ _ _ _________
? VariPC with tpmppraturp EN G IN E 4 .3 L, 5.0 L, 5.7 L, 7.4L

0. 1? \ J Firet twn cprnnrk on 0. II ft ^ Ol (1 fir«:t 70 <;prnnH<; nn 5 71 ft 7 41} V E H IC LE CKRVGPM

5 Measured between terminals C13 and A11 (± 05V).
6 Used on 4.3L, 5.0L or 5.7L engine. Wire color may also be black or yellow/red.
7 Also downshift control on THM 400 7S3582
8 Except 4.3L M & G Van - this system is wired at opposite terminals. 7-12-86

Figure 3-30 - ECM Connector Terminal End View, (4.3L, 5.0L, 5.7L, 7.4L)
 COMPUTER COMMAND CONTROL -3-101

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Figure 3-33 - Mem/Cal Unit Socket

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IF ECM IS BEING REPLACED:
Remove or Disconnect

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m ELAPSED TIMER MODULE 1. New ECM from its packaging and check the
service number to make sure it is the same as the

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m RETAINER
defective ECM.
m INSTRUM ENT PANEL
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[~4~| ELECTRONIC CONTROL MODULE 2. Access cover.
6S 2886-6E
+ 4- Install or Connect
b
Figure 3-31 - Electronic Control Module (ST)
1. VIem-Cal in Mem-Cal socket.
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Important
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Press only on the ends of the Mem-Cal.

Small notches in the Mem-Cal must be aligned
with the small notches in the Mem-Cal socket.
Press on the ends of the Mem-Cal, un til the
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retaining clips snap into the ends of the Mem-Cal.

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Do not press on the middle of the Mem-Cal, only

the ends.
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Figure 3-32 - Electronic Control Module (M)

3-1Q2-C0MPUTER COMMAND CONTROL

2. Access cover on ECM.

3. ECM in passenger compartment.
4. Connectors to ECM.

Functional Check
1. Turn ignition "ON”.
2. Enter diagnostics.
A. Code 12 should flash four times (if no other
codes are present). This indicates the Mem-
Cal is installed properly, and the ECM is
functioning.
B. If trouble Code 51 occurs, or, if the "Service
Engine Soon” light is on constantly, with no
codes, the Mem-Cal is not fully seated, or is

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defective.
• If not fully seated, press firmly on the ends
of the Mem-Cal.
• If it is necessary to remove the Mem-Cal,
follow the previous removal instructions.

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P n ECM HOUSING
ECM Replacement - With PROM & CALPAK m RETAINER

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Figures 3-31 and 3-32; 3-35 through 3-38 [ 3 | ELECTRONIC CONTROL MODULE
[~4~| BRACKET
|++ Remove or Disconnect
1. Negative battery cable or ECM B fuse
ar m SEAT RISER

7S 3765-6E
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2. Connectors from the ECM. Figure 3-36 - Electronic Control Module (G)
3. ECM. Refer to Figure 3-39, for servicing the ECM.
PROM
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|+4-| Install or Connect

1. ECM into vehicle. Refer to Figure 3-39, for removal and installation
a

2. Connector to the ECM. of a PROM.

3. Negative battery cable or ECM B fuse.
cc

4. Perform System Check. CALPAK

Refer to Figure 3-39, for removal and installation
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of a CALPAK.
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[T] HEATER AND A C MODULE

m RETAINER
f ¥ ] ELECTRONIC CONTROL MODULE
7S 3763-6E n~1 ECM HOUSING (BEHIND GLOVE BOX)
[ T 1 ELECTRONIC CONTROL MODULE
Figure 3-35 - Electronic Control Module (CK)
m RETAINER
7S 3762-6E
Figure 3-37 - Electronic Control Module (RV)
 COMPUTER COMMAND CONTROL -3-103

1. Remove ECM access cover.

T
* / C A LPA K REM OVAL
TO O L

CA LPA K C A R R IER

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2. Remove PROM using the rocker-type PROM removal
6. If a service controller is being installed, check the
too! shown. Engage one end of the PROM carrier with
service number on the controller to make sure it is the
the hook end of the tool. Press on the vertical bar end same as the removed ECM. Remove access cover.
of the tool and rock the engaged end of the PROM car­

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rier up as far as possible. Engage the opposite end of
the PROM carrier in the same manner and rock this end
up as far as possible. Repeat this process until the
PROM carrier and PROM are free of the PROM socket.
The PROM carrier with PROM in it should lift off of
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the PROM socket easily.
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7. Install PROM and C A LP A K (if used). If a service PROM

or C A LP A K is being installed, make sure they have the
same part number as the removed PROM or C A LPA K.
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3. Inspect reference end of the PROM carrier and care­ Important (Before installing PROM)
fully set aside. Do not remove PROM from the carrier
to confirm PROM correctness. Notch ini^PR ^ R O M re­ A N Y TIM E TH E PROM IS IN S T A LLE D BACKW ARDS
as

ferenced to smaller notch in carrier and the © AND TH E IGNITION SWITCH TU RN ED ON. T H E PROM
IS D ESTR O YED .

Important
PROM

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PROM C A R R IER DO NOT press on PROM or C A LPA K - O N LY C A R R IER .

Small notch of carrier must be aligned with small notch

4. Remove C A LP A K (if used) using removal tool shown. in socket. Press on PROM or C A LP A K carrier until it
Grasp the C A LP A K carrier of the narrow ends only. is dirmly seated in the socket. Do not press on PROM
Gently rock the carrier from end to end while applying or C A LP A K , only the carrier.
a firm upward force.
5. Inspect reference end of the C A LP A K carrier and 8. Install ECM access cover.
carefully set aside. Do not remove C A LP A K from 9. Install ECM in passenger compartment and perform a
the carrier to confirm C A LP A K correctness. Notch in "D IAG N O STIC C IR C U IT C H E C K " to confirm proper
C A LP A K reference to smaller notch in carrier and installation.
the ( Y ) .
11 1984
6S2511-6E
Figure 3-39 - Servicing the ECM - Except 2.5L
3-1Q4-C0MPUTER COMMAND CONTROL

[T1 DASH AND TOE PANEL

[~2~| BRACKET

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|~n RETAINER m COO LANT TEM PERATURE SEN SO R
|~4~| ELECTRONIC CONTROL MODULE |~2~| IN LET MANIFOLD
7S 3760-6E 7S 3815-6E
Figure 3-38 - Electronic Control Module (P) Figure 3-40 - Coolant Sensor

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COOLANT SENSOR MAP SENSOR

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Figure 3-40 Figure 3-41 through 3-47
Other than checking for loose hoses and electrical
NOTICE: Care must be taken, when handling connections, the only service possible is u n it
coolant sensor. Damage to coolant sensor
will affect proper operation of the Fuel
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replacement, if diagnosis shows sensor to be faulty.
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Control system.
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|++| Remove or Disconnect

1. Negative battery cable.
a

2. Drain cooling system below level of sensor.

3. Electrical connector.
cc

4. Coolant sensor.

Install or Connect
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1. Sensor in engine.
2. Electrical connector.
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3. Refill coolant system.

4. Negative battery cable.
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m PORT "J"
[T l HARNESS ASSEM BLY
|~3l RETAINER
[T ] MAP SENSOR
m BRACKET
7S 3754-6E
Figure 3-41 - MAP Sensor - 2.5L (ST)
 COMPUTER COMMAND CONTROL -3-105

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IT I
PORT " J"
H ARN ESS ASSEM BLY
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m BRACKET
[~4~| MAP SEN SO R
I 5 [ RETAINER
7S3753-6E
Figure 3-43 - MAP Sensor-2.5L(M)

Figure 3-45 - MAP Sensor - 5.0L/5.7L (CKRVP)

3-106 COMPUTER COMMAND CONTROL

Take care, when handling the oxygen sensor. The

in-line electrical connector and louvered end must be
kept free of grease, dirt, or other contaminants. Also,
avoid using cleaning solvents of any type. Do not drop
or roughly handle the oxygen sensor.

Remove or Disconnect
The oxygen sensor may be difficult to remove,
when engine temperature is below 48°C (120°F).
Excessive force may damage threads in exhaust
manifold or exhaust pipe.
1. Negative battery cable.
2. Electrical connector.
3. Carefully back out Oxygen Sensor.

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Install or Connect

Important

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A special anti-seize compound is used on the
oxygen sensor threads. The compound consists of
rn port"F" a liquid graphite and glass bead. The graphite

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[ T ] HARNESS ASSEM BLY
will tend to burn away, but the glass beads will
[~3~| MAP SENSOR
ra remain, making the sensor easier to remove.
m BRACKET
7S3749-6E
Figure 3-46 - MAP Sensor - 7.4L (CKRV)
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EXHAUST MANIFOLD
m ELECTRICAL CONNECTOR
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|~3~| OXYGEN SENSOR

[ T l GASKET
1 PORT "F” 7S 3743-6E
~2~j HARNESS ASSEM BLY Figure 3-48 - Oxygen Sensor - 2.5L (ST)
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~T~ MAP SENSOR

~4~ BRACKET New, or service, sensors will already have the
_______________________________________________7S 3752-6E compound applied to the threads. If a sensor is
Figure 3-47 - MAP Sensor 5.0L/5.7L (G) removed from an engine, and, if for any reason it is to
be reinstalled, the threads m ust have anti-seize
OXYGEN SENSOR compound applied, before reinstallation.
Figure 3-48 through 3-56 1. Coat threads of oxygen sensor with anti-seize
compound P/N 3613695, or e q u iv a le n t, if
NOTICE: The oxygen sensor uses a permanently necessary.
attached pigtail and connector. This 2. Sensor, and torque to 41 N*m (30 ft. lbs.).
pigtail should not be removed from the 3. Electrical connector.
oxygen sensor. Damage or removal of the 4. Negative battery cable.
pigtail or connector could affect proper
operation of the oxygen sensor.
 COMPUTER COMMAND CONTROL -3-107

CALIFORNIA

EXCEPT CALIFORNIA
m EXHAUST MANIFOLD
m OXYGEN SENSOR m OXYGEN SENSOR

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|T] EXHAUST PIPE 6S 2888-6E 7S 3742-6E
Figure 3-49 - Oxygen Sensor-2.8L (ST) Figure 3-52 - Oxygen Sensor - 4.3L (RVMG)

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n~l EXHAUST MANIFOLD

m ELECTRICAL CONNECTOR
m OXYGEN SENSOR
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m GASKET
[~2~l OXYGEN SENSOR
7S 3744-6E 7S 3745-6E
Figure 3-50 - Oxygen Sensor-2.5L (M) Figure 3-53 - Oxygen Sensor - 5.0L/5.7L (RVPG)
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 3-108 COMPUTER COMMAND CONTROL

P n THROTTLE BODY ASSEM BLY

|~2l THROTTLE POSITION SENSOR

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|~3~| SCREW ASSEM BLY
7S3415-6E
Figure 3-55 - Oxygen Sensor - 7.4L (CK) Figure 3-57 - Throttle Position Sensor-TBI 700

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^ Tighten
• Screw assemblies to 2.0 N«m (18.0 in. lbs.).

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3. Air cleaner and new gasket.

Replacement - TBI 220

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Figure 3-58
Important
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On 2.8L (V-6) engines, the TPS is adjustable and is
supplied with attaching screw retainers. On all
other engines, it is non-adjustable, w ithout
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retainers. In addition, on 2.8L (V-6) and 7.4L (V-

8) engines, the TPS has a horizontal electrical
connector; on all other engines, the connector is
cc

vertical.

Remove or Disconnect
si

1. Air cleaner, adapter, and gaskets. D iscard

THROTTLE POSITION SENSOR gaskets.
Replacement - TBI 700
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2. Two TPS atta ch in g screw assem b lies and

Figure 3-57 retainers (if applicable).
3. TPS from throttle body assembly.
NOTICE: The TPS is an electrical component and
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must not be soaked in any liquid cleaner NOTICE: The TPS is an electrical component and
or solvent, as damage may result. must not be soaked in any liquid cleaner,
or solvent, as damage may result.
|++| Remove or Disconnect
1. Air cleaner and gasket. Discard gasket. Install or Connect
2. Two TPS attaching screw assemblies. 1. TPS on throttle body assembly, while lining up
3. TPS from throttle body assembly. TPS lever with TPS drive lever, on throttle body.
2. Two TPS atta ch in g screw assem b lies and
Install or Connect retainers (if applicable).
l. With throttle valve closed, install TPS on throttle
shaft. R otate counter-clockw ise, to a lig n pP| Adjust -(2.8L V-6 engines only)
mounting holes. • Follow "A djustable TPS O utput C heck”
2. Two TPS attaching screw assemblies. procedure, below.
 COMPUTER COMMAND CONTROL 3-109

fl~1 THROTTLE POSITION SENSOR - NON-ADJUSTABLE

IT 1 THROTTLE POSITION SENSOR - NON-ADJUSTABLE
[~4~| THROTTLE POSITION SENSOR - ADJUSTABLE
I 5 I SCREW ASSEM BLY f T I ENGINE INTAKE MANIFOLD
fTI RETAINER

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7S3652-6E 7S 3544-6E
Figure 3-58 - TPS Configurations-TBI 220 Figure 3-59 - MAT Sensor-2.5L

VEHICLE SPEED SENSOR

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• Screw assemblies to 2.0 N«m (18.0 in. lbs.). Figure 3-60
3. Air cleaner, adapter, and new gaskets. Refer to "Section 8C, in Service M anual, for

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vehicle speed sensor service, which is part of the
ADJUSTABLE TPS OUTPUT CHECK - TBI 220 speedometer and instrument cluster.
2.8L Engines Only
This check should be performed, only, when
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throttle body parts have been replaced, or after the
minimum idle speed has been adjusted.
1. C onnect d ig ita l v o ltm e te r J2 9 1 2 5 -A , or
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equivalent, from TPS connector, center terminal

"B” to outside terminal "A”, (jumpers for terminal
access can be made using terminals 1214836 and
a

12014837). ALDL Scanner can be used, to read

TPS output voltage.
cc

2. With ignition "ON”, engine stopped, TPS voltage

should be less than 1.25 volts.
3. If voltage is more than 1.25 volts, rotate TPS until
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0.48 ± .06 volts are obtained.

4. If above voltage limitation cannot be obtained,
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replace TPS.
5. Remove voltmeter and jumpers, reconnect TPS
connector to sensor.
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MAT SENSOR PARK/NEUTRAL SWITCH

Refer to Figure 3-59, for replacement of the MAT The Park/Neutral switch is located on the steering
sensor.
column.
E-CELL
Adjustment
Refer to Figure 3-32, for replacement of the E-Cell
(Elapsed Timer module). 1. Move the switch housing all the way toward "low
gear” position.
KNOCK SENSOR 2. Move gear selector to "park” position. The main
housing and housing back should ra tc h e t,
Refer to Section 7, Electronic Spark Control, for providing proper switch adjustment.
replacement of the Knock Sensor.
3-110 COMPUTER COMMAND CONTROL

A/C CONTROL
Remove or Disconnect
:e gear selector in "neutral”. Refer to Figure 3-62 and 3-63, for replacement of
2. Electrical connectors. the A/C clutch control relay, on S/T Truck and M Van.
3. Spread tangs on housing and pull switch.

□ Install and Connect

1. Align actuator on switch, with hole in shift tube.
2. Position rearward portion of the switch (connector
side) to fit into cutout in lower jacket.
3. Push down on front of switch to engage the two
tangs.
4. Move gear selection to "park” and switch is
adjusted.
5. Electrical connectors.

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m ELECTRICAL CONNECTOR
FT1 OIL PRESSURE RELAY
POWER STEERING PRESSURE SWITCH
[~3~1 A C RELAY
Figure 3-61 |~4~| RELAY BRACKET
The switch is located in the inlet pipe of the power
IT!
nn BULKHEAD CONNECTOR

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steering gear.
FUEL PUMP RELAY 6S2885-6E

□ Remove or Disconnect Figure 3-62 - A/C Clutch Control Relay - (S/T)

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1. E lectrical connector.
2. Power Steering Pressure switch.
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Install and Connect
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1. Power Steering Pressure switch.
2. Electrical connector.
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F T | A/C CLU TCH CO N TRO L R E L A Y

6S 2857-6E
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Figure 3-63 - A/C Clutch Control Relay - (M)

PARTS INFORMATION
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PART NAME GROUP

Controller, E C M .......................................... ..3.670
Calibrator, PR O M ..........................................3.670
Sensor, Coolant Temp......................................3.670
Sensor, Exhaust O x y g e n ............................. ..3.670
Sensor, M A P ...................................................3.670
rn OUTLET PIPE Sensor, Throttle Position: Part of
Sensor Kit, Throttle Position.........................3.440
1 2 | POWER STEERING GEAR
l~3~| IN LET PIPE Switch, Neu. St. & Backing L P .................... ..2.698
m POWER STEERING PRESSURE SWITCH
m ELEC TR IC A L CONNECTOR 6S 2708-6E
Figure 3-61 - Power Steering Pressure Switch
 FUEL CONTROL 4-1

SECTION 4
FUEL CONTROL
TBI 220 (V-6 & V-8)
TBI 700 (L-4)
CONTENTS
GENERAL DESCRIPTION ........................... 4-2 FUEL PIPES AND HOSES .......................... 4-10
PURPOSE................................................ 4-2 FUEL TANK .................................... .. 4-10
BASIC SYSTEM OPERATION .................. 4-2 ACCELERATOR CONTROL....................... 4-10
MODE OF OPERATION........................... 4-3 EVAPORATIVE EMISSION CONTROL . . . 4-10
Starting M o d e................................. 4-3 ON-VEHICLE SERVICE ................................. 4-11
4-3 GENERAL SERVICE INFORMATION ------ 4-11

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Clear Flood Mode ...........................
Run M o d e ....................................... 4-3 Thread Locking Compound ............4-11
Open Loop ............................... 4-3 THROTTLE BODY INJECTION UNIT-

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Closed Loop ............................. 4-3 TBI 220 & 700 ................................. 4-11
Acceleration Mode ........................ 4-3 FUEL METER COVER ASSY.-TBI 220 . . . 4-15
Deceleration Mode ........................ 4-3 FUEL INJECTORASSY.-TBI 220 ............... 4-16
4-3 FUEL METER BODY ASSY. -TBI 220 ------- 4-18

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Battery Voltage Correction Mode . .
Fuel Cutoff M ode............................. 4-4 THROTTLE POSITION SENSOR-TBI 220 . 4-19
TBI UNIT OPERATION............................. 4-4 IAC VALVE-THREADED-TBI 220 ............. 4-19
Model 220 TBI .................................
Model 700 TBI .................................
Fuel Injector(s).................................
4-4
4-4
4-4
arIAC VALVE-FLANGE - TBI 220 ................. 4-21
THROTTLE BODY ASSY-TBI 220 ............ 4-22
MINIMUM SPEED ADJUSTMENT-TBI 220 4-22
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Pressure Regulator ........................ 4-4 TPS OUTPUT CHECK -TBI 220 4.3L/V-8 . 4-23
IAC Valve ........................................ 4-5 TPS OUTPUT CHECK-TBI 220 2.8L ------ 4-23
TPS (Throttle Position Sensor)......... 4-5 FUEL INJECTOR ASSY.-TBI 700 ............. 4-23
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FUEL PUMP OPERATION ...................... 4-5 PRESSURE REGULATOR ASSY. - TBI 700 . 4-24
Fuel Pump Electrical C ir c u it ........... 4-6 FUEL METER ASSY.-TBI700 ................... 4-25
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FUEL FILTER .......................................... 4-6 THROTTLE POS. SEN.(TPS) - TBI-700 . . . 4-25

Inline Filters......... ............................ 4-6 IAC VALVE-FLANGE-TBI 700 ................. 4-26
In Tank F ilte r................................... 4-6 TUBE MODULE ASSY.-TBI 700 ............... 4-27
4-6 THROTTLE BODY ASSY.-TBI 700 .......... 4-27
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FUEL AND VAPOR PIP ES........................

FUEL TANK ............................................ 4-6 MINIMUM IDLE SPEED AD J.-TBI 7 0 0 ... 4-28
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Filler N e c k ....................................... 4-6 TPS OUTPUT CHECK-TBI 700 ................. 4-28

Fuel Filler Cap ................................. 4-7 FU ELPU M P.............................................. 4-29
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ACCELERATOR CONTROL...................... 4-7 Fuel Pump Relay ............................. 4-29

EVAPORATIVE EMISSION CNTL SYS. . . . 4-7 FUEL M O DULE................. ........................ 4-30
D IA G N O SIS.................................................. 4-7 OIL PRESSURE SW ITCH ............................4-31
FUEL C O N TR O L..................................... 4-7 FUEL FILTER ........................................... 4-31
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Idle Air Control ............................... 4-7 Inline Filter ...................................... 4-31

Throttle Position Sensor ................ 4-7 In Tank F ilte r.................................... 4-32
Driveability Symptoms.................... 4-7 FUEL HOSE/PIPE ASSEM BLIES................. 4-33
Fuel System Pressure Relief ........... 4-7 Materials ........................................ 4-33
V-6 & V-8 Engines...................... 4-7 Fuel Line Repair............................... 4-34
CHART - Idle Speed Error - All FUEL TANK ............................................ 4-34
Engines, except 2.5L ................ 4-8 Draining .......................................... 4-34
L-4 E n g in e ................................. 4-10 Replacement .................................. 4-34
Fuel System Pressure Test ......... 4-10 FUEL SYSTEM CLEANING ........................ 4-35
FU ELP U M P ............................................ 4-10 AUXILIARY FUEL TANK CONTROL -------4-40
Fuel Pump Relay ............................. 4-10 ACCELERATOR CONTROLS..................... 4-41
Oil Pressure Switch ........................ 4-10 Accelerator Control Cable ..............4-41
Fuel Module ................................... 4-10 Accelerator Pedal ........................... 4-42
FUEL FILTER............................................ 4-10 PARTS INFORM ATION.................................. 4-44
4-2 FUEL CONTROL

GENERAL DESCRIPTION
The following is general information required BASIC SYSTEM OPERATION
when working on the fuel system:
• Any time the fuel system is being worked on, Fuel is delivered to the engine by a Throttle Body
disconnect the negative battery cable or Injection (TBI) unit.
cables, except for those tests where battery The main control sensor is the Oxygen (O2 )
voltage is required. Sensor, which is located in the exhaust manifold. The
• Always keep a dry chemical (Class B) fire O2 sensor tells the ECM the ratio of oxygen in the
extinguisher near the work area. exhaust gas, and the ECM changes the air/fuel ratio to
• The torque on a screw fitting is 30 N*m (22 ft. the engine by controlling the fuel injector. A 14.7:1
lbs.). air/fuel ratio is required, for efficient C atalytic
• F uel pipe fittings require the use of an O-ring. Converter operation. Because of the c o n stan t
• All fuel pipe must meet the GM Specification measuring and adjusting of the air/fuel ratio, the Fuel

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124-M, or its equivalent. Control system is called a "Closed Loop" System
• All fuel hose must meet GM Specification (Figure 4-1).
6163-M, or its equivalent. The fuel control system (Figure 4-2) has an

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• Do not replace fuel pipe with fuel hose. electric fuel pump, located in the fuel tank with
• Always allow fuel pressure to bleed off before
servicing any fuel system components.

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• Do not do any repairs on the fuel system until
you have read the copy and checked the
pictures relating to that repair.
• Adhere to all Notices and Cautions.
All gasoline engines are designed to use only
ar
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unleaded gasoline. Unleaded gasoline must be used
for proper emission control system operation. Its use
will also minimize spark plug fouling and extend
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engine oil life. Using leaded gasoline can damage the

emission control system and could result in loss of
emission warranty coverage.
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All vehicles in the manual are equipped with an

Evaporative Emission System. The purpose of the
system is to minimize the escape of fuel vapors to the
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atmosphere. Information on this system will be found

in Section 5.
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PURPOSE
as

The basic function of the fuel control system is to

control fuel delivery to the engine.
The Fuel Control System is made up of the
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following components:
• Throttle Body Injection (TBI) Unit
Fuel Injector
Fuel Pressure Regulator
Idle Air Control (IAC) Valve
• Fuel Pump
• Fuel Pump Relay p n F U E L PUMP AND
• Fuel Tank ------- SENDING UNIT
• Accelerator Control 1~2~| F U E L SU PPLY LINE
• Fuel Lines m F U E L F IL T E R
• Fuel Filters l~4~1 TBI UNIT
• Evaporative Emission Control System f~5~l F U E L RETU RN LIN E
4S 0055-6E
Figure 4-2 - Fuel Control System
 FUEL CONTROL 4-3

the gage sending unit, which pumps fuel to the TBI Open Loop
through the fuel supply line, then through an in-line
fuel filter. The pump is designed to provide When the engine is first started, and engine is
pressurized fuel at about 125 kPa (18 psi). A pressure above 400 rpm, the system goes into "Open Loop”
regulator in the TBI keeps fuel available to the operation. In "Open Loop”, the ECM will ignore the
injector(s) at a constant pressure between 62 and 90 signal from the Oxygen (O2 ) sensor, and calculates the
kPa (9 and 13 psi). Fuel, in excess of injector(s) needs, air/fuel ratio based on inputs from the Coolant and
is returned to the fuel tank by a separate line. MAP Sensors. At idle, the 2.8L and the 7.4L engine
The ECM controls the injector(s) and is located in will run in an "Open Loop” condition.
the fuel m eter body assembly of the TBI. The The system will stay in "Open Loop” until the
injector(s) deliver fuel in one of several modes, as following conditions are met:
described below. 1. The O2 sensor has varying voltage output,
In order to properly control the fuel supply, the showing that it is hot enough to operate properly.
fuel pump is operated by the ECM, through the fuel (This depends on temperature.)
pump relay and oil pressure switch (see Fuel Pump 2. The C oolant S ensor is above a sp ecified
Electrical Circuit). temperature.

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3. A specific am ount of time has elapsed after
MODES OF OPERATION starting the engine.

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The ECM looks at voltages from several sensors to Closed Loop
determine how much fuel to give the engine. The fuel
is delivered under one of several conditions, called The specific values for the above conditions vary

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"modes". All the modes are controlled by the ECM. with different engines, and are stored in the PROM.
When these conditions are met, the system goes into
Starting Mode
When the key is first turned "ON", the ECM will
ar "Closed Loop” operation. In "Closed Loop”, the ECM
will calculate the air/fuel ratio (injector on-time)
based on the signal from the O2 sensor. This allows
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turn on the fuel pump relay and fuel pump for two the air/fuel ratio to stay very close to 14.7:1.
seconds for most systems. On some vehicles, the fuel
pump will run for twenty seconds. This will build up Acceleration Mode
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fuel pressure to the TBI unit. The ECM then checks

the coolant temperature sensor, throttle position The ECM looks at rapid changes in th ro ttle
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sensor, and crank signal, and determines the proper position and manifold pressure, and provides extra
air/fuel ratio for starting. This ranges from 1.5:1 at - fuel.
36°C (-33°F) to 14.7:1 at 94°C (201°F).
The ECM controls the amount of fuel delivered in Deceleration Mode
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the Starting Mode by changing how long the injector

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is turned "ON” and "OFF”. This is done by "pulsing” When deceleration occurs, the fuel remaining in
the injector for very short times. the intake manifold can cause excessive emissions and
backfiring. Again, the ECM looks a t changes in
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Clear Flood Mode throttle position and manifold pressure and reduces
the amount of fuel. When deceleration is very fast, the
If the engine floods, clear it by pushing the ECM can cut off fuel completely for short periods.
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accelerator pedal down all the way. The ECM then

pulses the injector at a 20:1 air/fuel ratio. The ECM Battery Voltage Correction Mode
holds this injector rate as long as the throttle stays
wide open, and the engine is below 600 rpm. If the When battery voltage is low, the ECM can
throttle position becomes less than 80%, the ECM compensate for a weak spark delivered by the
returns to the Starting Mode. distributor by:
• Increasing injector on time of fuel delivered;
Run Mode • Increasing the idle rpm; and
• Increasing ignition dwell time.
The Run Mode has two conditions called "Open
Loop” and "Closed Loop”.
4-4 FUEL CONTROL

Fuel Cutoff Mode

No fuel is delivered by the injectors, when the
ignition is "OFF”. This prevents dieseling. Also, fuel
is not delivered, if no reference pulses are seen from
the distributor, which means the engine is not
running. Fuel cutoff will also occur at high engine
rpm, to protect internal engine components from
damage.

TBI UNIT OPERATION

Model 220 TBI
The Model 220 TBI unit, used on the the V-6 and

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V-8 engines (Figure 4-3), consists of three major [Tl FUEL INJECTOR
casting assemblies: |~ n INLET FILTER
1) A fuel meter cover with: m PRESSURE REGULATOR

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• A pressure regulator. [Tl SPRING
2) A fuel meter body with: |~ n DIAPHRAGM ASSEM BLY
• Two fuel injectors. A - FUEL FROM PUMP

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3) A throttle body with: B - INJECTOR ELECTRICAL
• Two throttle valves (TV) TERMINALS
• An idle air control (IAC) valve C - CONSTANT BLEED
• A throttle position sensor (TPS).

Model 700 TBI

ar D - FUEL RETURN TO TANK
E - THROTTLE VALVE 7S 3655-6E
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Figure 4-3 - TBI 220 Unit Operation
The Model 700 TBI unit, used on the L-4 engine
(Figure 4-4), is made up of two major castin g A fuel injector, which does not open, may cause a
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assemblies: no-start condition. An injector, which is stuck partly

1) A fuel meter body with: open, could cause loss of pressure after sitting, so, long
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• A fuel meter assembly, including a pressure crank times would be noticed on some engines. Also,
regulator dieseling could occur, because some fuel could be
• A fuel injector. delivered to the engine after the key is turned "OFF”.
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2) A throttle body with:

• A throttle valve (TV) Pressure Regulator
• An idle air control (IAC) valve (Figure 4-3 or 4-4)
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• A throttle position sensor (TPS). The pressure regulator is a diaphragm operated

relief valve, with injector pressure on one side and air
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The throttle body portion of the TBI unit may

contain ports located above, or below, the throttle cleaner pressure on the other. The function of the
valve. These ports generate the vacuum signals for regulator is to maintain a constant pressure a t the
the EGR valve, MAP sensor, and the canister purge injector(s) at all times, by controlling the flow in the
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system. return line (i.e. a calibrated bypass).

The pressure regulator is serviced as part of the
Fuel Injector(s) fuel meter cover (TBI 220 units), or fuel m eter
(Figure 4-3 or 4-4) assembly (TBI 700 units). On TBI 220 units, the
A fuel injector is a solenoid operated device pressure regulator should not be disassem bled.
controlled by the ECM. The ECM turns on the However, disassembly is permitted on TBI 700 units.
solenoid, which lifts a normally closed ball valve off a If the pressure regulator in the TBI supplies
seat. The fuel, under pressure, is injected in a conical pressure which is too low (below 62 kPa or 9 psi), poor
spray pattern at the walls of the throttle body bore performance could result. If the pressure is too high,
above the throttle valve. The fuel, which is not used unpleasant exhaust odor may result.
by the injector(s), passes through the pressure
regulator, before being returned to the fuel tank.
 FUEL CONTROL 4-5

allowed to the manifold, and idle speed will be high. If

it is stuck closed, too little air will be allowed in the
manifold, and idle speed will be too low. If it is stuck
part way open, the idle may be rough, and will not
respond to engine load changes.
On 2.5L (TBI 700) and 7.4L (TBI 220) engines, the
IAC valve is flange-mounted. On all other engines, it
is thread mounted. The IAC valve is available in
several different pintle shapes. However, on TBI 220
and 700 applications, a dual taper pintle shape is used.
The diam eter of the pintle is 10mm (w ith th e
exception of the 7.4L engine, which has an IAC valve
with a 12mm pintle diameter). If replacement is
necessary, only an IAC valve with the appropriate
pintle shape and diameter should be used.

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TPS (Throttle Position Sensor)
[Tl FUEL INJECTOR (Figure 4-20 or 4-33)

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m INLET FILTER The Throttle Position Sensor (TPS), is mounted on
|~3l PRESSURE REGULATOR the side of the throttle body opposite the throttle lever
[~4~| SPRING assembly. Its function is to sense the current throttle
m DIAPHRAGM ASSEM BLY valve position and relay that information to the ECM.

y.
m FUEL METER ASSEMBLY Knowledge of throttle position is needed by the ECM
A - FUEL FROM PUMP to generate the required injector control signals
B -
C -
PURGE FILTER
FUEL RETURN TO TANK______________7S3657,6E
ar (pulses). Should the TPS sense a wide open throttle, a
voltage signal indicating this condition is sent to the
ECM. The ECM will then widen the injector pulses or
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Figure 4-4 - TBI 700 Unit Operation increase the repetition rate (frequency of the applied
pulses) permitting increased fuel flow.
IAC Valve As the th ro ttle valve ro tates in response to
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(Figure 4-21 or 4-34) movement of the accelerator pedal, the throttle shaft
The purpose of the Idle Air Control (IAC) valve, is transfers this rotational movement to the TPS. A
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to control engine idle speed, while preventing stalls potentiometer (variable resistor) w ithin the TPS
due to changes in engine load. assembly changes its resistance (voltage drop) in
The IAC valve, mounted on the throttle body, proportion to throttle movement. By applying a
controls bypass air around the throttle valve. By reference voltage (5.0 VDC) to the TPS input, a
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moving a conical valve IN (to decrease air flow) or varying voltage (reflecting th ro ttle position) is
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OUT (to increase air flow), a controlled amount of air av ailab le a t the TPS o u tp u t. For ex am p le,
can move around the throttle valve. If rpm is too low, approximately 2.5 VDC results from a 50% throttle
more air is bypassed around the throttle valve to valve opening (depending on TPS calibration). The
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increase rpm. If rpm is too high, less air is bypassed voltage output from the TPS assembly is routed to the
around the throttle valve to decrease rpm. ECM for use in determining throttle position.
The IAC valve moves in small steps called
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"counts", which can be measured by a "Scan” tool, FUEL PUMP OPERATION

which plugs into the ALDL. (Figure 4-5 and 4-6)
During idle, the proper position of the IAC valve is The fuel pump is a turbine type, low pressure,
calculated by the ECM based on battery voltage, electric pump, mounted in the fuel tank. Fuel is
coolant temperature, engine load, and engine rpm. If pumped at a positive pressure (above 62kPa or 9psi)
the rpm drops below a specified rpm, and the throttle from the fuel pump through the in-line filter to the
valve is closed, the ECM senses a near stall condition. pressure regulator in the TBI assembly. Excess fuel is
The ECM will then calculate a new IAC valve position returned to the fuel tank, through the fuel return line.
to prevent stalls. The fuel pump is attached to the fuel gage sender
If the IAC valve is disconnected or connected with assembly. A fuel strainer is attached to the fuel pump
the engine running, the idle rpm may be wrong. In inlet line and prevents dirt particles from entering the
this case, the IAC valve may be reset by turning the fuel line and tends to separate water from the fuel.
ignition switch "ON” and "OFF” one time.
The IAC valve affects only the idle characteristics
of the engine. If it is open fully, too much air will be
4-6 FUEL CONTROL

oil pressure switch will turn "ON” the fuel pump, as

soon as oil pressure reaches about 28 kPa (4psi).
An inoperative fuel pump would cause a no start
condition. A fuel pump, which does not provide
enough pressure, can result in poor performance.

FUEL FILTER
Inline Filters
CAUTION: To re d u c e th e r i s k o f fire a n d
personal injury, it is necessary to
allow fuel p r e s s u r e to b le e d off
b efore s e rv ic in g fuel sy ste m
c o m p o n e n ts. (See F u e l S y ste m

om
Pressure Relief.)

The inline filter is located in the fuel feed line. It

prevents dirt from entering the TBI unit.

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In Tank Filter

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A woven plastic filter is located on the lower end of
the fuel pickup tube in the fuel tank. This filter
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prevents dirt from entering the fuel line and, also,
stops water, unless the filter becomes completely
submerged in water. This filter is self-cleaning and
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normally requires no maintenance. Fuel stoppage, at
this point, indicates that the fuel tank contains an
Vapor lock problems are reduced, when using an
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abnormal amount of sediment or water; the tank

electric pump, because the fuel is pushed from the should, therefore, be thoroughly cleaned.
tank under pressure rath er than pulled under
a

vacuum, a condition that produces vapor. FUEL AND VAPOR PIPES

An inoperative fuel pump would cause a no start
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condition. A fuel pump which does not provide enough The fuel feed and return pipes and hoses extend
pressure can result in poor performance. (See "Fuel from the fuel pump and sender to the TBI unit. They
System Pressure Test” procedure). are secured with clamps and are routed along the
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frame side member.

Fuel Pump Electrical Circuit The vapor pipe and hoses extend from fuel pump
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and sender unit to the canister.

When the key is first turned on, without the
engine running, the ECM will turn the fuel pump FUELTANK
relay on for two seconds, on most vehicles. On some
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5.7L and 7.4L engines, a fuel module circuit is The fuel tank, at the rear of the underbody, is held
installed so that the fuel pump will run for about 20 in place by two metal straps. Anti-squeak pieces are
seconds, when ignition switch is turned "ON”. If the used on top of the tank to reduce rattles.
engine is not started within two seconds, the ECM will
shut the fuel pump off. As soon as the engine is Filler Neck
cranked, the ECM will turn the relay on and run the
fuel pump. To help prevent refueling with leaded gasoline,
As a backup system to the fuel pump relay, the the fuel filler neck on gasoline engine vehicles has a
fuel pump can also be turned on by the oil pressure built-in restrictor and deflector. The opening in the
switch. The oil pressure switch is, normally, open and restrictor will only admit the smaller unleaded gas
closes when oil pressure reaches about 28 kPa (4 psi). nozzle spout, which must be fully inserted to bypass
If the fuel pump relay fails, the oil pressure switch the deflector. Attempted refueling with a leaded gas
circuit will run the fuel pump. nozzle, or failure to fully insert the unleaded gas
An inoperative fuel pump relay can result in long nozzle, will result in gasoline splashing back out of the
cranking times, particularly if the engine is cold. The filler neck.
 FUEL CONTROL 4-7

Figure 4-6 - Submersible In-Tank Electric Fuel Pump

ACCELERATOR CONTROL

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Fuel Filler Cap
The accelerator control system is a control cable
The fuel tank filler neck is equipped with a screw- type, attached to a accelerator pedal assembly.
type cap. The threaded part of the cap requires

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several turns counterclockwise to remove. The long EVAPORATIVE EMISSION CONTROL SYSTEM
threaded area was designed to allow any remaining
fuel tank pressure to escape, while the cap was being This system transfers fuel vapors from the fuel

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removed. A built-in torque-limiting device prevents tank into a vapor canister and then vapors are purged
overtightening. To install, turn the cap clockwise
until a clicking noise is heard. This signals that the
correct torque has been reached and the cap is fully
ar into the intake manifold air flow and consumed in
combustion. Refer to Section 5, for additional
information, diagnosis, and on-vehicle service.
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seated.

DIAGNOSIS
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FUELCONTROL Driveability Symptoms

The diagnosis of fuel control and the TBI unit is in Refer to Section 2, for additional fuel control
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Section 3, because the Computer Command Control diagnosis.

system controls fuel delivery. This system has a
built in diagnostic system in the ECM to indicate a Fuel System Pressure Relief
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failed circuit. This section will explain the system

check and the codes related to fuel control. Whenever there is fuel system service required
as

The fuel control can be the reason that the engine for the fuel lines, the TBI unit, fuel pump, or pressure
cranks, but will not run and the diagnosis is, also, in test, the following procedure should be followed:
Section 3. If diagnosis indicates that the engine will
not run because there is a fuel delivery problem, the V-6 and V-8 Engines
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diagnosis of the fuel system is, also, included in

Section 3. The TBI 220 for the V-6 and V-8 engines contains a
constant bleed feature in the pressure regulator that
Idle Air Control relieves pressure. Therefore, no special procedures
are required for relieving fuel pressure, other than
The diagnosis of idle air control can be found in disconnecting the fuel line fittings.
Code 35, Section 3, for the 2.5L engine and in this
section for all other engines. CAUTION: A small amount of fuel may still be
r e l e a s e d , w h e n t h e f u e l lin e is
Throttle Position Sensor disconnected. To reduce the chance
of personal injury, cover the fitting to
Refer to Section 3 for diagnosis of the throttle be disconnected w ith a shop cloth.
position sensor. P la c e th e c lo th in an a p p r o v e d
c o n t a i n e r , w h e n d i s c o n n e c t is
completed.
4-8 FUEL CONTROL

IDLE SPEED ERROR

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ALL ENGINES EXCEPT 2.5L
Circuit Description:
The ECM sends voltage pulses to the proper IAC motor winding, which causes the motor shaft and valve to

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move "in” and "out” a given distance for each pulse (called counts) received. This movement controls air flow
around the throttle plate, which, in turn, controls engine idle speed.
Test Description: Step numbers refer to step

.
If idle is too high, stop engine. Ignition "ON”.

ry
numbers on diagnostic chart. Ground diagnostic terminal. Wait a few seconds for
1. Continue with test, even if engine will not idle. If IAC to seat, then disconnect IAC. Start engine. If idle
idle is too low, "Scan” will display 80, or more, speed is above 800, ± 50 rpm, locate and correct
counts or steps. Occasionally, an erratic, or
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vacuum leak.
unstable, idle may occur. Engine speed may vary • System too lean (High Air/Fuel ratio) - Idle speed
200 rpm, or more, up and down. Disconnect IAC. may be too high, or too low. Engine speed may
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If the condition is unchanged, the IAC is not at vary up and down, disconnecting IAC does not
fault. There is a system problem. Proceed to help. May set Code 44. "Scan” and/or Voltmeter
paragraph three below. will read an oxygen sensor output less than 300mv
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2. When the engine was stopped, the IAC valve (.3v). Check for low regulated fuel pressure or
retracted (more air) to a fixed "Park” position, for water in fuel. A lean exhaust with an oxygen
increased air flow and idle speed during the next sensor output fixed above 800mv (.8v) will be a
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engine start. A "Scan” will display 100 or more contaminated sensor, usually silicon. This may,
counts. also, set a Code 45.
3. Be sure to disconnect the IAC valve prior to this • System too rich (Low Air/Fuel ratio) - Idle speed
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test. The test light will confirm the ECM signals too low. "Scan” counts usually above 80. System
by a steady or flashing light, on all circuits. obviously rich and may exhibit black smoke
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4. There is a remote possibility th a t one of the exhaust. "Scan” tool and/or Voltmeter will read
circuits is shorted to voltage, which would have an oxygen sensor signal fixed above 800mv (.8v).
been indicated by a steady light. Disconnect ECM Check:
and turn the ignition "ON” and probe terminals to High fuel pressure
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check for this condition. Injector leaking or sticking

• Throttle body - Remove IAC and inspect bore for
Diagnostic Aids: foreign m a te ria l or evidence of IAC valve
dragging the bore.
A slow unstable idle may be caused by a system • A/C Compressor or Relay Failure - See A/C
problem that cannot be overcome by the IAC. "Scan” diagnosis if circuit is shorted to ground. If the
counts will be above 60 counts, if too low, and 0 counts, relay is faulty, idle problem may exist.
if too high. • Refer to Rough, U nstable, Incorrect Idle or
Stalling, in Symptoms in Section 2.
 FUEL CONTROL 4-9

IDLE SPEED ERROR

ALL ENGINES
EXCEPT 2.5L

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. co
ry
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cc
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as
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4-16-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. * J$ ^ 51 gE
4-10 FUEL CONTROL

L-4 Engine 6. Re-install fuel hose, or pipe assembly, to in-line

fuel filter.
The TBI 700, for the L-4 engine, contains no 7. Start engine and check for fuel leaks.
constant bleed feature and requires relieving the fuel 8. Remove plug covering THERMAC vacuum port,
pressure as follows: on TBI 700 unit, and install air cleaner.

1. Place transmission selector in Park (Neutral on FUEL PUMP

manual transmissions), set parking brake, and
block drive wheels. Refer to fuel system diagnosis in Section 3, for fuel
2. Disconnect three terminal electrical connector at pump diagnosis.
fuel tank.
3. Start engine and allow to run a few seconds, until it Fuel Pump Relay
stops for lack of fuel.
4. Engage starter for three seconds to dissipate fuel Refer to fuel pump relay circuit check in Section 3,
pressure in lines. Fuel connections are now safe for for relay diagnosis.

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servicing.
Oil Pressure Switch
CAUTION: A sm all a m o u n t of fuel m ay be

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r e le a s e d , a f t e r th e fu e l lin e is Refer to fuel pump relay circuit check in Section 3,
disconnected. In o rder to red uce for switch diagnosis.
the chance of personal injury, cover

.
the fitting to be disconnected with a Fuel Module

ry
shop cloth. P lace the cloth in a
ap p ro v ed c o n ta in e r, w hen Refer to fuel pump relay circuit check in Section 3
for fuel module diagnosis.
disconnect is completed.
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5. When pressure is relieved, and servicing is FUEL FILTER
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complete, connect electrical c^.^iector at the fuel
tank. The diagnosis of the fuel filter is covered in
Section 3, as part of the fuel system diagnosis.
Fuel System Pressure Test A plugged fuel filter may cause a restricted fuel
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delivery, or a no start condition.

Several system checks and diagnoses require
FUEL PIPES AND HOSES
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observing the fuel system pressure. This test provides

a visual fuel pressure reading.
1. Turn engine "OFF” and relieve fuel pressure. The diagnosis of gasoline odor may be a condition
of a leaking fuel feed, or return pipe or hose. Fuel
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CAUTION: A sm all a m o u n t of fuel m ay be pipes that are pinched, plugged, or mis-routed may
r e le a s e d , a f t e r t h e fu e l lin e is cause restricted fuel delivery.
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disconnected. In o rd e r to red uce

the chance of personal injury, cover FUELTANK
the fitting to be disconnected with a
The diagnosis of gasoline odor may be a condition
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shop cloth. P la c e th e cloth in a

approved c o n ta in e r, w hen of a leaking fuel tank, filler neck, or filler cap.
disconnect is completed. A defective filler cap, or plugged, or pinched vapor
pipe can cause a collapsed fuel tank.
2. Remove air cleaner, adapter, and gaskets, and Loose mounting straps, or foreign m aterial in
plug THERMAC vacuum port on TBI 700 unit. tank, may be the cause of a rattle at the fuel tank.
3. Install fuel pressure gage J-29658A/BT8205, or
equivalent, at the outlet side of the in-line fuel ACCELERATOR CONTROL
filter (Figure 4-51 through 4-57).
Check for correct cable routing, or binding, and
Measure correct as necessary.
• S tart engine and observe fuel p ressu re
reading. It should be 62-90 kPa (9-13 psi); if EVAPORATIVE EMISSION CONTROL
not, refer to CHART A-6, in Section 3.
4. Relieve fuel pressure. Refer to Section 5, for diagnosis of the Evaporative
5. Remove fuel pressure gage. Emission Control system.
 FUEL CONTROL 4-11

ON-VEHICLE SERVICE
GENERAL SERVICE INFORMATION 1. Clean all metal parts thoroughly and blow dry
with shop air. Be sure that all fuel and air
CAUTION: B*efore servicing, refer to the "Fuel passages are free of dirt or burrs.
P r e s s u r e R e l ie f P r o c e d u r e ” , 2 . Inspect mating casting surfaces for damage that
whenever service on the fuel lines, could affect gasket sealing.
or fuel h an d lin g co m po n ents of
the TBI unit components are to be Thread Locking Compound
a c c o m p lis h e d . To r e d u c e th e
chance of personal injury, cover Service repair kits are supplied with a small vial
the fuel line with a shop cloth to of thread locking compound with directions for use. If
collect the fuel d u rin g servicing, material is not available, use Loctite 262, or GM part
and then, place the cloth in an number 10522624, or equivalent.

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approved container, when work is
completed. NOTICE: Do not use a higher stren g th locking
compound than recommended, since to do
The TBI unit repair procedures cover component so could m ake rem oving the screw
replacement with the unit on the vehicle. However, extremely difficult, or result in damaging

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throttle body replacem ent req u ires th a t the the screw head.
complete unit be removed from the engine.

ry
Refer to the disassembled view (Figure 4-7 or 4- THROTTLE BODY INJECTION UNIT
8), for id entification of p a rts d u rin g re p a ir TBI 220 and 700
procedures. Service repair of individual components Replacement (Figures 4-9 through 4-13)
is performed without removing the TBI unit from
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the engine. If removed, it is essential that the unit «-♦ Remove or Disconnect
be placed on a holding fixture, such as J-9789-118,
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BT-3553, or equivalent, to prevent damage to the l. THERMAC hose from engine fitting (TBI 700).
throttle valves, before performing any service. 2. Air cleaner, adapter, and gaskets. Discard
gasket.
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IG3 CLEANING AND 3. Electrical connectors - Idle Air Control valve,

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Throttle Position Sensor, and Fuel Injectors. (On

TBI 220 units, squeeze plastic tabs on injectors
! ? INSPECTION and pull straight up.)
All TBI component parts, with the exception of 4. Grommet with wires from throttle body.
ic

those noted below, should be cleaned in a cold 5. Throttle linkage, return spring(s), transmission
immersion cleaner such as Carbon X (X-55), or control cable, and cruise control (w herever
s

equivalent. applicable).
6 . Vacuum hoses, noting positions of hoses.
as

NOTICE: The throttle position sensor (TPS), idle 7. Inlet and outlet fuel line nuts, using back-up
a ir control (IAC) valve, p re s su re wrench J-29698-A or BT-8251-A.
regulator diaphragm assembly, fuel
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injectors or other components containing CAUTION: R e f e r to f u e l p r e s s u r e r e l i e f

rubber, SHOULD NOT be placed in a p ro c e d u re , (above), b e fo re
solvent or cleaner bath. A chemical disconnecting fuel lines.
reaction will cause these parts to swell,
harden or distort. Do not soak the 8. Fuel line O-rings from nuts and discard.
throttle body with the above p a rts 9. TBI mounting hardware.
attached. If the throttle body assembly 10. TBI unit from intake manifold and place on
requires cleaning,soaking time in the holding fixture J-9789-118 or BT-3553.
cleaner should be kept to a minimum.
Some models have hidden throttle shaft
d u st sea ls th a t could lose th e ir
effectiveness by extended soaking.
4-12 FUEL CONTROL

Model 700 TBI

Gasket — Air Filter
O-Ring — Fuel Line Inlet Nut
O-Ring — Fuel Line Outlet Nut
Gasket — Flange
Fuel Meter Assembly
Screw & Washer Assembly —
Fuel Meter Body Attaching
Gasket — Fuel Meter Body to
Throttle Body

om
Screw — Injector Retainer
Retainer — Injector
Fuel Injector
O-Ring — Fuel Injector —
Upper

c
O-Ring — Fuel Injector —

y.
Lower
Filter — Injector
Pressure Regulator Cover •
ar Assembly
Screw — Pressure Regulator
Attaching
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Seat — Spring
Spring — Pressure Regulator
Pressure Regulator Diaphragm
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Assembly
Nut — Fuel Inlet
ca

Seal — Fuel Nut

Nut — Fuel Outlet
Throttle Body Assembly
Plug — Idle Stop Screw
ic

Screw & Washer Assem bly —

Idle Stop
s

Spring — Idle Stop Screw

Sensor — Throttle Position
as

(TPS)
Screw & Washer Assem bly —
TPS Attaching
cl

28 Screw — TPS
29 Idle Air Control Valve (IACV)
30 Screw — IACV Attaching
31 O-Ring — IACV
32 Tube Module Assembly
33 Screw — Manifold Attaching
34 Gasket — Tubes Manifold

7S 3656-6E
Figure 4-7 - Model 700 TBI Parts Identification (L-4 Engine)
 FUEL CONTROL 4-13

Model 220 TBI

Screw Assem bly — Fuel Meter
Cover Attaching — Long
Screw Assem bly — Fuel Meter
Cover Attaching — Short
3 Fuel Meter Cover Assem bly
4 Gasket — Fuel Meter Cover
5 Gasket — Fuel Meter Outlet
6 Seal — Pressure Regulator
7 Pressure Regulator
8 Injector — Fuel
9 Filter — Fuel Injector Inlet

m
10 O-ring — Fuel Injector —
Lower
11 O-ring — Fuel Injector —

co
Upper
12 W asher— Fuel Injector
13 Screw Assem bly — Fuel Meter

y.
Body — Throttle Body
Attaching
14 Fuel Meter Body Assem bly

r 15 Gasket — Throttle Body to

ra Fuel Meter Body
16 Gasket — Air Filter
17 O-ring — Fuel Return Line
b
18 Nut — Fuel Outlet
19 O-ring — Fuel Inlet Line
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20 Nut — Fuel Inlet

21 Gasket — Fuel Outlet Nut
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22 Gasket — Fuel Inlet Nut

23 Screw — TPS Lever Attaching
24 Lever — TPS
25
c

Screw Assem bly — TPS

Attaching
si

26 Retainer — TPS Attaching

Screw
27
as

Sensor — Throttle Position

(TPS)
28 Plug — Idle Stop Screw
29 Screw Assem bly — Idle Stop
cl

30 Spring — Idle Stop Screw

31 Throttle Body Assem bly
32 Gasket — Flange
33 Valve Assem bly — Idle Air
Control (IAC)
34 Gasket — Idle Air control
Valve Assem bly

7S3658-6E
Figure 4-8 - Model 220 TBI Parts Identification (V-6 and V-8 Engine)
4-14 FUEL CONTROL

m
co
y.
n~| BOLT - TIGHTEN TO 16 N m (12 FT. LBS.)
m STUD - TIGHTEN TO 17 (12
Nm FT. LBS.)
m
f T I TBI UNIT
GASKET (MUST BE INSTALLED WITH
f T I TBI UNIT
|~3l GASKET
fTI ENGINE INTAKE MANIFOLD 7S 3546-6E
ar STRIPE FACING UP)
fTI ENGINE INTAKE MANIFOLD
6S 2799-6E
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Figure 4-9 - Replacing TBI 700 Unit - 2.5L Figure 4-11 - Replacing TBI 220 Unit - 4.3L
rli
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as
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f T I TBI UNIT
[T~|
m
|~2~1 NUT-TIGHTEN TO 25 N m (18 FT. LBS.)
GASKET
fTI ENGINE INTAKE MANIFOLD
BOLT - TIGHTEN TO 16 N m (12 FT. LBS.)
IT 1 TBI UNIT
[~3l GASKET
fTI ENGINE INLET MANIFOLD
6S 2797-61 7S 3547-6E
Figure 4-10-Replacing TBI 220 Unit - 2.8L Figure 4-12 - Replacing TBI 220 Unit - 5.0L/5.7L
 FUEL CONTROL 4-15

• Hardware on 4.3L and V-8 engines, 16 N m

(12 ft. lbs.).
• Hardware on 2.8L engine, 25 N-m (18
ft. lbs.).
3. New O-rings on fuel line nuts.
4. Fuel line inlet and outlet nuts by hand.

• Fuel line nut to 26 N-m (20 ft. lbs.). Use

back-up wrench to keep TBI nuts from
turning).

5. Vacuum hoses.
6. Throttle linkage, return spring(s), transmission
control cable, and cruise control (wherever

om
applicable).
7. Grommet, with wire harness, to throttle body.
8. Electrical connectors, making sure connectors
are fully seated and latched.

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Check to see if accelerator pedal is free, by
depressing pedal to the floor and releasing,
while engine is "OFF”.

y
m
[T ]
BOLT - TIGHTEN TO 16 Nm (12 FT. LBS.)
TBI UNIT
10 . With engine "OFF”, and ignition "ON,” check
fT I
fT I
GASKET
HEATER
7S3543-6E
ar
11.
12 .
for leaks around fuel line nuts.
Air cleaner, adapter, and new gaskets.
Start engine and check for fuel leaks.
br
Figure 4-13 - Replacing TBI 220 Unit - 7.4L
FUEL METER COVER ASSEMBLY-TBI 220
Replacement(Figure4-14)
rli

NOTICE: To prevent damage to the throttle valve, it The fuel meter cover assembly contains the fuel
is essential that the unit be placed on a pressure regulator assemble. The regulator has been
holding fixture, before performing service. adjusted at the factory and should only be serviced as
a

a complete preset assembly.

cc

11. TBI flange (manifold mounting) gasket.

CAUTION: Do n o t rem o ve th e fo u r sc re w s
NOTICE: Stuff the manifold opening with a rag, to securing the p ressure regulator to
prevent m a te ria l from e n te rin g the the fuel m e te r co ver. T he fuel
si

engine, and remove the old g a sk e t p ressure regulator includes a large

material from surface of intake manifold. spring u n d e r heavy com pression,
as

w h ich , if a c c id e n ta lly re le a s e d ,
[y | Inspect co u ld c a u se p e rs o n a l in ju r y .
• Manifold bore for loose parts and foreign Disassembly might, also, result in a
cl

material, etc. fuel leak between the d ia p h ra g m

• In ta k e m anifold s e a lin g su rfa c e for and the regulator container.
cleanliness.
Remove or Disconnect
-►«* Install or Connect □
1 Relieve fuel line pressure, per instructions under
1. TBI flange (manifold mounting) gasket.
2. TBI with mounting hardware. "Fuel System Pressure Relief Procedure”.
Air cleaner, adapter, and gaskets. Discard
Tighten gaskets.
3. Electrical connectors to fuel injectors.
• Hardware on L-4 engine, 17 N m (12 ft. 4. Long and short fuel meter cover screw assemblies.
lbs.).
5. Fuel meter cover assembly.
4-16 FUEL CONTROL

NOTICE: DO NOT immerse the fuel meter cover 4. Electrical connectors to fuel injectors.
(with pressure regulator) in cleaner, as 5. With engine "OFF”, and ignition "ON”, check for
damage to the regulator diaphragm and leaks around gasket and fuel line couplings.
gasket could occur. 6. Air cleaner, adapter, and new gaskets.

6. Fuel meter outlet passage gasket, cover gasket, FUEL INJECTOR ASSEMBLY - TBI 220
and pressure regulator seal. Discard gaskets and Replacement (Figure 4-15)
seal.
NOTICE: Use care in removing the fuel injectors, to
I? Inspect prevent damage to the electrical connector
Cover for dirt, foreign material, and casting terminals, the injector filter, and the fuel
warpage. nozzle. The fuel injector is serviced as a
complete assembly only. Also, since the
Install or Connect assembly is an electrical component, it
should not be immersed in any type of

m
New pressure regulator seal, fuel meter outlet cleaner.
passage gasket, and cover gasket.
2. Fuel meter cover assembly.

co
3. A ttaching screw a sse m b lie s, coated w ith
appropriate locking compound to threads. (Short
screws are next to injectors.)

y.
Tighten
Screw assemblies to 3.0 N m (28.0 in. lbs.). ar
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rli
ca
ic

[~T~| FU E L IN JECTO R
l~2l IN LE T F IL T E R
I 3 | LOWER "O" RING
s

[~4~l UPPER "O" RING

as

[~5~~| WASHER
I 6 I F U E L METER BODY ASSEM BLY
cl

5S1698-6E

m ATTACHIN G SCREW-LONG Figure 4-15 Fuel Injector Parts - TBI 220

[E ATTACHIN G SCREW -SHORT
cm FU E L M ETER COVER ASSEM BLY
COVER G A SKET
m
cm O U TLET G A SKET
cm DUST S E A L
FU E L METER BODY ASSEM BLY
m
5S1700-6E
Figure 4-14 Replacing Fuel Meter Cover - TBI 220
 FUEL CONTROL 4-17

[Tl TOP VIEW OF IN JECTO R [c] BUILD DATE

|~2~l WELD STA K E p ' YEAR
i-----j E " DAY
[ a ] PART NUMBER F - MONTH
m VENDOR INDENTIFICATION [ g “] SERVICE

m
IDENTIFICATION
LETTER
7S 3653-6E

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Figure 4-16 Removing Fuel Injector - TBI 220 Figure 4-17 - Fuel Injector Part Number Location
TBI 220

4-+ Remove or Disconnect |+<-| Install or Connect

y.
Relieve fuel line pressure, per instructions, 1. L ubricate new lower (sm all) O -rings w ith
under "Fuel Pressure Relief Procedure”. automatic transmission fluid and push them on
Air cleaner, adapter, and gaskets. Discard
gaskets.
Electrical connectors to fuel injectors. (Squeeze
ar nozzle end of injectors, until they press against
injector fuel filters.
2. Steel injector backup washers, in counterbores of
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plastic tabs and pull straight up.) fuel meter body.
Fuel meter cover attaching screws. 3. L ubricate new upper (large) O -rings w ith
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Fuel meter cover assembly and outlet gasket automatic transmission fluid and install them
(see above procedure). Discard outlet gasket. directly over the backup washers. Be sure O-rings
With fuel meter cover gasket in place to prevent are seated properly and are flush with top of fuel
ca

damage to casting, use a screw driver and meter body surface.

fulcrum to carefully lift out each injector, as
shown in Figure 4-16. NOTICE: Backup washers and O -rings m ust be
c

Lower (small) O-rings from nozzle of injectors installed before injectors, or im proper
and discard. seating of large O-ring could cause fuel to
si

Fuel meter cover gasket and discard. leak.

Upper (large) O-rings and steel backup washers
as

from top of each fuel injector cavity and discard. Injectors, aligning raised lug on each injector base
with notch in fuel meter body cavity. As shown in
I? Inspect Figure 4-18, push down on injector until fully
seated in fuel meter body. (Electrical terminals of
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Fuel injector filter for evidence of dirt and

contamination. If present, check for presence injector should be parallel with throttle shaft.)
of dirt in fuel lines and fuel tank. Fuel meter cover gasket.
Fuel meter cover (see above procedure).
9 1 Important Fuel meter cover attaching screws, coated with
appropriate thread locking compound.
Be sure to replace the injector with an identical With engine "OFF”, and ignition "ON”, check for
part. Injectors from other models can fit in the fuel leaks.
Model 220 TBI, but are calibrated for different Electrical connectors to fuel injectors.
flow rates. (See Figure 4-17 for part number
location.)
4-18 FUEL CONTROL

om
P H FU E L IN JECTO R
f ~ 2 ~ ] F U E L METER BODY 4S 0099-6E

Figure 4-18- Installing Fuel Injector-TBI 221

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FUEL METER BODY ASSEMBLY - TBI 220
Replacement (Figure 4-19)

y
[^►j Remove or Disconnect
1. Relieve fuel line pressure, per instructions, under
"Fuel System Pressure Relief’ procedure.
2. Air cleaner, adapter, and gaskets. Discard
ar
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n~| ATTACHING SCREW ASSEM BLY
gaskets. m FUEL METER BODY ASSEM BLY
3. Electrical connections to fuel injectors. [~3l GASKET
4. Fuel m eter cover a sse m b ly , p e r above
li

[~4~~| OUTLET NUT GASKET

instructions.
nn "0"
fT 1 OUTLET NUT
ar

5. Fuel meter cover gasket, fuel meter outlet gasket, OUTLET RING
and pressure regulator seal. Discard all. [T]
6. Fuel injectors, per above instructions. nn INLET "O" RING
INLET NUT
cc

7. Fuel inlet and return lines and O-rings. Discard IT1 INLET NUT GASKET
O-rings. 7S 3654-6E
8. Fuel inlet and outlet nuts and gaskets from the Figure 4-19 - Fuel Meter Body Assembly - TBI 220
si

fuel meter body assembly. Discard gaskets.

2. Fuel m eter body assem bly, on th ro ttle body
Important
as

assembly.
Note locations of nuts, for proper re-assembly 3. Fuel meter body-to-throttle body attaching screw
later. Inlet nut has a larger passage than outlet assem blies, coated with appropriate locking
nut. compound.
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9. Fuel meter body to throttle body attaching screw

assemblies. • Screw assemblies to 4.0 N»m (35.0 in. lb.).
10. Fuel meter body assembly from throttle body
assembly. 4. Fuel inlet and outlet nuts, with new gaskets, to
11. Throttle body to fuel m eter body gasket and fuel meter body assembly. Use backup wrench to
discard. prevent nuts from turning.

Tighten
•¥+ Install or Connect
• Inlet nut to 40.0 N»m (30.0 ft. lbs.).
1. New throttle body to fuel meter body gasket. • Outlet nut to 29.0 N*m (21.0 ft. lbs.).
Match cut-out portions in gasket with openings in
throttle body. 5. Fuel inlet and return lines and new O-rings. Use
backup wrench to prevent nuts from turning.
 FUEL CONTROL 4-19

|^J Tighten Remove or Disconnect

• Fuel line nuts to 26 N«m (20 ft. lbs.). l. Air cleaner, adapter, and gaskets. Discard
Injectors, with new upper and lower O-rings, in gaskets.
fuel meter body assembly. 2 . Two TPS a tta c h in g screw a sse m b lie s and
Fuel meter cover gasket, fuel meter outlet gasket, retainers (if applicable).
and pressure regulator seal. 3. TPS from throttle body assembly.
Fuel meter cover assembly.
Long and short fuel meter cover attaching screw NOTICE: The TPS is an electrical component and
assem blies, coated with appropriate th read must not be soaked in any liquid cleaner
locking compound. or solvent, as damage may result.

• Attaching screws to 3.0 N*m (27.0 in. lbs.). ♦«- Install or Connect
l. TPS on throttle body assembly, while lining up

om
10. Electrical connectors to fuel injectors. TPS lever with TPS drive lever on throttle body.
11. With engine "OFF”, and ignition "ON”, check for 2. Two TPS a tta c h in g screw a sse m b lie s and
leaks around fuel meter body, gasket, and around retainers (if applicable).
fuel line nuts.

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12. Air cleaner, adapter, and new gaskets. ft Adjust
Follow "A djustable TPS O utput C heck”
THROTTLE POSITION SENSOR (TPS) - TBI 220

ry
procedure, below.
Replacement (Figure 4-20)
Important
ra
• Screw assemblies to 2.0 N*m (18.0 in. lbs.).
On 2.8L (V-6) engines, the TPS is adjustable, and
is supplied with attaching screw retainers. On all
lib
3. Air cleaner, adapter, and new gaskets.
other engines, it is non-adjustable, w ithout
retainers. In addition, on 2.8L (V-6) and 7.4 (V-8)
IAC VALVE - THREAD MOUNTED - TBI 220
engines, the TPS has a horizontal electrical
(Except on 7.4L Engines)
r

connector; on all other engines, the connector is

Replacement(Figure 4-21)
ca

vertical.
NOTICE: The IAC valve is an electrical component
and must not be soaked in any liquid
ic

cleaner or solvent. Otherwise, damage

could result.
s

-►4- Important
as

All pintle configurations, for thread-mounted IAC

valves on Model 220 TBI units, have the same
dual taper. However, with the exception of the
cl

pintle diameter on 7.4L engines (which is 12 mm),

m THROTTLE BODY ASSEM BLY the pintle diameter on all other IAC valves, with
m THROTTLE POSITION SENSOR - NON-ADJUSTABLE TBI 220 applications, is 10 mm. (See dimension
[Tl THROTTLE POSITION SENSOR - NON-ADJUSTABLE "B” in Figure 4-21). Any replacement of an IAC
[Tl THROTTLE POSITION SENSOR - ADJUSTABLE valve must have the appropriate pintle taper and
m SCREW ASSEM BLY diameter for proper seating of the valve in the
m RETAINER throttle body.
7S 3652-6E
Figure 4-20 - TPS Configurations - TBI 220 Remove or Disconnect
1. Air cleaner, adapter, and gaskets, Discard
gaskets.
2. Electrical connector from IAC valve.
3. IAC valve, using 32 mm (1 | ”) wrench.
4. IAC valve gasket and discard.
4-20 FUEL CONTROL

ADJUSTING IAC VALVES WITHOUT COLLAR

IJJjl Clean • Compress valve reta in in g spring, while
• Old gasket material from surface of throttle turning valve "in”, clockwise (Figure 4-23).
body assembly, to insure proper seal of new Return spring end to its original position, with
gasket. straight portion aligned in slot, under flat
surface of valve (Figure 4-24).
NOTICE: Before in sta llin g a new IAC valve,
measure the distance between the tip of
the valve pintle and the housing mounting
surface, when the pintle is fully extended.
If dimension "A” distance (Figure 4-21) is
greater than 28 mm (1.10 in.), it must be
reduced to prevent damage to the valve.

m
co
y.
ar (With Collar at Electric Terminal End)
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a rli
cc

n~l IDLE AIR CONTROL VALVE

f~A~| LESS THAN 28mm (1-1/8 IN.)
n n TYPE I (WITH COLLAR)
si

l~C~l TYPE II (WITHOUT COLLAR)

l~P~l GASKET (PART OF IAC
as

VALVE SERVICE KIT)

4S0104-6E
(Without Collar at Electric Terminal End)
Figure 4-21 Thread Type IAC Valves - TBI 220
cl

Adjust
Identify replacement IAC valve (Figure 4-21) as
either the type with a collar at electric terminal
end, or without one. Reduce distance "A” as
follows:

ADJUSTING IAC VALVES WITH COLLAR

• Exert firm pressure, with a slight side-to-side
movement on valve pintle to retract it (Figure
4-22).
 FUEL CONTROL 4-21

|T| Important
No physical adjustment of the IAC valve assembly
is required, after installation. The IAC valve is
reset, by the ECM.

Install or Connect
AC valve, with new gasket into throttle body.

^ Tighten
• IAC valve assemble to 18.0N»m (13.0 ft. rn o-ring
m SCREW AND WASHER ASSY.
lbs.), with 32mm (1 -J-") wrench.
[~A~1 DISTANCE OF PINTLE EXTENSION

om
2. Electrical connector to IAC valve. [ T 1 DIAMETER OF PINTLE
3. Air cleaner, adapter, and new gaskets. 7S 3792-6E
4. Start engine and allow engine to reach operating Figure 4-25 - Flange Type IAC Valve - TBI 220
temperature.
NOTICE: Before in s ta llin g a new IAC valve,

.c
Important measure the distance between the tip of
When the engine is turned off, the IAC valve will the valve pintle and the flange mounting

y
be reset, by the ECM. surface, when the pintle is fully extended.
If dimension "A” distance (Figure 4-25) is
IAC VALVE - FLANGE MOUNTED - TBI 220
(Used on 7.4L Engines)
ar greater than 28mm (1.10 in.), it must be
reduced to prevent damage to the valve.
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Replacement (Figure 4-25)
Important Adjust
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All pintle configurations, for IAC valves on Model xert firm pressure, with a slight side-to-side
220 TBI un its, have the same dual tap er. movement, on valve pintle to retract it (Figure
ca

However, on 7.4L engines, the pintle diameter is 4-26).

12mm, rather than the 10mm diameter used for
other engines (See Figure 4-25, dimension "B”). Important
c

Any replacement of an IAC valve must have the No physical adjustment of the IAC valve assembly
appropriate pintle taper and diameter, for proper is required, after installation. The IAC valve is
si

seating of the valve in the throttle body. reset, by the ECM.

NOTICE: The IAC valve is an electrical component,

as

and must not be soaked in any liquid

cleaner or solvent. Otherwise, damage
could result.
cl

Remove or Disconnect
1. Air cleaner, adapter, and gaskets.
2. Electrical connector from Idle Air Control valve.
3. Screw assemblies and IAC valve.
4. IAC valve O-ring and discard.

G3 Clean
• IAC valve sealing surfaces on throttle body, to
assure proper seal of new O-ring and contact of
IAC valve flange.
Figure 4-26 - Adjusting IAC Valve - TBI 220
4-22 FUEL CONTROL

Install or Connect -►4- Instali or Connect

□
1. New O-ring on IAC valve.
2. IAC valve on throttle valve body. NOTICE: Procedures, related to replacement of the
3. IAC valve, attaching screw assemblies that have individual components below, have been
been coated with appropriate locking compound. described previously and should be
followed, or damage could result.

1. Invert throttle body on flat surface, for stability

• Screw assemblies to 3.2 N*m (28.0 in. lbs.). and install IAC valve assembly and TPS.
2 . New throttle body-to-fuel meter body gasket.
4. Electrical connector to IAC valve. 3. Fuel m eter body assembly on th ro ttle body
5. Air cleaner, adapter, and new gaskets. assembly.
6. Start engine and allow engine to reach operating Fuel meter body-throttle body attaching screw
temperature. assemblies that have been coated with locking

m
compound.
Important
When the engine is turned "OFF’ the IAC valve

co
will be reset, by the ECM. • Attaching screw assemblies to 4.0 N.m (35.0
in. lbs.).
THROTTLE BODY ASSEMBLY-TBI 220 5. TBI unit to engine as described previously under

y.
Replacement (Figure 4-8) "Throttle Body Injection Unit”.
1. Relieve fuel line pressure, per instructions, under
"Fuel Pressure Relief Procedure-V-6 and V-8
Engines”.
2. Remove throttle body injection unit. (See
ar
MINIMUM IDLE SPEED ADJUSTMENT-TBI 220
(V-6 and V-8 Engine)
This adjustment should be performed, only when
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instructions under "Throttle Body Unit”.) the throttle body assembly has been replaced. Engine
3. Place TBI unit on holding fixture J-9789-118, or should be at normal operating temperature, before
BT-3553, or equivalent. making adjustment.
rli

NOTICE: It is essential that the unit be placed on a

holding fixture, to prevent damage to the Important
a

throttle valve, before performing service. The throttle stop screw, used for regulating
cc

minimum idle speed, is adjusted at the factory.

The screw is covered, with a plug, to discourage
Remove or Disconnect
□ unauthorized adjustments.
si

1. Fuel meter body-to-throttle body attaching screw

assemblies.
2. Fuel meter body assembly. Adjust
as

3. Throttle body-to-fuel meter body gasket. Discard 1. Remove air cleaner, adapter, and gaskets. Discard
gasket. gaskets.
4. Throttle position sensor (TPS). 2 . Plug any vacuum line ports, as required.
cl

5. Invert throttle body on flat surface, for greater 3. With IAC valve connected, ground diagnostic
stability in removal of IAC valve assembly. terminal (ALDL connector).
Turn on ignition, do not start engine. W ait at
pQKl Clean least 30 seconds, (this allows IAC valve pintle to
• Throttle body assembly in accordance with the extend and seat in throttle body).
in s tru c tio n s u n d e r " G e n e ra l S erv ice With ignition "ON”, disconnect IAC valve
Information”. electrical connector.
Remove ground from Diagnostic Terminal and
start engine.
Inspect Remove plug by first piercing it with awl, then,
applying leverage (Figure 4-27).
t Throttle lever and valve for dirt, binds, nicks, 8. Adjust idle stop screw, to obtain 700 rpm + 25
and other damage. Replace, if necessary. rpm in neutral for 2.8L engine, 500-550 rpm in
drive with automatic trans. and 600-650 rpm in
neutral with manual trans. for 4.3L & V8 engines.
 FUEL CONTROL 4-23

9. Turn ignition "OFF”, and reconnect IAC valve 1. C onnect d ig ita l v o ltm e te r J-2 91 2 5 -A , or
electrical connector. equivalent, from TPS connector, center terminal
10. Unplug any plugged vacuum line ports and install "B” to outside terminal "A”, (jumpers for terminal
air cleaner, adapter, and new gaskets. access can be made using terminals 1214836 and
12014837). ALDL scanner can be used to read
TPS output voltage.
2. With ignition "ON”, engine stopped, TPS voltage
should be between .42 and .54 volts.
3. If voltage is out of range, rotate TPS until 0.48 ±
.06 volts are obtained.
4. If above voltage limitation cannot be obtained,
replace TPS.
5. Remove voltmeter and jumpers, reconnect TPS
connector to sensor.

om
FUEL INJECTOR ASSEM BLY - TBI 700
Replacement (Figure 4-28)
NOTICE: Use care in removing the fuel injector to
prevent damage to the electrical connector

.c
terminal, the injector filter, and the fuel
nozzle. The fuel injector is serviced as a

ry
complete assembly only. Also, since the
assembly is an electrical component, it
should not be immersed in any type
ra cleaner.
lib
m IDLE STOP SCREW
[ T ] PLUG
7S 3425-6E
r

Figure 4-27 - Removing Idle Stop Screw Plug-TBI 220

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NON-ADJUSTABLE TPS OUTPUT CHECK -

TBI 220 (4.3Land V-8 Engine)
ic

This check should be performed, only, when

throttle body or TPS has been replaced or, after the
s

minimum idle speed has been adjusted.

1. C onnect d ig ita l v o ltm e te r J-29125-A , or
as

equivalent, from TPS connector, center terminal

"B” to outside terminal "A”, (jumpers for terminal
access can be made using terminals 1214836 and
12014837). ALDL scanner can be used to read
cl

TPS output voltage.

2. With ignition "ON”, and engine stopped, TPS
voltage should be less than 1.0 volt. If more than
1.0 volt, check minimum idle speed before m SCREW ASSEM BLY
replacing TPS. m RETAINER
3. Remove voltmeter and jumpers and reconnect TPS HI FUEL METER ASSEM BLY
connector to sensor. m LOWER "O” RING
[ T l UPPER "O" RING
ADJUSTABLE TPS OUTPUT CHECK-TBI 220 m INJECTOR
(2.8L Engine Only) 7S3416-6E
This check should be performed, only, when Figure 4-28 - Fuel Injector Parts - TBI 700
throttle body parts have been replaced or, after the
minimum idle speed has been adjusted.
4-24 FUEL CONTROL

Remove or Disconnect |^J Tighten

B
Relieve fuel line pressure, per instructions under • Injector retainer attaching screw to 3.0 N«m
"Fuel System Pressure Relief’ procedure. (27.0 in. lbs.).
2 . Air cleaner and gasket. Discard gasket. 4. With engine "OFF”, and ignition "ON”, check for
3. Electrical connector to fuel injector. fuel leaks.
4. Injector retainer screw and retainer. 5. Air cleaner and new gasket.
5. Injector, by placing screwdriver blade under ridge
opposite connector end and carefully prying it out
(Figure 4-29).
6 . Upper and lower O-rings, from injector and in fuel
injector cavity and discard.

[jy| Inspect

m
• Fuel injector filter for evidence of dirt and
contamination. If present, check for presence
of dirt in fuel lines and fuel tank.

. co
ry
f T I TOP VIEW OF INJECTOR
Ha H PART NUMBER
n n BUILD DATE CODE
7S 3420-6E
ra
Figure 4-30 - Fuel Injector Pat Number Location
f T I FUEL METER BODY
f T I FUEL INJECTOR
lib

nn
[~A~1 SCREWDRIVER
FULCRUM
7S3419-6E
ar

Figure 4-29 - Removing Fuel Injector - TBI 700

Important
cc

Be sure to replace the injector with an identical

part. Injectors from other models can fit in the
si

Model 700 TBI, but are calibrated for different

flow rates. (See Figure 4-30, for part numbers m PRESSURE REGULATOR COVER
location.) |~2~| SCREW ASSEM BLY
as

fT I SPRING - SEAT
□0 SPRING
♦ 4- Install or Connect |~5~| DIAPHRAGM
cl

Lubricate new upper and lower O-rings, with \T } FUEL METER ASSEM BLY 7S 3421-6E
automatic transmission fluid, and place them on Figure 4-31 - Pressure Regulator - TBI 700
injector. (Make sure upper O-ring is in groove and
lower one is flush up against filter.) PRESSURE REGULATOR ASSEM BLY - TBI 700
Injector assembly, pushing it straight into fuel Replacement (Figure 4-31)
injector cavity.
NOTICE: To prevent leaks, the pressure regulator
Important diaphragm assembly must be replaced,
Be sure the electrical connector end, on the whenever the cover is removed.
injector, is facing in the general direction to the
Remove or Disconnect
cut-out in the fuel m eter body for the wire
grommet. □
ir
l. Relieve fuel line pressure, per instructions under
Injector retainer, using appropriate thread locking "Fuel Pressure Relief Procedure-L-4 Engines”.
compound on retainer attaching screw. 2 . Air cleaner and gasket. Discard gasket.
3. Four pressure regulator attaching screws, while
keeping pressure regulator compressed.
 FUEL CONTROL 4-25

CAUTION: The pressure regulator contains a

la rg e s p r in g , u n d e r h e av y
c o m p re s s io n . Use c a r e , w h e n
removing the screw s to p re v e n t
personal injury.

4. Pressure regulator cover assembly.

5. Pressure regulator spring.
6. Spring seat.
7. Pressure regulator diaphragm assembly.

‘S j Inspect
Pressure regulator seat in fuel meter body
cavity for pitting, nicks, or irregularities.
(Use magnifying glass, if necessary, to do

om
this.) If any of above is present, whole fuel
body casting must be replaced.
[Tl AIR FILTER G A SKET
|~2~| FUEL INJECTOR

.c
|++| Install or Connect [~T1 SCREW AND W ASHER A SS Y.
m FUEL METER A SS Y.
1. New pressure regulator diaphragm assembly,
nn
m o-ring
|~5~1 G A SKET

y
making sure it is seated in groove, in fuel meter
body.
2. Regulator spring seat and spring into cover
assembly.
3. Cover assembly over diaphragm, while aligning
r ar nn seal
m
FUEL OUTLET NUT

pr essu r e reg u la to r co ver

7S 3783-6E
mounting holes. Figure 4-32 - Fuel Meter Assembly - TBI 700
lib

NOTICE: Use care, while installing the pressure

regulator, to prevent misalignment and Install or Connect
ar

possible leaks. 1. New fuel meter to throttle body gasket. Match

4. While maintaining pressure on regulator spring, cut-out portions of gasket w ith openings in
four screw assemblies that have been coated with throttle body assembly.
cc

appropriate thread locking compound. 2 . Fuel meter assembly onto throttle body assembly
and gasket.
si

• Attaching screw assemblies to 2.5 N*m (22.0

in. lbs.). Attaching screws to 6.0 N*m (53 in. lbs.).
as

6. With engine "OFF”, and ignition "ON”, check for 3. Throttle body injection unit to inlet manifold, as
fuel leaks. described previously.
7. Air cleaner and new gasket.
cl

THROTTLE POSITION SENSOR (TPS) - TBI 700

FUEL METER ASSEMBLY - TBI 700 Replacement (Figure 4-33)
Replacement (Figure 4-32)
NOTICE: The TPS is an electrical component and
|++| Remove or Disconnect must not be soaked in any liquid cleaner
1. T h rottle body injection u n it, as described or solvent as damage may result.
previously.
2. Two fuel meter body attaching screw and washer
assemblies. «--► Remove or Disconnect
3. Fuel meter assembly from throttle body assembly. 1. Air cleaner and gasket. Discard gasket.
4. Fuel meter body to throttle body gasket and 2. Two TPS attaching screw assemblies.
discard. 3. TPS from throttle body assembly.
4-26 FUEL CONTROL

©
rn o -r in g
F T I THROTTLE BODY ASSEM BLY fT I SCREW AND WASHER ASSY.
[~2~| THROTTLE POSITION SENSOR [~Al DISTANCE OF PINTLE EXTENSION

m
f T I SCREW ASSEM BLY |B [ DIAMETER OF PINTLE
7S 3415-6E 7S 3792-6E
Figure 4-33 - Throttle Position Sensor - TBI 700 Figure 4-34 - Flange Type IAC Valve - TBI 700

o
.c
Install or Connect [IJJp! Clean
l. With throttle valve closed, install TPS on throttle • IAC valve seating surfaces on throttle body, to

y
shaft. R otate counter-clockw ise, to a lig n assure proper seal of new O-ring and contact of
mounting holes. IAC valve flange.
2. Two TPS attaching screw assemblies. ar
NOTICE: Before in sta llin g a new IAC valve,
measure the distance between the tip of
br
• Screw assemblies to 2.0 N*m (18.0 in. lbs.). the valve pintle and the flange mounting
surface, when the pintle is fully extended.
rli

3. Air cleaner and new gasket. If dimension "A” distance (see Figure 4-
34) is greater than 28mm (1.10 in.), it
IAC VALVE-FLANGE MOUNTED - TBI 700 must be reduced, to prevent damage to the
ca

(Used on 2.5L Engines) valve.

Replacement (Figure 4-34)
Adjust
ic

Important
The IAC for valve on the Model 700 TBI unit, for • Exert firm pressure with a slight side-to-side
s

2.5L engines, has a dual taper, 10 mm diameter movement, on valve pintle, to retract it (see
pintle (see "B” in Figure 4-34). Any replacement Figure 4-35).
as

of an IAC valve must have the appropriate pintle

shape and diameter. Otherwise, improper seating
of the valve in the throttle body could occur. Important
cl

No physical adjustment of the IAC valve assembly

NOTICE: The IAC valve is an electrical component is required, after installation. The IAC valve is
and must not be soaked in any liquid reset by the ECM. When the vehicle is operated at
cleaner or solvent. Otherwise, damage normal engine temperature, at approximately 30
could result. mph (48 km/hr), the ECM causes the valve pintle
to seat in the throttle body. The ECM, then, has a
reset procedure to set the correct pintle position.
|*+| Remove or Disconnect Proper idle regulation should result.
1. Air cleaner and gasket. Discard gasket.
2.
3.
Electrical connector from IAC valve.
Screw assemblies and IAC valve.
EE Install or Connect
l. Lubricate new O-ring, with transmission fluid and
4. IAC valve O-ring and discard. install on IAC valve.
2. IAC valve to throttle body.
 FUEL CONTROL 4-27

fT l THROTTLE BODY ASSEM BLY

[~T1 GASKET
RT] MANIFOLD

m
fT l ATTACHING SCREW
7S 3424-6E
Figure 4-35 - Adjusting IAC Valve - TBI 700 Figure 4-36 - Tube Module Assembly - TBI 700

co
3. IAC valve attaching screw assemblies that have THROTTLE BODY ASSEM BLY - TBI 700
been coated with appropriate thread locking Replacement (Figure 4-37)

y.
compound.
Remove or Disconnect
^ Tighten

r
1. T hrottle body injection u n it, as previously
• Screw assemblies to 3.2 N»m (28.0 in. lbs.).
ra described.
4. Electrical connector to IAC valve.
5. Air cleaner and new gasket. Important
6. Start engine and allow engine to reach operating
lib
temperature. After removing from the engine, place TBI unit on
a holding fix tu re, J-9789-118, BT-3553 or
TUBE MODULE ASSEMBLY - TBI 700
ar

equivalent.
Replacement (Figure 4-36)
2. Fuel meter body attaching screw and w asher
cc

assemblies.
Remove or Disconnect
B
1. Air cleaner and gasket. Discard gasket.
3. Fuel meter assembly.
4. Fuel meter body to throttle body gasket and
discard.
si

2. Tube module assembly attaching screws.

3. Tube module assembly. 5. Throttle position sensor (TPS), per previous
4. Tube module assembly gasket and discard. instructions.
as

6. Idle a ir control (IAC) valve, per previous

instructions.
7. Tube module assembly, per previous instructions.
C lean
cl

• Old gasket material from surface of throttle -►«- Install or Connect

body assembly to insure proper seal of new
gasket. NOTICE: Procedures related to replacement of the

0 Install or Connect
individual components below have been
described p reviously and should be
1. New tube module assembly gasket. followed, or damage could occur.
2. Tube module assembly.
3. Tube module assembly attaching screws 1. Tube module assembly, idle air control (IAC)
valve, and throttle position sensor (TPS), per
Tighten previous instructions.
• Screw assemblies to 3.0 N»m 2. New fuel meter body to throttle body gasket.
(28.0 in. lbs.). 3. Fuel meter assembly.
4. Air cleaner and new gasket.
4-28 FUEL CONTROL

5. W ith ignition "ON”, disconnect IAC valve

electrical connector.
6. Remove ground from Diagnostic Terminal and
start engine.
7. Remove the plug, by first piercing it with an awl,
then applying leverage (Figure 4-38).
8. Adjust idle stop screw to obtain 650 rpm ± 25 rpm
in neutral.
9. Turn ignition "OFF”, and reconnect IAC valve
electrical connector.
10. Unplug any plugged vacuum line ports and install
air cleaner and new gasket.

NON-ADJUSTABLE TPS OUTPUT CHECK -

T B I700

m
This check should be performed, only, when
throttle body parts have been replaced, or, after the
fT ] IDLE AIR CONTROL VALVE minimum idle speed has been adjusted.

co
fT I IDLE STOP SCREW PLUG 1. Connect digital voltmeter J29125-A or equivalent,
HT] SCREW AND WASHER ASSY. from TPS connector, center term inal "B” to
IT 1 SPRING outside terminal "A” (jumpers for terminal access

.
fT I THROTTLE LEVER can be made using te rm in a ls 1214836 and

ry
f lT ]THROTTLE BORE 12014837). An ALDL scanner can be used to read
m THROTTLE BODY ASSEM BLY the TPS output voltage.
fTI THROTTLE POSITION SENSOR
|~9~| GASKET
ra
R o l TUBE MODULE ASSY.
7S3715-6E
lib
Figure 4-37 - Throttle Body Assembly - TBI 700
4. Fuel meter body assembly attaching screw and
washer assemblies.
ar
cc

• Screw to 6.0 N*m (53 in. lbs.).

MINIMUM IDLE SPEED ADJUSTMENT -

TBI 700 (L-4 Engines)
si

This adjustment should be performed only when

the throttle body assembly has been replaced. Engine
as

should be at normal operating tem perature before

making adjustment.

Important
cl

The throttle stop screw,, used for regulating minimum

idle speed, is adjusted at the factory. The screw is
covered with a plug to discourage unauthorized
adjustments.
F T I IDLE STOP SCREW
Adjust f~2~l PLUG 7S 3425-6E
1. Remove air cleaner and gasket. Disregard gasket. Figure 4-38 - Removing Idle Stop Screw Plug -
2. Plug any vacuum line ports, as required. TBI 700
3. With IAC valve connected, ground the diagnostic
terminal (ALDL connector).
4. Turn ignition, do not start engine. Wait at least
30 seconds (this allows the IAC valve pintle to
extend and seat in the throttle body).
 FUEL CONTROL 4-29

2. With ignition "ON”, engine stopped, the TPS

voltage should be less than 1.25 volts. If more *4- Install or Connect
than 1.25 volts, replace TPS.
3. Remove the voltmeter and jumpers, reconnect the 1. Fuel pump assembly into the attaching hose.
TPS connector to the sensor.
NOTICE: Care should be taken not to fold over or
FUELPUMP twist the strainer, when installing the
sending unit as this will restrict fuel flow.

E3 Remove or Disconnect 2. Sending unit and fuel pump assembly into the fuel
• Relieve fuel system pressure (2.5L Engine only). tank.
• Raise the vehicle on a hoist. • Use a new O-ring seal.
1. Negative battery cable. 3. Cam lock assembly.
2. Fuel tank. • Turn the cam lock clockwise to lock it.
3. Sender unit and pump by turning the cam lock 4. Fuel tank.

m
counterclockwise. 5. Negative battery cable.
4. Fuel pump from the sending unit.
• Pull the fuel pump up into the attaching hose Fuel Pump Relay

co
while pulling outw ard from the bottom
support. R efer to F ig u re s 4-40 th ro u g h 4-45, for
• Do not damage the rubber insulator or the replacement of the fuel pump relay.

y.
strainer.

[?| Inspect
r
ra
1. Fuel pum p a tta c h in g hose for s ig n s of
deterioration,
lib
2. Rubber sound insulation at the bottom of the
pump.
ar

[ T l ELECTRICAL CONNECTOR
m OIL PRESSURE RELAY
cc

[Tl A C RELAY
[~4~| RELAY BRACKET
m BULKHEAD CONNECTOR
si

I 6 | FUEL PUMP RELAY 6S 2885-6E

Figure 4-40 - Fuel Pump and A/C Relay (ST)
as
cl

n ~ | FUEL PUMP & [T ] ELECTRICAL CONNECTOR

_____ SENDER r z -[ CCA.

m
[ T ] CAM L jJ seal
GROUND WIRE ® FUEL TANK
7S 3789-6E
Figure 4-39 - Fuel Pump - Typical
4-30 FUEL CONTROL

f T I ELECTRICAL CONNECTOR [ T ] PLENUM PANEL

f T I FUEL PUMP RELAY [ T ] BRACKET

m
f T I RETAINER
7S 3757-6E
Figure 4-44 - Fuel Pump Relay (G)

o
y .c
ar
br
%
^ < o _ j p o o
rli

t j f \ 1
ca

m RETAINER
f T I RETAINER m BRACKET
i~F1 FUEL PUMP RELAY
m FUEL PUMP RELAY f T I ELECTRICAL
[T l ELECTRICAL CONNECTOR CONNECTOR
f T I DASH AND TOE PANEL
fT ] PLENUM PANEL
ic

7S 3756-6E 7S3758-6E
Figure 4-42 - Fuel Pump Relay (CK) Figure 4-45 - Fuel Pump Relay (P)
s

FUEL MODULE
as

Refer to Figure 4-46, for replacement of the fuel

[T l
module on "R,V,C,K” Series.
n Refer to Figure 4-47, for replacement of the fuel
cl

module on "G” Series.

fi
o j
ji ^

f T I RETAINER Q T ] BRACKET
f T I FUEL PUMP RELAY [ ¥ ] ELECTRICAL
|~3~|
1----- 1
PLENUM PANEL CONNECTOR
7S 3759-6E
Figure 4-43 - Fuel Pump Relay (RV)
 FUEL CONTROL 4-31

Figure 4-48 - Oil Pressure Switch (2.5L)

STEERING COLUMN

m
BRAKE PEDAL BRACKET
FUEL MODULE
7S 3790-6E

co
Figure 4-46 - Fuel Module (CKRV)

.
ry
ra
r lib
ca

Figure 4-49 - Oil Pressure Switch (2.8L)

FUEL FILTER
c
si

In-line Filter
(Figures 4-51 through 4-57)
as

4-+ Remove or Disconnect

m SEAT RISER • On 2.5L engine, relieve fuel system pressure.
cl

[ T l FUEL MODULE 1. Fuel Filler cap.

m ELECTRONIC CONTROL MODULE 2. Fuel feed nuts.
m ALDL CONNECTOR 3. Clamp bolt.
7S 3786-6E 4. Filter and clamp.
Figure 4-47 - Fuel Module (G) 5. Clamp from filter.

OIL PRESSURE SWITCH Install or Connect

l. Clamp to filter.
Refer to Figure 4-48 through 4-50, for replacement 2. Clamp bolt.
of the oil pressure switch. 3. Fuel feed nuts.
4. Fuel filler cap.
4-32 FUEL CONTROL

o m
[T] FUEL RETURN PIPE
I 2 [ CLAMP

.c
fTl FUEL RETURN HOSE
f T l IN-LINE FUEL FILTER

y
[T] CLAMP (DOUBLE)
m FUEL FEED HOSE

m
f T l FITTING
OIL PRESSURE SWITCH 7S3814-6E
ar f T l O-RING
[ T ] FUEL FEED PIPE-TIGHTEN NUT TO
26 N m (20 FT. LBS.) 7S 3646-6E
br
Figure 4-50 - Oil Pressure Switch (4.3L/V8) Figure 4-52 - Fuel Filter - 2.8L (ST)
rli
ca
s ic
as

CD RIGHT FRAME
SIDE MEMBER
I T ] CLAMP
rrn
INTERMEDIATE FUEL
m REAR FUEL FEED 1------1 FEED PIPE-TIGHTEN
PIPE-TIGHTEN NUT TO NUT TO 26N m
26 N m (20 FT. LBS.)
cl

(20 FT. LBS.)

BOLT-TIGHTEN TO H T ! TRANSMISSION
16 N m (24 FT. LBS.) L-L J SUPPORT
s IN-LINE FUEL
FILTER 7S 3644-6E
Figure 4-53 - Fuel Filter (RV)
In-Tank Filter
m FUEL FEED PIPE-TIGHTEN NUT TO 26 Nm
(20 FT. LBS.) Refer to fuel pump replacement, if the in-tank
fTl O-RING filter required service.
m IN-LINE FUEL FILTER
f T l FUEL FEED HOSE-TIGHTEN NUT TO
26 N m (20 FT. LBS.)
fTl FUEL RETURN HOSE-TIGHTEN NUT TO
26 N m (20 FT. LBS.) 7S 3645-6E
Figure 4-51 - Fuel Filter - 2.5L (ST)
 FUEL CONTROL 4-33

m cup
m LEFT FRAME SIDE MEMBER
I 3 I FRONT FUEL FEED HOSE-TIGHTEN NUT TO
26 N m (20 FT. LBS.)
I T ] IN-LINE FUEL FILTER

m
f T I REAR FUEL FEED HOSE-TIGHTEN NUT TO
26 N m (20 FT. LBS.)
7S 3650-6E
Figure4-54-Fuel Filter (CK)

o
.c
ry
fTI IN-LINE FUEL FILTER
fTI LEFT FRAME SIDE MEMBER
ra f T I FRONT FUEL FEED PIPE-TIGHTEN NUT TO
26 N m (20 FT. LBS.)
7S 3647-6E
Figure 4-56 - Fuel Filter (M)
lib

[~T1 REAR FUEL FEED PIPE-TIGHTEN NUT

TO 26 N-m (20 FT. LBS.)
ar

fTI IN-LINE FUEL FILTER

m CLAMP
[~4~| INTERMEDIATE FUEL FEED PIPE-TIGHTEN
cc

NUT TO 26 N m (20 FT. LBS.)

f T I RIGHT FRAME SIDE MEMBER
1-----'_____________________________________ 7S 3649-6E
Figure 4-55 - Fuel Filter (P)
si

FUEL HOSE/PIPE ASSEMBLIES

as

Materials
Fuel Lines - These are welded steel tubes, meeting
cl

GM Specification 124-M, or its equivalent. The fuel

feed line is 3/8” diameter and the fuel return line is
5/16” diameter. Do not use copper or alum inum
tubing to replace steel tubing. Those materials do not
have satisfactory durability to w ithstand normal fTI REAR FUEL FEED PIPE-TIGHTEN NUT
TO 26 N m (20 FT. LBS.)
vehicle vibration. |~2~l IN-LINE FUEL FILTER
Coupled Hose - These are not to be repaired and fTI BRACKET
are replaced only as an assembly. fTI VAPOR PIPE
Uncoupled Hose - Use only reinforced fuel fTI FUEL RETURN PIPE
resistant hose, made of "Fluroelastomer” material. fTI INTERMEDIATE FUEL FEED PIPE-TIGHTEN
Do not use a hose within 4 inches (100 mm) of any part NUT TO 26 N-m (20 FT. LBS.)
I 7 [ RIGHT FRAME SIDE MEMBER
7S 3648-6E
Figure 4-57 - Fuel Filter (G)
4-34 FUEL CONTROL

of the exhaust system, or within 10 inches (254 mm) of 3. Fuel tank retaining straps.
the catalytic converter. The hose’s inside diameter • Support the fuel tank.
must match the outside diameter of the steel tubing. 4. Sender unit wires, hoses, and ground strap.
Clamps - These are stainless steel, screw band- • Lower the fuel tank to gain access.
type clamps, #2494772, or equivalent. 5. Fuel tank from the vehicle.
6. Fuel sender and pump from the fuel tank.
Fuel Line Repair 7. Purge tank, if being repaired.

1. Cut a piece of fuel hose 4 inches (100 mm) longer

than the section of line to be removed. If more p 4-| Install or Connect
than 6 inches (152 mm) is to be removed, use a 1. Fuel sender and pump into fuel tank.
combination of steel pipe and hose. The hose 2. Fuel tank into the vehicle.
length should not be more than 10 inches total. 3. Sender unit wires, hoses, and ground straps.
2. Cut a section of pipe to be replaced with a tube 4. Fuel tank retaining straps with insulator strips in
cutter. Use the first step of a double flaring tool to place.

m
form a bead on the ends of the pipe and, also, on 5. Clamp to filler neck hose and vent line.
the new section of pipe, if used. 6. Bolts and nuts.
3. Slide the hose clamps onto the pipe and push the

co
hose 2 inches (51 mm) onto each portion of the fuel |^| Tighten
pipe. Tighten a clamp on each side of the repair.
4. Secure fuel line to the frame. Bolts, as shown in the illustrations.

.
ry
FUELTANK Purging

Draining The fuel tank should be purged, before being

ra
repaired.
1. Disconnect the negative battery cable.
lib
• Have a dry chem ical (Class B) fire
extinguisher nearby. |++| Remove or Disconnect
1. Fuel tank from the vehicle.
CAUTION: Never d ra in or store gasoline or 2. Fuel gage sending and pump unit.
ar

diesel fuel in an open container, 3. All remaining fuel from the tank.
du e to the po ssib ility of fire or
explosion. Inspect
cc

I?
• Fuel tank for any remaining fuel.
2. Use a hand operated pump device to drain as much
fuel as possible through the filler neck. On some Install or Connect
si

fuel tank installations, the filler neck is too long to

gain access to the fuel. If the tank is not full, 1. Tap water into the tank, until it is full.
• Move the tank to the flushing area (wash
as

disconnect filler neck nose, at the fuel tank, to

gain access to the fuel. rack).
Alternate method: • Agitate the water vigorously, and then, drain
a. Disconnect fuel feed pipe and attach a it.
cl

hand operated pump device. 2. Gasoline emulsifiying agent into the tank.
b. Energize the fuel pump relay. • Use an available emulsifying agent, such as
c. With fuel pump running, operate hand Product-Sol No. 913, or equivalent.
pump to remove fuel. 3. Water to the fuel tank.
3. After servicing fuel tank, install removed hose, • Refer to the emulsifying agent specifications
lines, and fuel filler cap. for the mixture ratio.
• Agitate the mixture for ten minutes.
Replacement • Drain the tank completely.
Figure 4-58 through 4-67 • Fill the tank with water, until it overflows.
• Completely flush out any remaining mixture.
Remove or Disconnect • Drain the fuel tank.
• Use an explosion meter (if available) to check
1. Fuel from the fuel tank. for a negative reading.
2. Clamps from filler neck hose and vent line. (Fig. 4- • Perform the required service work.
68 through 4-75).
 FUEL CONTROL 4-35

4. Repair fuel tank. Leak Test

5. Fuel gage sending and pump unit.
6. Fuel tank into vehicle. If fuel is leaking, from the tank, the tank should
be replaced. Make sure that the fuel lines are not
FUEL SYSTEM CLEANING leaking onto the tank.
1. Remove the fuel tank.
2. Drain the tank.
Remove or Disconnect
□
l. Negative battery cable.
3. Plug all of the outlets.
4. Apply 7 to 10 kPa (1 to 1^ psi) a ir pressure
2 . Engine harness connector on the distributor. through the vent tube.
• Have a dry c h e m ic a l (C la ss B) fire 5. Test for leaks, with a soap solu tio n , or by
extinguisher near the work area. submersion.
3. Fuel system pressure (2.5L engine only). 6 . Replace the tank, if a leak is found.
4. Fuel from the fuel tank.
5. Fuel tank.

om
6. Fuel gage sending and pump unit.
7. Purge fuel tank.

In Line Fuel Filter

.c
1? Inspect

y
• In-line filter, for contamination.
• Replace the filter, if it is plugged.

^
•
Clean
r
Fuel lines, by applying air pressure in the
ar
opposite direction of fuel flow.
lib

|-»4-| Install or Connect

ar

1. New strainer (if necessary) on the fuel gage

sending and pump unit.
fT I FUEL TANK
cc

NOTICE: Care should be taken not to fold over or

fT I BOLT — TIGHTEN TO 18 N m (13 FT. LBS.)
twist the strainer, when installing the
I 3 I STRAP
sending unit, as this will restrict fuel flow.
fT I PROTECTOR
si

I 5 I BOLT — TIGHTEN TO 35 N m (26 FT. LBS.)

2. Fuel gage sender and pump unit, with a new seal
m BOLT — TIGHTEN TO 35 N m (26 FT. LBS.)
into the fuel tank.
as

m NUT — TIGHTEN TO 7 N-m (5 FT. LBS.)

3. Fuel tank. 7S 3820-6E
4. Disconnect the fuel feed line at the front of the Figure 4-58 - Fuel Tank - ST (except Utility)
vehicle.
cl

5. Hose to the fuel feed line at the front of the vehicle

and insert the other end of the hose into a 3.8 liter
(one gallon) fuel can.
6. Negative battery cable.
7. Twenty three liters (six gallons) of clean fuel into
the fuel tank.
8. Energize fuel pump relay, to operate the fuel
pump, until two liters (£ gallon) of fuel flows into
the fuel can. This will purge the fuel pump.
9. Fuel line, at the front of the vehicle.
10. Engine harness connector to the distributor.
• Check all connections, for leaks, and tighten
all hose clamps.
4-36 FUEL CONTROL

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[Tl FUEL TANK

m NUT — TIGHTEN TO 45 N m (33 FT. LBS.)
[~3~| BOLT — TIGHTEN TO 35 N m (26 FT. LBS.)
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[~4~| STRAP
|~5l NUT — TIGHTEN TO 7 N m (5 FT. LBS.)
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I 6 [ BRACKET
7S 3821-6E
Figure 4-59 - Fuel Tank-ST Utility
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COMPLETELY INSTALL ONE STRAP PRIOR TO

INSTALLATION OF THE SECOND STRAP, HOWEVER,
THE TANK MUST REMAIN SUPPORTED UNTIL ALL
FOUR BOLTS ARE TORQUED TO SPECIFICATIONS.

[~T1 INSULATOR
m LOWER SHIELD
m STRAP
IT] FUEL TANK
INSTALLATION SEQUENCE
m BOLT — TIGHTEN TO 35 N m
(26 FT. LBS.)
H r ] BOLT — TIGHTEN TO 3.4 N m
(30 IN. LBS.)
f T l NUT — TIGHTEN TO 35 N m

Figure 4-60 - Fuel Tank-M

 FUEL CONTROL 4-37

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[Tl NUT — TIGHTEN TO 12 N m(10 FT. LBS.)

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m BOLT — TIGHTEN TO 12 N m (10 FT. LBS.)
I T 1 BOLT — TIGHTEN TO 33 N m (24 FT. LBS.)
f T l FUEL TANK fTl
ar STRAP — BASE FUEL TANK LOCATION

m (60
m SHIELD I 2 [ STRAP — 33 GAL. FUEL TANK LOCATION
I 6 | REAR STRAP NUT — TIGHTEN TO 7 N m IN. LBS.)
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I 7 I FRONT STRAP 7S 3829-6E fTl BOLT — TIGHTEN TO 33 N m (22 FT. LBS.) 7s 3817-6E
Figure 4-61 - Fuel Tank - CK Chassis Cab Figure 4-63 - Fuel Tank - RV Pickup
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PH STRAP — HOOK MUST FACE FORWARD

m REAR STRAP fTl FUEL TANK
E FRONT STRAP fTl UPPER NUT — TIGHTEN TO 14 N m
H BOLT — TIGHTEN TO 12 N m (10 FT. LBS.) (10 FT. LBS.) AND THEN TIGHTEN
m FUEL TANK LOWER NUT [ T ] TO 14 N m (10 FT. LBS.)
m SHIELD __________________________________________ 7S3818-6E
7S3830-6E
Figure 4-62 - Fuel Tank-CK {except Chassis Cab) Figure 4-64 - Fuel Tank - RV Utility & Suburban
4-38 FUEL CONTROL

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f T I STRAP
[~T1 BOLT — TIGHTEN TO 9.5 N m (85 IN. LBS.) [ T 1 LOWER NUT — TIGHTEN TO 12 N m [ T ] FUEL TANK
(10 FT. LBS.), THEN TIGHTEN p n i m c . .. a t o d
[~2~1 STRAP
FTI FUEL TANK
[~4~| LOWER NUT — TIGHTEN TO 14 N-m <10 FT. LBS.)
AND THEN TIGHTEN UPPER NUT [ T ] TO
ar MIDDLE NUT S TO 58 N-m
(42 FT. LBS.) AND THEN TIGHTEN
LOWER AND UPPER NUT E
_____ TO 58 N m (42 FT. LBS.)
\J= \ 'NSULATOR
[ T l NUT —
TIGHTEN TO
58 N m (42 FT. LBS.)
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I 5 I NUT — TIGHTEN TO 58 N m
(42 FT. LBS.) 75 3841-6E
Figure 4-65 - Fuel Tank-G Figure 4-67 - Fuel Tank - P (42)
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m
m STRAP
NUT TIGHTEN TO 12 (10
N-m FT. LBS.)
|T 1 UPPER NUT — TIGHTEN TO 35 N m (23 FT. LBS.)
AND THEN TIGHTEN LOWER NUT [ T ]
TO 35 N m (25 FT. LBS.)
I 5 I FUEL TANK
7S 3839-6E
Figure 4-66 - Fuel Tank - P (32)
 FUEL CONTROL 4-39

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Figure 4-68 - Filler Neck - ST Utility

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m VENT HOSE [T] FUEL FILLER CAP

[Tl FILLER PIPE [T] GROUND STRAP fTl VENT PIPE [T] HOUSING
[~3~l HOUSING [Tl INSULATOR GO FILLER PIPE
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7S 3824-6E 7S3822-6E
Figure 4-69 - Filler Neck - ST Pickup Figure 4-71 - Filler Neck-M
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fTl FUEL FILLER CAP

fTl HOUSING
m VENT PIPE [T]GROUND STRAP [Tl FILLER PIPE
|~2~l FILLER PIPE [ T ] SUPPORT I
m
r~4~| VENT PIPE
fTl FUEL FILLER PIPE [T]SHIELD GROUND STRAP 7S 3840-6E
Figure 4-70 - Filler Neck - ST Chassis Cab Figure 4-72 - Filler Neck - CK
4-40 FUEL CONTROL

AUXILIARY FUEL TANK CONTROL

Figure 4-77
The auxiliary fuel tank selector switch, located on
the instrument panel, activate either the left hand or
right hand fuel tank fuel pump and a selector valve
and meter switch to select right, or left, fuel feed and
return lines.

Remove or Disconnect

y ictor Valve Replacement

Figure 4-76
l. Battery.
2. Hose shield, if required.

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3. Electrical connector from valve.
4. Fuel feed and return hose. Note position and color
of hoses.
5. Selector valve from frame.

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Install and Connect

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1. Selector valve.
2. Fuel feed and return hoses.
3. Electrical connector.
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4. Hose shield.
5. Battery.
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fT I VENT PIPE
|~2~| FILLER NECK
|~3~| HOUSING
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|~4~| FUEL FILLER CAP 7S 3827-6E

Figure 4-74 - Filler Neck - RV Utility & Suburban
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P H BOLT — TIGHTEN TO 18 N m (12 LBS. FT.)

[~2~| FUEL TANK SELECTOR VALVE
FUEL FEED
m FUEL RETURN
[~C~] RH FUEL RETURN — PINK
n n RH FUEL FEED — ORANGE
[Tl LH FUEL RETURN — BLUE
m LH FUEL FEED — YELLOW 7S 3843-6E
Figure 4-76 - Selector Valve - RV
 FUEL CONTROL 4-41

PLUG CAVITY SEAL-

TO REAR
LAMP WIRING FUEL TANK
HARN FUEL SELECTOR VALVE
PUMP FEED & METER SWITCH

TO REAR LAMP
WIRING

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FUEL METER/PUMP
CONNECTION

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ELECTRIC ELECTRIC
FUEL FUEL
PUMP ASM

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PUMP ASM
(PRODUCTION (AUX RT. SIDE)
LT. SIDE)

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Figure 4-77 - Auxiliary Tank Wiring - RV
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ACCELERATOR CONTROLS
Accelerator Control Cable
a

Figures 4-78 through 4-80

There are no linkage adjustments. The throttle
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cable must be replaced with an identical replacement

part.
All linkages and cables must be checked, to assure
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free movement, with no rubbing, chafing, or binding.

The throttle must operate freely, without binding
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between full closed and side open throttle.

Observe the following, when performing service
on the accelerator control cable. m NUT — TIGHTEN TO [ T ] IDLER & CRUISE
The retainer must be installed with the tangs 27 N m (20 FT. LBS.) CAM
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| 2 | BRACKET AND PULLEY [ T ] PULLEY

secured over the head of the stud.
I 3 I CRUISE CABLE
The conduit fitting, at both ends of the cable,
f T l ACCELERATOR CABLE 7S3838-6E
must have the locking tangs expanded and
locked into the attaching holes. Figure 4-78 - Control Cable - 2.5L
The braided portion of the cable must not come
into contact with the front of dash sealer
during replacement.
Flexible components (hoses, wires, conduit,
etc.) must not be routed within 50 mm (2
inches) of the moving parts of the accelerator
lin k a g e , u n le ss ro u tin g is p o s itiv e ly
controlled.
4-42 FUEL CONTROL

Accelerator Pedal
Figure 4-81 through 4-87
The accelerator pedal controls the th ro ttle ,
through a cable. There are no linkage adjustments.
The throttle cable must be replaced with an identical
replacement part.
All linkages and cables must be checked, to assure
free movement with no rubbing, chafing, or binding.
The throttle must operate freely, without binding,
between full closed and wide open throttle.
Observe the following, when performing service
on the accelerator pedal.
- The mounting surface between the support
and the dash panel, must be free of insulation.
The carpet and padding in the pedal and

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tunnel area must be positioned to lay flat and
be free of wrinkles and bunches.
- Slip the accelerator control cable through the

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slot in the rod, before installing the retainer in
the rod. Make sure it is seated properly. Use
care in pressing retainer into the hole, so the

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cable is not kinked, or damaged.
- The linkage must operate freely, w ithout
binding, between closed th ro ttle and full

r throttle.
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- W ire, hoses, cable, and o th e r fle x ib le
components, must not be placed within 13 mm
(0.52 inch) of the cable or rod, at any point, in
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their travel.
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P H RETAINER
m LUBRICANT
[Tl THROTTLE LEVER STUD n ~ ] SPRING | T ] PLATE
f T l SPRING
f~2~l ROD [ T ] PIN
[~5~| CABLE
fTl SUPPORT m CABLE [7] PEDAL
7S3791-6E
fTl RETAINER 7S 3836-6E
Figure 4-80 - Control Cable-4.3L& V-8 Figure 4-81 - Accelerator Pedal - ST
 FUEL CONTROL 4-43

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[Tl PEDAL [Tl SUPPORT
[~2l PIN
[Tl SPRING
I 4 | ROD
| T ] CABLE
[ j J RETAINER
| T ] PLATE 7S 3837-6E
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Figure 4-82 - Accelerator Pedal - M
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Figure 4-85 - Accelerator Pedal - G

4-44 FUEL CONTROL

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Figure 4-86 - Accelerator Pedal - P (42)

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rn pin m u rod
m SPRING [ T ] PLATE
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m SUPPORT [ T ] PEDAL
I. 4 | BRACKET 7S3831-6E
Figure 4-87 - Accelerator Pedal - P (32)
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PARTS INFORMATION
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PART NAME GROUP

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Cover, w/Regulator, Fuel Meter:

Part of Meter Kit, F u el............................. 3.734
Injector, Fuel: Part of
Injector Kit, F u e l.......................................... 3.774
Pump, Fuel (In Tank) ................................. 3.990
Relay, Fuel Pump ........................................3.990
Switch, Oil Press............................................ 1.800
Throttle Body Injection Unit ...................... 3.725
Valve Asm, Idle Air Control: Part of
Control Kit, Idle Air V alve...................... 3.820
 EVAPORATIVE EMISSION CONTROL 5-1

SECTION 5
EVAPORATIVE EMISSION CONTROL SYSTEM (EECS)
CONTENTS
GENERAL DESCRIPTION................................. .5-1 FUNCTIONAL T E S T S .....................................5-3
PURPOSE......................................................5-1 Altitude C anister.....................................5-3
OPERATION................................................ .5-1 Tank Pressure Control V a lv e .................. .5-3
Evaporative System 2.5L & 2.8 L ........... 5-1 ON-VEHICLE SERVICE...................................... .5-3
Evaporative System - Except VAPOR CANISTER........................................ 5-3
Altitude 4 .3 L & V 8 ..............................5-2 VAPOR CANISTER H O S E S ........................... .5-3
Evaporative System-Altitude 4.3L & V8 . 5-2 VAPOR P IP E ................................................. ..5-4
Tank Pressure Control Valve .................5-3 Vapor Pipe Repair ...................................5-4
D IA G N O SIS......................................................5-3 FUEL C A P ..................................................... ..5-4

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RESULTS OF INCORRECT O PERATIO N ___ 5-3 PARTS INFORMATION .....................................5-4
VISUAL CHECK OF CANISTER...................... 5-3

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GENERAL DESCRIPTION
PURPOSE

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The Evaporative Emission Control System limits
fuel vapor escape into the atmosphere. The system
(EECS) transfers fuel vapor from a sealed fuel tank,
through a single vapor pipe to an activated carbon
(charcoal) storage device (vapor canister) to store the
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vapors when the vehicle is not operating. When the
engine is running, the fuel vapor is purged from the
carbon element by intake air flow and consumed in
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the normal combustion process.

The fuel tank has a fuel cap that is not vented to
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the atmosphere, but has a valve which allows both

pressure and vacuum relief.
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OPERATION
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Evaporative System
2.5L& 2.8L (Figure 5-5)
as

Fuel vapors from the fuel tank are purged and

flow into the vapor canister tube labeled "fuel tank”
and are absorbed by the carbon. The canister (Figure
5-1) is purged when the engine is running above idle
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speed. A timed vacuum source is applied to the vapor

canister tube labeled "canister purge” to draw fresh
air through the bottom of the canister. The air mixes
with vapor and the mixture is drawn into the intake
manifold to be consumed in the normal combustion
process.

2.8L Only
(Figure 5-6)
This system has a thermostatic vacuum switch
(TVS) installed in the intake manifold coolant passage
to sense engine coolant temperature. This TVS has
two ports and is located between the canister and the
 5-2 EVAPORATIVE EMISSION CONTROL

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Figure 5-2 - Vapor Canister - 4.3L & V8 Figure 5-3 - Vapor Canister - 4.3L & V8 - Altitude
Except Altitude
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TBI unit. When the engine is below 46° C (115° F), the Evaporative System - Altitude
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TVS is closed preventing purge of the canister. When 4.3L & V8 (Figure 5-8)
engine temperature is above 46° C (115° F), the TVS Fuel vapors from the fuel tank are purged and
opens, allowing purge of the canister. flow into the vapor canister tube labeled "fuel tank”
and are absorbed by the carbon. When the canister
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Evaporative System - Except Altitude (Figure 5-3) is purging, fresh air is drawn in through
4.3L& V 8 (Figure 5-7) the air inlet, at the top of the canister. This air flows
Fuel vapors from the fuel tank are purged and to the bottom of the canister and forces the vapors out
flow into the vapor canister tube labeled "fuel tank” the purge line.
and are absorbed by the carbon. The canister (Figure The purge valve is an integral part of the canister.
5-2) is purged when the engine is running above idle When the engine is running, full manifold vacuum is
speed. A timed vacuum source is applied to the vapor supplied to the top tube of the purge valve (Control
canister tube labeled "canister purge” to draw fresh Vacuum Signal) which lifts the valve diaphragm and
air through the air inlet, at the top of the canister. opens the valve. The lower Tube on the purge valve is
This air flows through a tube to the bottom of the connected to a timed port above the TBI throttle valve.
canister and forces the vapors out the purge line. The rate of purge is controlled through this port by
throttle valve location (throttle opening).
 EVAPORATIVE EMISSION CONTROL 5-3

Tank Pressure Control Valve VISUAL CHECK OF VAPOR CANISTER

The Tank Pressure Control Valve (Fig. 5-4), used • Replace vapor canister if cracked or damaged.
only on altitude applications, allows vapors to flow • Replace vapor canister if fuel is leaking from
from the fuel tank into the system. When fuel tank bottom and check operation of the to tal
pressure exceeds the spring pressure on the valve system.
diaphragm (4.3 kPa), the valve opens and allows • Replace filter at the bottom of the canister if
vapors to enter the canister or go directly to the engine dirty, plugged or damaged. (2.5L & 2.8L)
when purge is enabled.
FUNCTIONAL TESTS
Vapor Canister - Altitude Only
Apply a short length of hose to the lower tube of
purge valve, and attempt to blow through it. Little or
no air should pass into the canister. (A small amount

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of air will pass if the canister has a constant purge
hole).

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With hand vacuum pump, apply vacuum (15” Hg.
or 51 kPa) to the control valve tube (upper tube). If
the diaphragm does not hold vacuum for at least 20
seconds, the diaphragm is leaking, and the canister

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must be replaced.
If the diaphragm holds vacuum, again try to blow
arthrough the hose connected to the lower tube while
vacuum is still being applied. An increased flow of air
should be observed. If not, the canister must be
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replaced.

Tank Pressure Control Valve

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1 DIAPHRAGM
2 VENT RESTRICTION Install a short piece of hose on the valve inlet tube
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3 TUBE TO MANIFOLD VACUUM (fuel tank side) and blow into hose. You should feel
4 TUBE TO FUEL TANK the diaphragm pop open and air should pass through
the valve. If the valve does not open, it should be
5 TUBE TO CANISTER
replaced.
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6S2971-6E
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Figure 5-4 Fuel Tank Pressure Control Valve ON-VEHICLE SERVICE

VAPOR CANISTER
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DIAGNOSIS
4*+ Remove or Disconnect
RESULTS OF INCORRECT OPERATION
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1. Hoses from canister. Mark hoses for installation

• Poor idle, stalling and poor driveability can be on new canister.
caused by: 2. Screw from bracket and canister.
Damaged canister
Hoses split, cracked and or, not connected to -►«- Install or Connect
the proper tubes.
1. Canister and bracket screw.
• Evidence of fuel loss or fuel vapor odor can be
2. Hoses to canister.
caused by:
Liquid fuel leaking from fuel lines, fuel pump
VAPOR CANISTER HOSES
or TBI
Cracked or damaged vapor canister
Refer to Vehicle Emission Control Information
Disconnected, misrouted, kinked, deteriorated
Label for routing of canister hoses. When replacing
or damaged vapor pipe, or canister hoses
h oses, use hose id e n tif ie d w ith th e w ord
Air cleaner or air cleaner gasket improperly
"Fluoroelastomer”.
seated.
 5-4 EVAPORATIVE EMISSION CONTROL

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0 VAPOR CANISTER □ FUEL CAP
VAPOR RESTRICTION
□
5-21-86
ra 7S3513-6E
□ CANISTER HOSE
Figure 5-5 Evaporative Emissions Control System Schematic - 2.5L
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VAPOR PIPE 2. Cut ends of pipe remaining on vehicle square with
a tube cutter. Using the first step of a double
The vapor pipe is secured to the underbody with flaring tool, form a bead on the end of both pipe
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clamp and screw assemblies. Flexible hoses are sections. If pipe is too corroded to withstand bead
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connected at the fuel tank and the fuel vapor canister. operation without damage, the pipe should be
The pipe should be inspected occasionally for leaks, replaced. If a new section of pipe is used, form a
kinks, or dents and repaired as required. bead on both ends of it also.
ic

3. Use screw type hose clamp, Part Number 2494772

Vapor Pipe Repair or equivalent. Slide clamps onto pipe and push
hose 2" (51mm) onto each portion of fuel pipe.
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Repair vapor pipe in sections using brazed Tighten clamps on each side of repair.
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seamless steel tubing meeting GM Specification 123M

or its equivalent or hose identified with the words FUEL CAP
"Fluoroelastomer”. Hose not so marked could cause
early failure or failure to meet emission standard. If a fuel tank filler cap requires replacement, use
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• Do not use copper or aluminum tubing to only a cap with the same features. Failure to use the
replace steel tubing. Those materials do not correct cap can result in a malfunctioning of the
have satisfactory durability to w ithstand system.
normal vehicle vibrations.
• Do not use rubber hose within 4" (100mm) of PARTS INFORMATION
any part of the exhaust system or within 10"
(254mm) of the catalytic converter. Hose PART NAME GROUP
inside diam eter m ust match steel tubing
outside diameter. Canister, Fuel Vapor ....................................3.130
1. In repairable areas, cut a piece of fuel hose 4" Valve,Tank Pressure Control .......................3.140
(100mm) longer than portion of the line removed.
If more than a 6 inch (152 mm) length of pipe is
removed, use a combination of steel tubing and
hose so that hose lengths will not be more than 10
inches (254mm).
 EVAPORATIVE EMISSION CONTROL 5-5

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|T 1 TBI UNIT [F FUEL TANK 6 FUELCAP

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7 VAPOR CANISTER
[2~| VAPOR CANISTER |T ] VAPOR RESTRICTION
THERMOSTATIC
E VACUUM SWITCH
5/23/86 [ 5""
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VAPOR PIPE 7S-3512-6E

Figure 5-6 Evaporative Emissions Control System Schematic - 2.8L

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4 VAPOR RESTRICTION 7 VAPOR PIPE

□ TBI UNIT
5 FUEL TANK 8_ FUEL CAP
□ VAPOR CANISTER
I---- 1 AUXILIARY FUEL TANK |---- , rAMICTrD u n c c
5/28/86 ID AIR INLET PH ( R&V SERIES ONLY) Ej CANISTER HOSE 7S-3514-6E

Figure 5-7 Evaporative Emissions Control System Schematic - 4.3L & V8 - Except Altitude
5-6 EVAPORATIVE EMISSION CONTROL

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Figure 5-8 Evaporative Emissions Control System Schematic - 4.3L & V8 - Altitude
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 IGNITION SYSTEM /EST6-1

SECTION 6
IGNITION SYSTEM / EST
CONTENTS
GENERAL DESCRIPTION................................. 6-1 EST PERFORMANCE CHECK ...................... .6-3
PURPOSE.................................................... .6-1 ON-VEHICLE SERVICE..................................... .6-3
OPERATION................................................ .6-1 IGNITION SYSTEM .......................................6-3
Hall Effect Switch ................................. 6-2 SETTING TIMING .........................................6-3
D IA G N O SIS.................................................... .6-2 EST SYSTEM .............................................. .6-8
EST SYSTEM .............................................. .6-2 Hall Effect Switch T e s t ............................6-8
Results of Incorrect EST Operation . . . 6-3 PARTS INFORMATION ................................... .6-8
CODE 42........................................................6-3

GENERAL DESCRIPTION

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PURPOSE

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The ignition system controls fuel combustion by
providing a spark top ignite the compressed air/fuel

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mixture at the correct time. To provide improved
engine performance, fuel economy, and control of
exhaust emission, the ECM controls distributor spark
advance (timing) with the Electronic Spark Timing
(EST) system.
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Only the Electronic Spark Timing (EST) system
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will be described here. Additional information on the
ignition system if found in Section 6D.
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OPERATION
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The ignition system has a distributor module with

four terminals for the EST system (Figure 6-1 and 6-2)
that are connected by the Electronic Control Module
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(ECM).
To properly control ignition/combustion timing,
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the ECM needs to know:

• Crankshaft position
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• Engine speed (rpm)

• Engine load (manifold pressure or vacuum)
• Atmospheric (barometric) pressure
• Engine coolant temperature
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All engines except 2.5LS/T Truck

The EST system consists of the d istrib u to r
module, an ECM, and connecting wires. The four
terminals for EST are lettered in the module.
The distributor four terminal connector is lettered
A-B-C-D.
Figure 6-2 - Module (2.5L S/T Truck)
6-2 IGNITION SYSTEM / EST

These circuits perform the following functions:

• TERMINAL A - Reference Ground Lo
This wire is grounded in the distributor and
makes sure the ground circuit has no voltage drop
which could affect performance. If it is open, it
may cause poor performance.
• TERMINAL B - Bypass
At about 400 rpm, the ECM applies 5 volts to this
circuit to switch spark timing control from the
module to the ECM. An open or grounded by-pass
circuit will set a Code 42 and the engine will run
at base timing, plus a small amount of advance
built into the module.
• TERMINAL C - Distributor Reference Hi
This provides the ECM with rpm and crankshaft

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position information.
• TERMINAL D - EST
This circuit triggers the module. The ECM does

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not know what the actual timing is, but it does
know when it gets the reference signal. It then
advances or retards the spark from that point.

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f T l D ISTRIBU TO R HEI
Therefore, if the base timing is set incorrectly, the MODULE
engine spark curve will be incorrect. |~2~| PICK-UP CO IL

S/T Truck with 2.5L arRT1 H A L L E F F E C T SWITCH

[ T 1 IGNITION C O IL TERM IN ALS
1 5 | EST TERM IN A LS 6S2715
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The EST system consists of a hall effect switch, the
distributor module, an ECM, and connecting wires. Figure 6-3 - Distributor (2.5L S/T Truck)
The four terminal connector is lettered A-B-C-D.
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These circuits perform the following functions: Hall Effect Switch

• TERMINAL A -EST (Figure 6-3)
This circuit triggers the module. The ECM does
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The hall effect switch used on the 2.5L engine for

not know what the actual timing is, but it does S/T Truck is mounted above the pick-up coil in the
know when it gets the reference signal. It then distributor. It takes the place of the reference "R”
advances or retards the spark from that point. terminal on the module. The switch is an electronic
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Therefore, if the base timing is set incorrectly, the device, which puts out a voltage signal controlled by
engine spark curve will be incorrect. the presence or absence of a magnetic field on an
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• TERMINAL B - Distributor Reference Hi electronic circuit. This system tells the ECM which
This provides the ECM with rpm and crankshaft cylinder is next to fire.
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position information.
• TERMINAL C - Bypass DIAGNOSIS
At about 400 rpm, the ECM applies 5 volts to this
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circuit to switch spark timing control from the The description and operation of the ignition
module to the ECM. An open or ground bypass system can be found in Section 6D.
circuit will set a Code 42 and the engine will run Refer to charts in this section for Ignition System
at base timing, plus a small amount of advance Check.
built into the module.
• TERMINAL D - Reference Ground Lo EST SYSTEM
This wire is grounded in the distributor and
makes sure the ground circuit has no voltage drop Code 12 is used during the System Check in
which could affect performance. If it is open, it Section 3 procedure to test the code display ability of
may cause poor performance. the ECM. This code indicates that the ECM is not
receiving the engine rpm (REFERENCE) signal.
The "Reference” signal also triggers the fuel
injection system. Without the "Reference” signal, the
engine cannot run.
 IGNITION SYST EM /EST 6-3

Results of Incorrect EST Operation

The ECM used information from the MAP and

coolant sensors in addition to rpm to calculate spark
advance as follows:
Low MAP output voltage = More spark advance
Cold Engine = More spark advance
High MAP Output Voltage = Less spark advance
Hot engine = Less spark advance
Therefore, detonation could be caused by high
MAP output or low resistance in the coolant sensor
circuit.
Poor performance could be caused by high MAP
output or low resistance in the coolant sensor circuit. f T l TIMING CONNECTOR m ECM
\~4~\ IP. HARNESS
[ T l ELAPSED TIMER
CODE 42

m
MODULE
1/28/86 6S 3035-6E
A fault in the EST system will usually set a Code Figure 6-4 - Timing Connector (2.8L)

co
42, as diagnosed in Section 3.
When the system is running on the distributor SETTING TIMING
module, there is no voltage on the bypass line and the
module grounds the EST signal. The ECM expects to

y.
Set timing according to instructions on Vehicle
see no voltage on the EST line during this condition. Emission Control Information label under the hood.
If it sees a voltage, it sets Code 42 and will not go into Timing specifications for each engine are listed on
the EST mode.
When the rpm for EST is reached (about 400 rpm),
the ECM applies 5 volts to the bypass line and the EST
ar the Vehicle Emissions Control Information label on
the radiator support. When using a timing light,
br
connect an adapter between the No. 1 spark plug and
should no longer be grounded in the module, so the the No. 1 spark plug wire, or use an inductive type
EST voltage should be varying. pickup. Do not pierce the plug lead. Once the
If the bypass line is open, the module will not
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insulation of the spark plug cable has been broken,

switch to test mode, so the EST voltage will be low and voltage will jump to the nearest ground, and the spark
Code 42 will be set. plug will not fire properly. Always follow Vehicle
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If the EST line is grounded, the module will switch Emissions Control Information label procedures when
to EST but, because the line is grounded, there will be adjusting timing.
no EST signal and the engine will not run. A Code 42 Some engines incorporate a m agnetic tim ing
may or may not be set.
c

probe hole for use with special electronic tim ing

An open in the EST circuit will set a Code 42 and equipment. Consult manufacture’s instructions for
si

cause the engine to run on the distributor module use of this equipment.
timing. This will cause poor performance and poor Put the EST system in Bypass Mode on the 2.5L
fuel economy. A ground may set a Code 42, but the
as

engine by connecting terminal "B” to "A” at the ALDL

engine will not run. connector. On the V6 and V8 engines, the system will
go into Bypass Mode by disconnecting the timing
EST PERFORMANCE CHECK connector. This is a single wire sealed connector that
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has a tan with black stripe lead. On the 4.3L and V8

The ECM will set a specified value timing when engine, this connector breaks out of the engine wiring
the ALDL diagnostic terminal is grounded. To check harness conduit adjacent to the distributor. On the
the EST operation, record the timing at 2000 rpm with 2.8L engine, the connector breaks out of a taped
the diagnostic terminal not grounded. Then, ground section below the heater case in the passenger
the diagnostic terminal and the timing should change compartment (Figure 6-4).
at 2000 rpm, indicating that EST is operating.

ON-VEHICLE SERVICE
IGNITION SYSTEM
Refer to Section 6D for On-Vehicle Service of
distributor, pick-up coil, distributor cap, ignition coil,
hall effect switch, rotor, or distributor module.
6-4 IGNITION SYSTEM/EST

ECM
PICK-UP COIL HALL i
EFFECT
SWITCH

423 WHT - D4 _ EST

430 PPL/WHT B5 - REFERENCE
424 TAN/BLK - D5 BYPASS
453 BLK/RED - B3 - GROUND
*3/
EST CONNECTOR
IS 3643

m
IGN 7-8-86

IGNITION SYSTEM CHECK

co
(REMOTE COIL)
2.5L S/T TRUCK

y.
Test Description: Step numbers refer to step 5. Applying a voltage (1.5 to 8 volts) to module
numbers on diagnostic chart.
1. Two wires are checked, to ensure that an open is
not present in a spark plug wire.
ar terminal "P” should turn the module "ON” and the
tach. term, voltage should drop to about 7-9 volts.
This test will determine whether the module or
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1A. If spark occurs with 4 term inal d istrib u to r coil is faulty or if the pick-up coil is not generating
connector disconnected, pick-up coil output is too the proper signal to turn the module "ON”. This
low for EST operation. test can be performed by using a DC battery with a
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2. A spark indicates the problem m ust be the rating of 1.5 to 8 volts. The use of the test light is
distributor cap or rotor. mainly to allow the "P” term inal to be probed
3. Normally, there should be battery voltage at the more easily.
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"C” and " + ” term inals. Low voltage would Some digital multi-meters can also be used to
indicate an open or a high resistance circuit from trigger the module by selecting ohms, usually the
the distributor to the coil or ignition switch. If "C” diode position. In this position, the meter may
c

term, voltage was low, but " + ” term, voltage is 10 have a voltage across its terminals which can be
volts or more, circuit from "C" term, to ignition, used to trigger the module. The voltage in the
si

coil or ignition coil primary winding is open. ohm’s position can be checked by using a second
4. Checks for a shorted module or grounded circuit m eter or by ch eck in g th e m a n u fa c tu re ’s
as

from the ignition coil to the module. The dist. specification of the tool being used.
module should be turned "OFF”, so normal voltage 6. This should turn "OFF” the module and cause a
should be about 12 volts. spark. If no spark occurs, the fault is most likely in
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If the module is turned "ON”, the voltage would be the ignition coil because most module problems
low, but above 1 volt. This could cause the ign. coil would have been found before this point in the
to fail from excessive heat. procedure. A module te ster (J24642) could
With an open ignition coil prim ary winding, a determine which is at fault.
small amount of voltage will leak through the
module from the "Bat.” to the tach terminal. Diagnostic Aids:
The "Scan” tool does not have any ability to help
diagnose a ignition system check.
Refer to Section 2 for "ECM Intermittent Codes or
Performance”.
 IGNITION SYSTEM/EST 6-5

• Perform System Check before proceeding with this test. (If a

© tachometer is connected to the Tach term., disconnect it before
proceeding with the test).
• Check spark at plug with spark tester J-26792 or equivalent (ST-125)
IGNITION SYSTEM CHECK
(REMOTE COIL)
while cranking (if no spark on one wire, check a second wire) A few
sparks and then nothing is considered no spark. 2.5L S/T TRUCK
No Spark Spark
x iz - . : X I
• Disconnect 4 term, distributor Check fuel.spark plugs, etc.
connector and check for spark. See Section 2 symptoms. TEST LIGHT

(5 b TO D C.
No spark Spark 1— ^ - 1 -----POWER SUPPLY
T~... ~ n I (1.5 to 8V)
• Check for spark at coil wire with tester while cranking. Replace pick-up coil
© (Leave spark tester connected to coil wire for Steps 3-6). nnn

m
No Spark Spark
I H
• Disconnect distributor 2 term. "C / + " connector. Inspect cap for water, cracks,
©

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• Ignition switch "on". Engine stopped. etc. If OK, replace rotor. Fig. 1
• Check volts a t " + " and ' C" term's, of dist. harn. conn.

■ ■ — ------------------
Both term's. 10 volts or more Both term's, under 10 volts Under 10 volts “C" term, only

y.
• Reconnect dist. 2 term. conn.
© • With ign. "ON", check voltage from tach. term,
to gnd. (term, may be taped~back in harness).
Repair wire from module " + " term,
to "B" term, of black Ign. coil
ar
connector or primary ckt. to ign. sw.
Check for open or gnd. in ckt.
from "C" term, to ign. coil. If Ckt.
is OK, fault is. ign. coil or conn..

i
Over 10 volts Under 1 volt 1 to 10 volts
br
'i i_:z
• Connect test light from tach. term, to ground. Repair open tach. lead or Replace module and check for
• Crank engine and observe light. conn and repeat test #4. spark from coil as in Step 6.
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Light on steady Spark No Spark

blinks
_JL _ 1
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I
© • Disconnect distributor 4 term, connector.
• Remove dist. cap.
• Disconnect pick-up coil connector from module.
System
OK
Replace ign. coil,
it too is faulty

• Connect voltmeter from tach. term, to ground.

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• Ignition on.
• Insulate a test light probe to 1/4" from tip and note Replace ignition coil and recheck
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voltage, as test light is momentarily connected from a for spark with spark tester. If still
voltage source (1.5 t o 8V)to module term. "P". (Fig. 1). no spark, re-install original coil
and replace dist. module..
as

Voltage drops No drop in voltage

I i ..".t z z :
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© >Check for spark from coil wire with spark tester

as test light is removed from module term.
Check module ground.
If OK, replace module.

I
No Spark Spark

I
• If no module tester (J24642) is available; • If module tester (J24642) Check pick-up coil or conns. (Coil resistance
Replace ign. coil and repeat Step 5. is available: test module should be 500-1500 ohms and not grounded).

I
No Spark Spark OK
TIZI I I
Ign. coil removed is OK, System OK Check coil wire
reinstall coil and check coil from cap to coil. If
wire from dist. cap. if OK, OK, replace coil. 7S 3659
replace dist. module. 7-8-86
 6-6 IGNITION SYSTEM/EST

PICK-UP
COIL,
IGNITION ECM
MODULE
DISTRIBUTOR
GBRE

IGN.
tnran DISTRIBUTOR 4 TERM
CONNECTOR
IGN. COIL ' B 1 b"c d L 423 WHT - D4 EST
GRY.
CONN.
430 PPL/WHT ~ B5 REFERENCE

BLK. :<<- 424 TAN/BLK - D5 - BY-PASS

CONN. SET TIMING
CONNECTOR (EXCEPT 2.5L)

om
-------------------------------- 453 BLK/RED - B3

—□
TACH.LEAD
7S 3642
7-8-86

c
IGNITION SYSTEM CHECK

y.
(REMOTE COIL/ SEALED MODULE CONNECTOR DISTRIBUTOR)
ALL ENGINES EXCEPT 2.5L S/TTRUCK ar
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Test Description: Step numbers refer to step If the module is turned "ON”, the voltage would be
numbers on diagnostic chart. low, but above 1 volt. This could cause the
1. Two wires are checked, to ensure that an open is ignition coil to fail from excessive heat.
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not present in a spark plug wire. With an open ignition coil prim ary winding, a
1A. If spark occurs with EST connector disconnected, small amount of voltage will leak through the
pick-up coil output is too low for EST operation. module from the "Bat.” to the tach terminal.
a

2. A spark indicates the problem m ust be the 5. Checks for an open module, or circuit to it. 12
cc

distributor cap or rotor. volts applied to the module "P” terminal should
3. Normally, there should be battery voltage at the turn the module "ON” and the voltage should drop
"C” and " + ” term inals. Low voltage would to about 7-9 volts.
indicate an open or a high resistance circuit from 6. This should turn "OFF” the module and cause a
si

the distributor to the coil or ignition switch. If "C” spark. If no spark occurs, the fault is most likely
term, voltage was low, but " + ” term, voltage is 10 in the ignition coil because most module problems
as

volts or more, circuit from "C” term, to ignition would have been found before this point in the
coil or ignition coil primary winding is open. procedure. A module tester could determ ine
4. Checks for a shorted module or grounded circuit which is at fault.
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from the ignition coil to the module. The

distributor module should be turned "OFF”, so Diagnostic Aids:
normal voltage should be about 12 volts.
The "Scan” tool does not have any ability to help
diagnose a ignition system check.
Refer to Section 2 for "ECM Intermittent Codes or
Performance”.
 IGNITION SYSTEM/EST 6-7

IGNITION SYSTEM CHECK

© • Perform System Check before proceeding with this test. (If a tachometer is
connected to the Tach term., disconnect it before proceeding with the test).
• Check spark at plug with spark tester J-26792 or equivalent (ST-125) while
(REMOTE COIL/SEALED
cranking (if no spark on one wire, check a second wire) A few sparks and MODULE CONNECTOR
then nothing is considered no spark. DISTRIBUTOR)
I ALL ENGINES
No Spark Spark EXCEPT 2.5L S/T TRUCK
1 mz
• Disconnect 4 term, distributor Check fuel.spark plugs, etc.
connector and check for spark. See Section 2 symptoms. TEST LIGHT

TO D.C.
No spark Spark POWER SUPPLY
I nzz (1.5 to 8V)
• Check for spark at coil wire with tester while cranking. Replace pick-up coil
(Leave spark tester connected to coil wire for Steps 3-6).

m
No Spark Spark
T~ ' nzz
© • Disconnect distributor 2 term. "C / + " connector. Inspect cap for water, cracks,
HUD |U llu U | Fig. 1

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• Ignition switch "on". Engine stopped. etc. If OK, replace rotor.
• Check volts a t " + " and *C" term's, of dist. harn. conn.

■ ■
Both term's. 10 volts or more Both term's, under 10 volts Under 10 volts "C" term, only

y.
© • Reconnect dist. 2 term. conn.
• With ian. "ON", check voltage from tach. term,
to gnd. (term, may be taped oack in harness).
ar Repair wire from module " + " term,
to "B" term, of black Ign. coil
connector or primary ckt. to ign. sw.
Check for open or gnd. in ckt.
from "C" term, to ign. coil. If Ckt.
is OK, fault is. ign. coil or conn..

OverlO volts Under 1 volt 1 to 10 volts

br
I T , i.
• Connect test light from tach. term, to ground. Repair open tach. lead or Replace module and check for
• Crank engine and observe light. conn and repeat test #4. spark from coil as in Step 6.
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Light on steady Light Spark No Spark

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blinks
ZIZ T T
© • Disconnect distributor 4 term, connector.
• Remove dist. cap.
• Disconnect pick-up coil connector from module.
System
OK
Replace ign. coil,
it too is faulty
• Connect voltmeter from tach. term, to ground.
ic

• Ignition on.
• Insulate a test light probe to 1/4" from tip and note voltage, as test light Replace ignition coil and recheck
is momentarily connected from a voltage source (1.5 to 8V) to module for spark with spark tester. If still
s

term. "P".(Fig. 1). no spark, re-install original coil

and replace dist. module..
as

Voltage drops No drop in voltage

1... I
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© • Check for spark from coil wire with spark tester

as test light is removed from module term.
Check module ground.
If OK, replace module.

a.
No Spark Spark

I n
• If no module tester (J24642) is available; • If module tester (J24642) • Is rotating pole piece
Replace ign. coil and repeat Step 5. is available: test module still magnetized?
I
No Spark Spark OK Not OK Yes No
1 --------- I r ~e m H
Ign. coil removed is OK, System OK Check coil wire Replace Check pick-up coil Replace pole
reinstall coil and check coil from cap to coil. If module or conns. (Coil piece and
wire from dist. cap. if OK, OK, replace coil. --------------- resistance should shaft assy.
replace dist. module. be 500-1500 ohms
and not grounded). 7S 3660
7-8-86
6-8 IGNITION SYSTEM /EST

EST SYSTEM
Refer to Section 6D for replacem ent of the
distributor module or hall effect switch.
Refer to Section 3 for repair of the EST wires or
connectors.
Refer to Section 3 for replacement of the ECM.

Hall Effect Switch Test

1. Disconnect and remove hall effect switch from
distributor.
2. Noting polarity marking on the switch, connect a
12 volt battery and voltmeter (Figure 6-5).
3. Voltmeter should read less than 0.5 volts without

om
blade against magnet. Replace switch if above 0.5
volts.
4. With blade against magnet, voltage should be
within 0.5 volts of battery voltage. Replace switch

.c
if there is a low voltage reading.
f T I MAGNET
PARTS INFORMATION [ T l INSERT KNIFE BLADE IN

ry
THIS AREA WITH BLADE
STRAIGHT DOWN AGAINST
PART NAME GROUP THE MAGNET
ra
l~4~1 TERM INAL (UNDERNEATH)
Distributor .................................................... 1.150 I 5 1 BATTERY
Module, D istr.................................................. 2.383 I 6 | VOLTMETER
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Coil, D istr.........................................................2.170
Figure 6-5 - Hall Effect Switch
ar
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as
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 ELECTRONIC SPARK CONTROL 7-1

SECTION 7
ELECTRONIC SPARK CONTROL
ALL ENGINES EXCEPT 2.5L AND 7.4L
CONTENTS
GENERAL DESCRIPTION ON-VEHICLE SERVICE.......................................... 7-1
PURPOSE .................. ESC KNOCK SENSOR........................................ 7-1
OPERATION............. ESC MODULE AND BRACKET ......................... 7-4
DIAG N O SIS.................. PARTS INFORMATION ........................................ 7-4
CODE 43....................
GENERAL DESCRIPTION When the knock sensor detects spark knock, the
module turns "OFF” the circuit to the ECM. The ECM

m
PURPOSE then retards EST to reduce spark knock.

co
The Electronic Spark Control (ESC) system is DIAGNOSIS
designed to retard spark timing up to 20° to reduce
spark knock (detonation) in the engine. This allows Loss of the ESC knock sensor signal or loss of
the engine to use maximum spark advance to improve ground at ESC module would cause the signal to the

.
ry
driveability and fuel economy. ECM to remain high. This condition would cause the
Varying octane levels in today’s gasoline can ECM to control EST as if there was no spark knock.
cause detonation in an engine. Detonation is called No retard would occur, and spark knocking could
spark knock.
ra become severe under heavy engine load conditions.
Spark retard without the knock sensor connected
OPERATION could indicate a noise signal on the wire to the ECM or
lib
a malfunctioning ESC module.
The ESC system has three components: Loss of the ESC signal to the ECM would cause the
• ESC Module ECM to constantly retard EST. This could result in
ar

• ESC Knock Sensor sluggish performance and cause a Code 43 to be set.

• ECM When no Code 43 is present but the ESC system is
The ESC knock sensor (Figure 7-1) detects a possible cause of excessive spark knock, refer to
cc

abnormal vibration (spark knocking) in the engine. diagnosis chart for ESC system check.
The sensor is mounted in the engine block near the
cylinders (Figures 7-2 or 7-3). The ESC module CODE 43
si

receives the knock sensor information and sends a

signal to the ECM. The ECM then adjusts the Code 43 indicates that the ECM is receiving less
electronic spark timing (EST) to reduce spark than 6 volts for a 4 second period with the engine
as

knocking. running. If code is present, refer to Code 43 chart in

The ESC module (Figures 7-4 through 7-6) sends a Section 3.
voltage signal (8 to 10 volts) to the ECM when no
cl

spark knocking is detected by the ESC knock sensor, ON-VEHICLE SERVICE

and the ECM provides normal spark advance.
ESC KNOCK SENSOR
(Figures 7-2 or 7-3)
The ESC Knock Sensor is lcoated to the lower left
of the engine block, below the spark plugs for the 4.3L
engine and the lower right of the engine block for the
2.8L, 5.0L and 5.7L engine.

Remove or Disconnect
B
1. Negative battery cable.
2. Wiring harness connector from ESC knock sensor.
3. ESC knock sensor from engine block.

Figure 7-1 - ESC Knock Sensor

 7-2 ELECTRONIC SPARK CONTROL

ECM 1

ESC
MODULE

= 3
_J
......................._ .. J

m
8-18-86

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ELECTRONIC SPARK CONTROL SYSTEM CHECK
ALL ENGINES EXCEPT 2.5L AND 7.4L

.
Circuit Description:

ry
Electronic spark control is accomplished with a module that sends a voltage signal to the ECM. As the
knock sensor detects engine knock, the voltage from the ESC module to the ECM is shut "OFF” and this signals
the ECM to retard timing, if engine rpm is over about 900.
ra
Test Description: Step numbers refer to step Diagnostic Aids:
numbers in diagnostic chart.
lib
1. If A Code 43 is not set, but a knock signal is "Scan” tools have two positions to diagnose the
indicated while running at 1500 rpm, listen for an ESC system. The knock signal can be monitored to see
internal engine noise. Under a no load condition if the knock sensor is detecting a knock condition and
r

there should not be any detonation, and if knock is if the ESC miodule is functioning, knock signal should
ca

indicated, an internal engine problem may exist. display "yes”, whenever detonation is present. The
2. Usually a knock signal can be generated by knock retard position on the "Scan” displays the
tapping on the right exhaust manifold. This test amount of spark retard the ECM is commanding. The
c

can also be performed at idle. Test number 1 was ECM can retard the timing up to 20 degrees.
run at 1500 rpm to determine if a constant knock If the ESC system checks OK, but detonation is
si

signal was present, which would affect engine the complaint, refer to Detonation/Spark knock in
performance. Section 2.
as

3. This tests whether the knock signal is due to the This check should be used after other causes of
sensor, a basic engine problem, or the ESC spark knock have been checked such as engine timing,
module. EGR systems, engine temperature or excessive engine
4. If the module ground circuit is faulty, the ESC noise.
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module will not function correctly. The test light

should light indicating the ground circuit is OK.
5. Contacting CKT 496, with a test light to 12 volts,
should generate a knock signal to determ ine
whether the knock sensor is faulty, or the ESC
module can’t recognize a knock signal.
 ELECTRONIC SPARK CONTROL 7-3

o m
.c
ry
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ar
cc
si
as
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7-4 ELECTRONIC SPARK CONTROL

P H ESC KNOCK SENSOR

f~2~I HARNESS CONNECTOR 5S1535-6E I~2~l ELECTRICAL CONNECTOR 6S 2896-6E
Figure 7-2 - ESC Knock Sensor - 4.3L Figure 7-4 - ESC Module - ST Series

m
co
y.
f T l ESC KNOCK SENSOR
f T l ELECTRICAL CONNECTOR
ar P T I ESC MODULE
l~2~l ELECTRICAL CONNECTOR 7S 3713-6E
br
6S 2892-6E
Figure 7-3 - ESC Knock Sensor - 2.8L, 5.0L#5.7L Figure 7-5 - ESC Module - CK RV MP Series
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|++| Install or Connect

ca

1. Knock sensor into engine block. Apply water base

calk to sensor threads. Do not use silicon tape as
this will insulate sensor from the engine block.
2. ESC wiring harness connector to the ESC knock
c

sensor.
si

3. Negative battery cable.

ESC MODULE AND BRACKET

as

(Figures 7-4 through 7-6)

|++| Remove or Disconnect
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1. ESC module connector.

2. Attaching screws. P T I ESC MODULE QT| SEAT RISER
3. ESC module. n n ELECTRICAL CONNECTOR 7S 3714.6E
Figure 7-6 - ESC Module - G Series
p+| Install or Connect
1. ESC module. PARTS INFORMATION
2. Attaching screws.
3. ESC module connector. PART NAME GROUP
Sensor, ESC K n o c k ..........................................3.682
Module, Elek Spark C o n t............................... ..2.383
Bracket, Elek Spark Cont M d...........................2.383
Shield, Elek Spark Cont Knock .................... ..2.383
 AIR MANAGEMENT 8-1

SECTION 8
AIR MANAGEMENT SYSTEM
ALL ENGINES EXCEPT 2.5L
CONTENTS
GENERAL DESCRIPTION................................. .8-1 ON-VEHICLE SERVICE ......................................8-3
PURPOSE......................................................8-1 DRIVE B E L T ................................................. ..8-3
AIR OPERATION...........................................8-1 PUMP CENTRIFUGAL FILTER FAN ..............8-3
D IA G N O SIS......................................................8-2 AIR PUMP..................................................... ..8-6
AIR SYSTEM ................................................ .8-2 AIR CONTROL V A L V E ....................................8-6
Air P um p ................................................ .8-3 CHECK V A L V E ...............................................8-6
Check V alve ............................................ 8-3 AIR INJECTION PIPE ASSEMBLY ................ 8-6
Hoses And Pipes..................................... 8-3 PARTS INFORMATION ......................................8-10

m
AIR MANAGEMENT CHECK CH A RT........... 8-5
GENERAL DESCRIPTION

co
PURPOSE

y.
The air management system is used to reduce
carbon monoxide and hydrocarbon emissions.
This system, air injection reaction (AIR), under
certain conditions, adds air (oxygen) to the exhaust
manifold to continue combustion after the exhaust
ar
br
gases leave the combustion chamber. This added air
also brings the catalytic converter up to operating
temperature more quickly when the engine is cold.
I n
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12V
ca

CD A IR PUMP
m EAC V A LV E
CD A IR TO A IR C LE A N E R
c

m A IR TO EAC V A LV E
EEJ AIR TO EXH A U ST PORTS
si

e M ANIFOLD VACUUM SIG N A L

m INJECTION PIPES (7-4L SHOWN. 4.3L, 5 0L
as

'NLET PIPE AT ™ E FR° NT ° F

□H ECM
CIj EAC SOLENOID
[To1 CH ECK V A LV E S
cl

6S2714-6E
Figure 8-2 - AIR System - 4.3L & V8

rn a ir p u m p AIR OPERATION

m
m EAC VALVE
AIR TO AIR CLEANER The system consists of an air pump, an (electric)
air control valve with solenoid, check valve(s), and
[T] AIR TO EAC VALVE
I 5 I AIR TO EXHAUST PORT necessary plumbing.
I 6 [ MANIFOLD VACUUM SIGNAL A belt driven air pump supplies air through a
rri ecm centrifugal filter fan to the electric air control (EAC)
I 8 I EAC SOLENOID valve 2.8L (Figure 8-3) or an electric air control valve
[Tl CHECK VALVE with relief tube (ECT) 4.3L and V8 (Figure 8-4). This
R o l EXHAUST MANIFOLD 6S 3040-6E valve, directs the air to either the engine exhaust
manifold ports or to the air cleaner.
Figure 8-1 - AIR System - 2.8L
8-2 AIR MANAGEMENT

NOTICE: On the EAC valve, the divert and signal

tube locations are reversed from the
previous model year.

When the engine is cold or in wide open throttle

condition, the ECM energizes the solenoid on the
valve and air is directed to the exhaust manifold ports.
When the coolant temperature increases, the solenoid
is de-energized and air goes into the air cleaner which
also acts as a silencer. At higher engine speeds, air is
directed to the air cleaner through the pressure relief
valve even though the solenoid may be energized.
There should be n o air going to the exhaust ports
while operating in the "Closed Loop” mode.
During engine decel, when there is a rise in the

m
manifold vacuum signal, air is directed to the air
cleaner.
A Check valve, on the air injection pipe, prevents

co
m ELECTRIC AIR m DIVERT ASSIST
back flow of exhaust into the air pump if there is an CONTROL VALVE WITH ORIFICE
exhaust backfire or pump drive belt failure. RELIEF TUBE DIAPHRAGM & GUIDE
m OUTLET SEAT ASSEM BLY
If the engine is operating under a rich condition or

y.
m METERING VALVE m DIAPHRAGM SPRING
the "Service Engine Soon” lamp lights, the solenoid is CHAMBER VACUUM CHAMBER
de-energized and air goes to the air cleaner. ca RELIEF VALVE &
BODY ASM GD MANIFOLD VACUUM
arm
m
PRESSURE PASSAGE
BAND — CLAMP
rnn
SIGNAL TUBE
DIAPHRAGM COVER
ASSEM BLY
7S 3613-6E
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Figure 8-4 - ECT Valve
DIAGNOSIS
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AIR SYSTEM
ca

Refer to Air Management Check ch art for the

diagnosis of the AIR System.
c

NOTICE: If the engine or underhood compartment is

si

to be cleaned with steam or high-pressure

detergent, the centrifugal filter fan should
be masked off to prevent liquids from
as

entering the pump.

If no air (oxygen) flow enters the exhaust stream at

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the exhaust ports, HC and CO emission levels may be

too high.
PH ELEC T R IC AIR C O N T R O L □ F ] D E C E L TIM IN G C H A M B ER Air flowing to the exhaust ports at all times could
(EA C ) V A LV E p H A |R TO AIR C LEA N ER cause a ric h ECM com m and and in c re a s e d
m D E C E L TIM IN G A S S EM B L Y ■
p8~] AIR FRO M AIR PUM P temperature of the converter.
fTl M A N IFO LD V A C U U M | 9 1 AIR TO EX H A U S T PORTS The AIR System is not completely noiseless. Under
SIG N A L TU B E O R M A N IFO LD
normal conditions, noise rises in pitch as engine speed
r~4~] E L E C T R IC A L TER M IN A L [~To~| P R ESSU R E R ELIEF
increases. To determine if excessive noise is the fault
[ J ] E A C SO LEN O ID A SSEM BLY __
6S 2609-6E of the AIR System pump, momentarily operate the
engine with the pump drive belt removed.
Figure 8-3 - EAC Valve
 AIR MANAGEMENT 8-3

If noise is caused by the AIR System pump, check ON-VEHICLE SERVICE

fo r:
• A seized air pump. DRIVE BELT
• Proper mounting and bolt torque of pump.
• Proper routine and connections of hoses. Remove or Disconnect
NOTICE: Do not oil air pump. Inspect drive belt for wear, cracks or deterioration
and replace if required. When installing new belt,
• Replace pump if there is excessive noise. it must be seated and fully secured in grooves of
A/C com pressor, a ir pump, g e n erato r, and
Air Pump crankshaft pulleys.
The air pump is a positive displacement vane type PUMP CENTRIFUGAL FILTER FAN
which is permanently lubricated and requires no
periodic maintenance. The centrifugal filter fan should not be cleaned,
Accelerate engine to approximately 1500 rpm and either with compressed air or solvents.

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observe air flow from hose. If air flow increases as
engine is accelerated, pump is operating satisfactorily. CAUTION: C e n t r i f u g a l fa n s h o u l d n o t b e
If air flow does not increase or is not present, proceed re m o v e d from p u m p u n le ss it is
as follows: dam aged, as rem oval will d e stro y

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the fan.
Inspect
Before starting replacement note the following:

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1. For proper drive belt tension.
• Do not allow any filter fragments to enter the air
2. For a leaky pressure relief valve. Air may be heard
pump intake hole.
leaking with the pump running.
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Check Valve between pump and filter fan. Air damage to
sealing lip pump will result.
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Inspect • Do not remove metal drive hub from filter fan.
• It is seldom possible to remove the filter fan
1. A check valve should be inspected whenever the without destroying it.
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hose is disconnected from it or whenever check

valve failure is suspected (A pump that had |++| Remove or Disconnect
become inoperative and had shown indications of
Figure 8-5
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having exhaust gases in the pump would indicate

check valve failure). 1. Air pump.
2. Remove the check valve.
2. Pump pulley.
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3. Blow through the check valve tow ard the 3. Insert needle nose pliers and pull filter fan from
exhaust manifold side. Air should pass freely. pump hub.
Turn the valve around and attem pt to blow
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through the valve toward the air pump side. No

Install or Connect
air should pass through the valve.
4. Replace valve which does not operate properly. 1. New filter fan on pump hub.
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2. Spacer and pump pulley against centrifugal

Hoses and Pipes filter fan.
3. Pump pulley bolts and tighten equal to torque
Inspect spec, in Figure 8-6. This will compress the
centrifugal filter fan onto the pump hole. Do not
l. Hose or pipe for deterioration or holes. drive filter fan on with a hammer. A slight
2. All hoses or pipe connections, and clamp amount of interference with the housing bore is
tightness. normal. After a new filter fan has been installed,
3. Hose or pipe routing. Interference may cause it may squeal upon initial operation or until O.D.
wear. sealing lip has worn in. This may require a short
4. If a leak is suspected on the pressure side of the period of pump operation a t various engine
system, or if a hose or pipe has been disconnected speeds.
on the pressure side, the connections should be 4. Air pump.
checked for leaks with a soapy water solution.
With the pump running, bubbles will form if a
leak exists.
8-4 AIR MANAGEMENT

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AIR MANAGEMENT CHECK
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(ELECTRONIC AIR CONTROL VALVE)

Circuit Description:
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An electric air control valve solenoid directs air into the exhaust ports or the air cleaner. During cold start
on all systems except 2.8L Federal engines, the ECM completes the ground circuit, the EAC solenoid is
energized, and air is directed to the exhaust ports. As "coolant” temperature increases, or system goes to
"Closed Loop”, the ECM opens the ground circuit, the EAC solenoid is de-energized, and air goes to the air
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cleaner.
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On 2.8L Federal engines, the ECM completes the ground circuit, the EAC solenoid is energized, and the
valve directs air to the exhaust port whenever the engine is started. The only time the air is directed to the air
cleaner, is during decel. If the system is not operating properly, check manifold vacuum signal (10”Hg/34kPa)
as

at the valve and check the electrical circuit from the solenoid to the ECM.
Test Description: Step numbers refer to step 3. Checks for an open control circuit. Grounding
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numbers on diagnostic chart and to all systems except diagnostic terminal will energize the solenoid, if
the 2.8L Federal engine. ECM and circuits are normal. In this step, if test
1. This is a system performance test. When vehicle light is "ON”, circuits are normal and fault is in
goes to "Closed Loop”, air will switch from the valve connections or valve.
ports and divert to the air cleaner. 4. Checks for voltage from battery through a fuse to
2. Tests for a grounded electric divert circuit. the solenoid.
Normal system light will be "OFF”.
 AIR MANAGEMENT 8-5

AIR MANAGEMENT CHECK

(ELECTRONIC AIR CONTROL VALVE)

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7-23-86
*6S 2839-6EB
8-6 AIR MANAGEMENT

it may squeal upon initial operation or until O.D.

sealing lip has worn in. This may require a short
period of pump operation a t various engine
speeds.
6. Pump drive belt and adjust.
7. Check air m anagem ent system for proper
operation (see Air Management Check chart).

AIR CONTROL VALVE

(Figures 8-7 thru 8-11)
4--4 Remove or Disconnect
l. Battery ground cable.
2. Electrical connector on control valve.

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3. Manifold vacuum signal hose.
4. Air inlet and outlet hoses from valve.
5. Control valve.
fT~| AIR PUMP
|~2~| PU LLEY BOLT •44- Install or Connect

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TIGHTEN TO
10 N-m 1. Control valve.
(90 IN. LBS.)
2. Air inlet and outlet hoses to valve.

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[~3~1 PU LLEY
3. Manifold vacuum signal hose.
[ T ] FILTE R FAN
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4.
5.
6.
Electrical connector on control valve.
Battery ground cable.
Check system operation (See Air Management
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04 13 84 5S 1616-6E Check chart).
Figure 8-5 - Pump Filter Fan Service
CHECK VALVE
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(Figures 8-7 thru 8-11)

AIR PUMP (Figure 8-6)
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4-4 Remove or Disconnect

Remove or Disconnect
□
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1. Any parts required for access.

l. Hold pump pulley from turning by compressing 2. Release clamp and disconnect air hoses from
drive belt, then loosen pump pulley bolts. check valve.
Loosen bolt, holding pump to mounting brackets, 3. Unscrew check valve from air injection pipe.
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release tension on drive belts.

3. Move belts out of the way, then remove pump Install or Connect
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hoses, vacuum and electrical connections, and

control valve. 1. Screw check valve onto air injection pipe.
4. Pulley, then pump. 2. Position air hose on check valve and secure with
5. If required, insert needle nose pliers and pull clamp.
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filter fan from hub (see Figure 8-5). 3. Any parts removed for access.

Install or Connect AIR INJECTION PIPE ASSEM BLY

1. Air pump assembly, and tighten mounting bolts. Remove or Disconnect
2. Hose.
3. New filter fan on pump hub. 1. Hose.
4. Spacer and pump pulley against centrifugal 2. Check Valve.
filter fan. 3. Nuts attaching pipes-to-manifold.
Pump pulley bolts and tighten equally to torque 4. Pipe Assembly.
spec, in Figure 8-6. This will compress the
centrifugal filter fan onto the pump hole. Do not Install or Connect
drive filter fan on with a hammer. A slight 1. Nuts attaching pipes-to-manifold.
amount of interference with the housing bore is 2. Check Valve.
normal. After a new filter fan has been installed, 3. Hose.
 AIR MANAGEMENT 8-7

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f T l AIR PUMP □ □ BRACE [ T ] BOLT - TORQUE TO 30 N m (22 FT. LBS.)

\J~ \ PULLEY [ ¥ ] SUPPORT R o l BOLT - TORQUE TO 40 N m (29 FT. LBS.)
m SPACER [ T ] BOLT - TORQUE TO 15 N m (11 FT. LBS.) Q T ] BOLT - TORQUE TO 80 N m (59 FT. LBS.)
fTl BRACKET [T] BOLT - TORQUE TO 25 N m (18 FT. LBS.) QH NUT - TORQUE TO 30 N m (22 FT. LBS.)
7S 3615-6E
Figure 8-6 - AIR Pump Mounting
8-8 AIR MANAGEMENT

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n ~| AIR PUMP [ j ] AIR INJECTION PIPE — TIGHTEN NUTS TO 28 N m (20 FT. LBS.)
f T l SILENCER [ T ] BOLT — TIGHTEN TO 25 N m (18 FT. LBS.)
[Tl EAC VALVE
f T l HOSE
I 5 | CHECK VALVE — TIGHTEN TO 85 N m (26 FT. LBS.)
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[T] GASKET
| T ] SHIELD
[To] PORT VACUUM HARNESS 6S 2897-6E
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Figure 8-7 - A IR System - 2.8L
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fTl AIR PUMP [T] DIVERTER VALVE OR EAC VALVE

[Tl ADAPTER AND SEAL - TIGHTEN SCREWS TO 25 N m (18 FT. LBS.) [ ] [ ] AIR CLEANER
fTl AIR INJECTION PIPE — TIGHTEN NUTS TO 28 N m (20 FT. LBS.) [T] BOLT - TIGHTEN TO 34 N m (25 FT. LBS.)
[Tl CHECK VALVE - TIGHTEN TO 25 N m (18 FT. LBS.) 7S 3309-6E
Figure 8-8 - A IR System - 4.3L - G & M Series
 AIR MANAGEMENT 8-9

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NOTE: ON SOME VEHICLES THE EAC VALVE IS MOUNTED ON THE PUMP ADAPTER

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P7~[ A |R pUMp |T] DIVERTER VALVE OR EAC VALVE
[ T l ADAPTER AND SEAL - TIGHTEN SCREWS TO 25 N m (18 FT. LBS.) [T ] AIR CLEANER
| 3 | AIR INJECTION PIPE — TIGHTEN NUTS TO 28 N m (20 FT. LBS.) [T ] BOLT - TIGHTEN TO 34 N m (25 FT. LBS.)
m CHECK VALVE - TIGHTEN TO 35 N m (26 FT. LBS.)
ar [T ] NUT - TIGHTEN TO 34 N m (25 FT. LBS.)
7S 3412-6E
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Figure 8-9 - A IR System - 4.3L. 5.0L, 5.7L - C, K, P, R, & V Series
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| -| | AIR PUMP 1 5 1 DIVERTER VALVE OR EAC VALVE

[Tl ADAPTER AND SEAL - TIGHTEN SCREWS TO 25 N m (18 FT. LBS.) |jF] AIR CLEANER
[Tl AIR INJECTION PIPE — TIGHTEN NUTS TO 28 N m (20 FT. LBS.) [T] BOLT - TIGHTEN TO 3 N m (26 IN. LBS.)
[~4~l CHECK VALVE - TIGHTEN TO 25 N m (18 FT. LBS.) 7S

Figure 8-10 - A IR System - 5.0L, 5.7L - G Series

 8-10 AIR MANAGEMENT

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PARTS INFORMATION
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PART NAME GROUP

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Adapter, AIR Inj Cont V l v ...............................3.671

Bracket, AIR Inj Pump Supt ........................ ..3.655
Bracket, AIR Inj Pum p................................... ..3.655
Fan, AIR P u m p .............................................. ..3.665
Gasket, AIR Inj Dvtr Vlv E l .......................... 3.671
Harness, AIR Inj Cont Vlv V ac...................... 3.675
Hose, AIR Inj Cont V lv................................... 3.675
Hose, AIR Inj Cont Vlv D v tr.......................... ..3.675
Pulley, AIR Inj P um p..................................... ..3.650
Pump, AIR I n j ................................................ ..3.660
Valve, AIR Inj C o n t....................................... ..3.670
Valve, AIR Inj Eng C h k ................................. 3.670
Valve, AIR Inj Control (Divert)...................... 3.670
Valve, AIR Inj Sw itching...............................3.670
 EXHAUST GAS RECIRCULATION 9-1

SECTION 9
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
CONTENTS
GENERAL DESCRIPTION................................. 9-1 DIAG N O SIS..................................................... ..9-3
PURPOSE .................................................. 9-1 RESULTS OF INCORRECT O PERA TIO N ___ 9-3
OPERATION .............................................. .9-1 SYSTEM C H E C K .......................................... ..9-3
EGR CONTROL ...........................................9-1 ON-VEHICLE SERVICE ......................................9-3
TYPES OF EGR VALVE ................................9-2 EGR VALVE ................................................. ..9-3
Port V a lv e .............................................. .9-2 EGR Manifold P assage........................... 9-8
Negative Backpressure V a lv e ................9-2 EGR SYSTEM H O SES......................................9-9
EGR VALVE IDENTIFICATION ..................9-2 EGR SOLENOID .......................................... ..9-10
PARTS INFORMATION ......................................9-10

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GENERAL DESCRIPTION
PURPOSE
The EGR system is used to lower NOx (oxides of

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nitrogen) emission levels caused by high combustion
temperatures. The EGR valve feeds small amounts of

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exhaust gas back into the combustion chamber to
decrease combustion temperature.
The main element of the system is an EGR valve
operated by vacuum, and mounted on the intake
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manifold.

OPERATION
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The EGR valve is opened by vacuum to let exhaust

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gas flow into the intake manifold. The exhaust gas

then moves with the air/fuel m ixture into the
combustion chamber. If too much exhaust gas enters,
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combustion will not occur. For this reason, very little

exhaust gas is allowed to pass through the valve, f T l EGR VALVE [ T l AIR BLEED
especially at idle. The EGR valve is usually open
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[ T l PINTLE VALVE HOLE

under the following conditions:
□ D INTAKE AIR I T ] SMALL SPRING
• Warm engine operation
[3D
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• Above idle speed VACUUM PORT m LARGE SPRING

EGR CONTROL
HID DIAPHRAGM 6S 2608-6E
Figure 9-1 - Negative Backpressure EGR Valve 2.5L,
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4.3L, 5.0L& 5.7L (under 8500 GVW)

2.5L, 4.3L, 5.0L & 5.7L (under 8500 GVW)
EVRV 2.8L, 7.4L & 5.7L (over 8500 GVW)
To regulate EGR flow an ECM controlled solenoid
is used in the vacuum line. This is a normally closed To regulate EGR flow, an ECM co n tro lled
solenoid vacuum valve which is opened when the ECM Electronic Vacuum Regulator Valve (EVRV) solenoid
completes the ground. The ECM will energize the is used in the vacuum line. The ECM uses information
EGR solenoid (EGR "ON”) when the engine is warm from the following sensors to regulate the solenoid:
and above idle, but not at wide open throttle due to • Coolant Temperature
lack of vacuum. • Throttle Position (TPS)
2.5Lonly • P/N switch
On cold engine start-up the ECM receives input • Distributor (rpm Signal)
from the MAT sensor (Manifold Air Temperature), The EGR vacuum control has an EVRV solenoid that
and if the MAT reading is less than 12° C (57° F) the uses "pulse width modulation". This means the ECM
EGR solenoid is off until the coolant warms to 80° C turns the solenoid "ON” and "OFF” many times a
(176°F). If there is a malfunction of the MAT sensor second and varies the amount of "ON" time ("pulse
then the ECM receives input from the coolant sensor. width") to vary the amount of EGR.
9-2 EXHAUST GAS RECIRCULATION

TYPES OF EGR VALVES

Two types of EGR valves are used on these
engines:
• Ported (2.8L, 7.4L & 5.7L) (over 8500 GVW)
• Negative backpressure (2.5L, 4.3L, 5.0L &
5.7L) (under 8500 GVW)

Port EGR Valve

This valve is controlled by a flexible diaphragm

which is spring loaded to hold the valve closed. Ported
vacuum applied to the top side of the diaphragm
overcomes the spring pressure and opens the valve in
the exhaust gas port. This allows exhaust gas to be

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pulled into the intake manifold and enter the engine
cylinders.

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[T] EGR V ALVE [T] MAP SENSOR
l~2] EXHAUST GAS [ T ] COOLANT TEMPERATURE
[ T ] INTAKE AIR SENSOR

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R H DIAPHRAGM H P0SITI0N
1---- 1 SENSOR
m MANIFOLD VACUUM ----- -
ar H VACUUM S O L E N C D ^ f e S j U S 01" 0 C ° N TR° L

6 S 2861-6E
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Figure 9-3 - EGR System - with Solenoid
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P H EGR VALVE [ 5 | DIAPHRAGM

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[ 2 | EXHAUST GAS f T l VALVE OPEN

[ 3 | INTAKE AIR F T ] VALVE CLOSED
[~4l VACUUM PORT f T l SPRING 4S 0536-6E
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Figure 9-2 Port EGR Valve

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2.8L, 7.4L & 5.7L(over 8500 GVW)

Negative Backpressure EGR Valve fTl ASSEMBLY PLANT CODE

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|~~2~| PART NUMBER

The negative backpressure EGR valve has the f T l DATE BUILT
bleed valve spring below the diaphragm, and the valve n r 1LOOK HERE FOR LETTER
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P = POSITIVE BACK PRESSURE

is normally closed. The negative backpressure valve N = NEGATIVE BACK PRESSURE
varies the amount of exhaust gas flow into the BLANK = PORTED VALVE 7S3219-6E
m anifold depending on m anifold vacuum and
variations in exhaust back pressure. Figure 9-4 - EGR Valve Identification
The diaphragm on this valve has an internal air
bleed hole which is held closed by a small spring when EGR VALVE IDENTIFICATION
there is no exhaust backpressure.
Engine vacuum opens the EGR valve against the • Positive backpressure EGR valves will have a "P"
pressure of a large spring. When manifold vacuum stamped on the top side of the valve after the part
combines with negative exhaust backpressure, the number.
vacuum bleed hole opens and the EGR valve closes. • Negative backpressure EGR valves will have a
This valve will open if vacuum is applied with the "N" stamped on the top side of the valve after the
engine not running. part number.
• Port EGR valves have no identification stamped
after the part number.
 EXHAUST GAS RECIRCULATION 9-3

DIAGNOSIS
RESULTS OF INCORRECT OPERATION
With too much EGR flow at idle, cruise, or cold
operation, any of the following conditions may occur:
• Engine stops after cold start.
• Engine stops at idle after deceleration.
• Vehicle surges during cruise.
• Rough idle.
If the EGR valve should stay open all of the time,
the engine may not idle.
Too little or no EGR flow allows combustion
temperatures to get too high during acceleration and fTl EGR VALVE [Tl MANIFOLD VACUUM
load conditions. This could cause: fTl VACUUM HARNESS (PORT-F)

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f T l BOLT-TIGHTEN
• Spark knock (detonation). fTl EGR SOLENOID TO 2 N m (18 IN. LBS.)
• Engine overheating. 7S 3029-6E
Figure 9-5 - EGR & Solenoid (2.5L)

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SYSTEM CHECK
Diagnosis of the EGR system is covered in the

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following charts. These charts begin on page 9-4.
• EGR System Check on a 2.5L, 4.3L, 5.0L & 5.7L
(under 8500 GVW) engine.
• EGR System Check on a 2.8L, 7.4L & 5.7L (over
8500 GVW) engine.
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EGR Vacuum Switch and Solenoid
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Refer to Code 32 CHART (2.8L engine) for

diagnosis of the vacuum switch and solenoid
assembly.
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fTl
EGR Vacuum Control m EGR VALVE
VACUUM HARNESS
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fTl EGR VACUUM SWITCH & SOLENOID

Refer to EGR System Check for diagnosis of the l~4~l PORTED MANIFOLD VACUUM 6S 2g;
vacuum solenoid. Figure 9-6 - EGR, Switch, & Solenoid (2.8L)
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ON-VEHICLE SERVICE
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EGR VALVE
B Remove or Disconnect
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1. Air Cleaner.
2. EGR valve vacuum tube at valve. (Figure 9-5
to 9-10).
3. Bolts or nuts.
4. EGR valve from manifold. (Figures 9-11 to 9-
15)
fTl [T] BOLT—TIGHTEN
-►4- Important
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[Tl
EGR VALVE
VACUUM HARNESS ,-----, TO 2 N m (18 IN. LBS.)
EGR SOLENOID
HARNESS CONNECTOR
H I MANIFOLD VACUUM
Do not wash EGR valve in solvents or degreaser - (PORT-J) 7S 3459-6E
permanent damage to valve diaphragm may result.
Figure 9-7 - EGR & Solenoid (4.3L)
9-4 EXHAUST GAS RECIRCULATION

TO EGR VALVE
MANIFOLD
M -------- = VACUUM

IGN EGR SOLENOID

N.C.

— 39 -
PNK/BLK

7S 3737-6E

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8-18-86 7-23-86

EGR SYSTEM CHECK

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2.5L, 4.3L, 5.0L & 5.7L (UNDER 8500 GVW)
Circuit Description:

.
The ECM operates a solenoid to control the Exhaust Gas Recirculation (EGR) valve. This solenoid is

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normally closed. By providing a ground path, the ECM energizes the solenoid which then allows vacuum to pass
to the EGR valve. The ECM control of the EGR is based on the following inputs:
• Engine coolant temperature - above 25°C.
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• TPS - "OFF” idle
• MAP
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If Code 24 is stored, use that chart first.

Test Description: Step numbers refer to step Diagnostic Aids:

numbers on diagnostic chart.
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1. Checks for solenoid stuck open. • Before replacing ECM, use an ohmmeter and
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2. Checks for solenoid always being energized. check the resistance of each ECM controlled relay
3. Grounding test terminal should energize solenoid and solenoid coil. See ECM wiring diagram for
and vacuum should drop. coil term. I.D. of solenoid(s) and relay(s) to be
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4. Negative backpressure valve should hold vacuum checked. Replace any solenoid where resistance
with engine "OFF”. measures less than 20 ohms.
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5. When engine is started, exhaust backpressure

should cause vacuum to bleed off and valve to fully
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close.
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 EXHAUST GAS RECIRCULATION 9-5

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9-6 EXHAUST GAS RECIRCULATION

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EGR SYSTEM CHECK

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2.8L, 7.4L & 5.7L (OVER 8500 GVW)
Circuit Description: ar
The EGR valve is controlled by a normally closed solenoid (allows a vacuum to pass when energized). The
ECM pulses the solenoid to turn "ON” and regulate the EGR. On 2.8L engine, the ECM monitors vacuum to the
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EGR with the EGR vacuum switch. On 5.7L & 7.4L, the ECM diagnoses the system using an internal EGR test
procedure.
Code 32 will detect a faulty solenoid, vacuum switch (2.8L), vacuum supply, or EGR Valve (5.7L & 7.4L).
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This chart checks for plugged EGR passages, a sticking EGR valve, or a stuck open or inoperative solenoid.
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Test Description: Step numbers refer to step Diagnostic Aids:

numbers on diagnostic chart.
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1. With the ignition "ON”, engine stopped, the • Before replacing ECM use ohmmeter and check
solenoid should not be energized and vacuum resistance of each ECM controlled relay and
should not pass to the EGR valve. solenoid coil.
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2. Grounding the diagnostic terminal will energize See ECM wiring diagram for coil te rm in a l
the solenoid and allow vacuum to pass to valve. identification of solenoid(s) and relay(s) to be
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3. Checks for plugged EGR passages. If passages are checked.

plugged, the engine may have severe detonation Replace any relay or solenoid if the coil resistance
on acceleration. measures less than 20 ohms.
4. The EGR solenoid will not be energized in Park or
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N eu tral. T his te s t w ill d e te rm in e if the

Park/Neutral switch input is being received by the
ECM.
 EXHAUST GAS RECIRCULATION 9-7

EGR SYSTEM CHECK

2.8L, 7.4L & 5.7L (OVER 8500 GVW)
ASSUMES NO CODE 32 IS STORED

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7S 3740
CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7-23-86
9-8 EXHAUST GAS RECIRCULATION

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m EGR VALVE
[ T l VACUUM HARNESS m VACUUM HARNESS
H I EGR SOLENOID (MOUNTED ON TOP SIDE OF m EGR SOLENOID (MOUNTED ON TOP SIDE OF

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BRACKET ON G-SERIES) BRACKET ON G-SERIES)
m MANIFOLD VACUUM (PORT-J) m PORTED MANIFOLD VACUUM (PORT-S)
|~5~1 BOLT—TIGHTEN TO 2 N m (18 IN. LBS.) BOLT—TIGHTEN TO 2 N m (18 IN. LBS.)
m
m HARNESS CONNECTOR
ram HARNESS CONNECTOR
m BRACKET BRACKET
7S 3460-6E 7S 3461-6E
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Figure 9-8 - EGR & Solenoid Figure 9-9 - EGR & Solenoid (5.7L over 8500 GVW)
(5.0L & 5.7L under 8500 GVW)
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Also, sand blasting of the valve is not recommended

since this can affect the operation of the valve.
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EGR Manifold Passage

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If EGR passage indicates excessive build-up of

deposits, the passage should be cleaned. Care should
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be taken to ensure th a t all loose particles are

completely removed to prevent them from clogging the
EGR valve or from being ingested into the engine.
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H I EGR VALVE [ T ] PORTED MANIFOLD

Ie B Clean
f~2~1 VACUUM HARNESS .-----. VACUUM (PORT-S)
HARNESS CONNECTOR
1. With a wire wheel, buff the exhaust deposits from IT 1 EGR SOLENOID *-----*
the mounting surface and around the valve. 7S 3462-6E
2. Look for exhaust deposits in the valve outlet. Figure 9-10 - EGR & Solenoid (7.4L)
Remove deposit build-up with a screwdriver.
3. Clean mounting surfaces of intake manifold and
valve assembly.
 EXHAUST GAS RECIRCULATION 9-9

fTl EGR VALVE

fTl GASKET

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[~3~| STUD
m NUT-TIGHTEN TO 20 N m (15 FT. LBS.) 7

Figure 9-14 - EGR Valve (5.0L & 5.7L)

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m EGR VALVE D U EGR VALVE

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fTl GASKET l~2~l GASKET

i 3 | BOLT-TIGHTEN TO 25 N m (18 FT. LBS.) 6 S 2899-6E: [ T ] BOLT—TIGHTEN TO 25 N m (18 FT. LBS.) 7S 3458-6E

Figure 9-12 - EGR Valve (2.8L) Figure 9-15 - EGR Valve(7.4L)

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Install or Connect
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1. EGR valve to manifold.

2. Bolts or nuts.
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3. Vacuum tube to valve.

4. Air cleaner.

SYSTEM HOSES
Refer to Vehicle Emission Control Information
NOTE: M VAN
USES BOLTS label for routing of system hoses.
TO RETAIN VALVE When replacing hoses, use hose identified with the
m EGR VALVE
word "Fluoroelastromer”.
m GASKET
|~3~| STUD
[T l NUT-TIGHTEN TO 20 N m (15 FT. LBS.) 7 S 3456-6E

Figure 9-13 - EGR Valve (4.3L)

9-10 EXHAUST GAS RECIRCULATION

EGR VACUUM SWITCH AND SOLENOID EGR VACUUM SOLENOID

2.8L, 7.4L & 5.7L (over 8500 GVW) 2.5L, 4.3Lf 5.0L 8t 5.7L (under 8500 GVW)
Figure 9-16 Figure 9-17
|++| Remove or Disconnect Remove or Disconnect
l. Negative battery cable. 1. Negative battery cable.
2. Air cleaner, if necessary. 2. Electrical connector at solenoid.
3. Electrical connector at solenoid. 3. Vacuum hoses.
4. Vacuum hoses. 4. Bolt(s) and solenoid.
5. Bolt(s) and solenoid.
6. Filter, if required. +4- Install or Connect

♦I Install or Connect 1. Solenoid. See Figures 9-5 thru 9-10 for torque
specification.
l. Filter, if required. 2. Vacuum hoses

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2. Solenoid. Tighten bolts to 3. Electrical connector.
24 N*m (17 ft. lbs). 4. Negative battery cable.

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3. Vacuum hoses.
4. Electrical connector.
5. Air cleaner, if removed
6. Negative battery cable.

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EGR FILTER REPLACEMENT
(SHOULD BE DONE EVERY 30,000 MILES)
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1. Grasp and pull filter off with a rocking motion.
2. Push new filter on making sure cut-out for
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wires is properly aligned.
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(2.5L, 4.3L, 5.0L & 5.7L Under 8500 GVW)

PARTS INFORMATION
0 ELECTRICAL CONNECTOR
PARTS NAME GROUP
0 VACUUM CONNECTOR FROM SOURCE
Valve, EGR ................................................. 3.670
0 VACUUM CONNECTOR TO EGR VALVE Solenoid, EGR contVLVRLY ....................
Solenoid, EGR C o n t......................................
3.670
3.670
5-3-85 *6S 2687-6E Gasket, EGR V a lv e ...................................... 3.680
Figure 9-16 EGR Control Solenoid
(2.8L, 7.4L, & 5.7L) (Over 8500 GVW)
 TRANSMISSION CONTROLS 10-1

SECTION 10
AUTOMATIC AND MANUAL TRANSMISSION CONTROLS
CONTENTS
GENERAL DESCRIPTION............................... 10-1 MANUAL TRANSMISSION SHIFT
AUTOMATIC TRANSMISSION .............. ___ 10-1 LIGHT CHECK.................................
TCC System ................................. D IA G N O SIS............................................
O peration............................... TCC SYSTEM ......................................
Downshift Control...................... DOWNSHIFT CONTROL SYSTEM ___ . . . 10-10
MANUAL TRANSMISSION............... SHIFT LIGHT S Y S T E M ......................................
Shift Light System ..................................... ON-VEHICLE SERVICE.............................
TCC ELECTRICAL DIAGNOSIS TCC SYSTEM .....................................
2.5L&2.8L ................................. DOWNSHIFT CONTROL SYSTEM ___
4.3L&V-8 ................................. SHIFT LIGHT S Y ST E M .........................

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DOWNSHIFT CONTROL DIAGNOSIS . . . . 10-6 PARTS INFORMATION ...........................

GENERAL DESCRIPTION

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Downshift Control System
AUTOMATIC TRANSMISSION While operating a vehicle equipped with a THM
TCC System 400 transmission, at speeds below 70 mph, a forced or

.
The Transm ission C onverter C lutch (TCC)

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detent downshift is possible, by depressing the
System, used on a 7004R transmission, uses a solenoid accelerator fully.
operated valve, in the automatic transmission, to The ECM will recognize the rapid increase in
couple the engine flywheel to the output shaft of the
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transmission through the torque converter. This vacuum, and turn on the downshift control relay. The
reduces the slippage losses in the converter, which relay will, then, send battery voltage to the detent
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increases fuel economy. solenoid, in the transmission, which opens an orifice
and forces a transmission downshift.
Operation
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MANUAL TRANSMISSION
For the converter clutch to apply, two conditions
must be met:
• Internal transmission fluid pressure must be Shift Light System
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correct. For information on internal transmission

operation, see Section 7A. This section will cover only A vehicle, with manual transmission, has a shift
the electrical operation of the TCC system. light, on the instrument panel, to indicate the best
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• The ECM completes a ground circuit to energize a shift point for maximum fuel economy. The light is
TCC apply solenoid in the transmission which moves a controlled by the ECM and is turned "ON” by
grounding CKT 456.
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check ball in a fluid line (Figure 10-1). This allows the

converter clutch to apply, if the hydraulic pressure is
correct, as described above.
The ECM controls the TCC apply solenoid by
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looking at several sensors:

• Coolant Temperature Sensor. Engine must be
warmed up, before clutch can apply.
• T h ro ttle P osition Sensor (TPS). A fter the
converter clutch applies, the ECM uses the
information from the TPS to release the clutch,
when the vehicle is accelerating, or decelerating
at a certain rate.
• Brake Switch. This switch in the TCC circuit
opens, when the brake pedal is depressed. This de­
energizes the TCC solenoid. [ T ] TCC SOLENOID [ T l CHECK BALL SEAT
• Pulse switch. This is a downshift 4-3 pulse switch, | 2 | CHECK BALL
which opens th e TCC so len o id c ir c u it,
__________________________________________________________ 4S 0548-6E
momentarily, during a downshift.
Figure 10-1 - TCC Solenoid
 10-2 TRANSMISSION CONTROLS

WHITE ECM
CONNECTOR T
437 DK BROWN A10
VSS SPEED INPUT

® < s >
_______ 422 TAN/BLACK A7
TCC TEST
5 POINT TCC BRAKE SW. 20A
---- IGN.
F“ T PPL m e. GAGE
TRANS FUSE A2
CONNECTOR D A C B

8-18-86

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TCC SOLENOID
8 - 20-86 *7S 3857-6H

TRANSMISSION CONVERTER CLUTCH (TCC)

ELECTRICAL DIAGNOSIS

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2.5L AND 2.8L ENGINES
Circuit Description:

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The purpose of the automatic transmission converter clutch feature is to eliminate the power loss of the

transmission and the fuel economy of a manual transmission.

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torque converter stage when the vehicle is in a cruise condition. This allows the convenience of the automatic

Fused battery ignition is supplied to the TCC solenoid through the TCC brake switch.
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The ECM will engage TCC by grounding CKT 422 to energize the solenoid.
TCC will engage when:
Vehicle speed above 24 mph (39 km/h.)
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Engine at normal operating temperature (above 65°C) (149°F).

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Throttle position sensor output not changing, indicating a steady road speed.
Brake switch closed.
3rd or 4th gears.
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Test Description: Step numbers refer to step Diagnostic Aids:

numbers on diagnostic chart.
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1. Checks continuity through brake switch and TCC Solenoid coil resistance must measure more than
solenoid. 20 ohms. Less resistance will cause early failure of
2. Checks capability of ECM to energize solenoid. the ECM "DRIVER”. Using an ohm meter, check the
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Grounding the diagnostic connector should solenoid coil resistance of all ECM controlled solenoids
energize the relay and cause the light to go out. and relays, before installing a replacement ECM.
3. This test by-passes the TCC solenoid and checks Replace any solenoid, or relay, that measures less
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for an open or short in CKT 422. than 20 ohms resistance.

 TRANSMISSION CONTROLS 10-3

TRANSMISSION CONVERTER
CLUTCH (TCC)
(ELECTRICAL DIAGNOSIS)
2.5L AND 2.8L ENGINES

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9-5-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S3858-6E
 10-4 TRANSMISSION CONTROLS

ECM
Of? ------- v\C
f/@dr VSS 437 BRN A10
SPEED INPUT
o o
A7

J
422 TAN/BLK

f-t ALCL
BRAKE SW. 20A
IGN.
TCC
' 1
PPL • n .c .
1 GAGE
TRANS FUSE C7 M h
D A c B 446 LT BLU
CONNECTOR
12V 4TH
GEAR
SIGNAL

J 4TH GEAR

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SWITCH 8-19-86
TCC SOLENOID
8 - 20-86 *7S 3859-6E|

TRANSMISSION CONVERTER CLUTCH (TCC)

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ELECTRICAL DIAGNOSIS
4.3L, 5.0L AND 5.7L (UNDER 8500 GVW)

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Circuit Description:
The purpose of the automatic transmission torque converter clutch feature is to eliminate the power loss of

automatic transmission and the fuel economy of a manual transmission.

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the torque converter stage when the vehicle is in a cruise condition. This allows the convenience of the

Fused battery ignition is supplied to the TCC solenoid through the TCC brake switch.
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The ECM will engage TCC by grounding CKT 422 to energize the solenoid.
TCC will engage when:
Vehicle speed above 30 mph (48 km/h.)
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Engine at normal operating temperature (above 65°C) (149°F).

Throttle position sensor output not changing, indicating a steady road speed.
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Brake switch closed.

3rd or 4th gears.
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Test Description: Step numbers refer to step Diagnostic Aids:

numbers on diagnostic chart.
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1. A test light on indicates battery voltage and Solenoid coil resistance must measure more than
continuithy through the TCC solenoid is OK. 20 ohms. Less resistance will cause early failure of
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2. Checks for vehicle speed sensor signal to ECM the ECM "DRIVER”. Using an ohm meter, check the
using a "Scan” tool. solenoid coil resistance of all ECM controlled solenoids
3. Checks for 4th gear signal to ECM. This signal and relays before installing a replacement ECM.
will not prevent TCC engagement, but could cause Replace any solenoid or relay that measures less than
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a change in the engage and disengage speed 20 ohms resistance.

points.
 TRANSMISSION CONTROLS 10-5

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 10-6 TRANSMISSION CONTROLS

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THM 400 TRANSMISSION DOWNSHIFT CONTROL

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ELECTRICAL DIAGNOSIS
Circuit Description:
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When the accelerator pedal is fully depressed, manifold vacuum in the engine drops causing the MAP sensor
signal voltage to increase to approximately 4 volts. The ECM responds by grounding CKT 422 to turn "ON” the
downshift control relay. The relay then sends battery voltage to the detent solenoid, which causes a forced
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transmission downshift.

Diagnostic Aids:
• If problem is diagnosed as being an internal
transm ission problem, see Section 7 of the
appropriate series Service Manual as listed in the
Forward.
• Relay coil resistance must measure more than 20
ohms. Less resistance will cause early failure of
the ECM "Driver”. Using an ohm meter, check
the coil resistance of all ECM controlled solenoids
and relays before installing a replacement ECM.
Replace any solenoid or relay that measures less
than 20 ohms resistance.
 TRANSMISSION CONTROLS 10-7

THM 400 TRANSMISSION

THIS CHART ASSUMES THERE IS NO
CODE 33 OR 34 STORED DOWNSHIFT CONTROL
ELECTRICAL DIAGNOSIS

NO FORCED DOWNSHIFT TRANSMISSION WILL NOT UPSHIFT

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9-5-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
7S 3862-6E
 10-8 TRANSMISSION CONTROLS

ECM

IGN/GAGE
FUSE I.P. CONNECTOR
IGNITION PNK/BLK 39 -------« -------- TAN/BLK 456
20 A SHIFT LIGHT

ECM

IGN/GAGE
FUSE I.P. CONNECTOR
IGNITION --------- • ' V * -------- PNK/BLK 39 -------« --------
20 A SHIFT LIGHT

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ECM

ECM/IGN
FUSE I.P. CONNECTOR

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IGNITION --------- 9T \J i --------- PNK/BLK 439 -------« --------

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10 A SHIFT LIGHT
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8 - 20-86 7S 3863-6E

MANUAL TRANSMISSION SHIFT LIGHT CHECK

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ALL ENGINES
Circuit Description:
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The ECM uses information from the following inputs to control the Shift light:
• Coolant temperature
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• TPS
• vss
• RPM
The ECM uses the meassured rpm and the vehicle speed to calculate what gear the vehicle is in. It’s this
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calculation that determines when the Shift light should be turned on.
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Test Description: Step numbers refer to step 3. This checks for an open in the Shift light circuit,
numbers on diagnostic chart. or a faulty ECM.
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1. This should not turn "ON” the Shift light. If the

light is "ON”, there is a short to ground in CKT
456 wiring, or a fault in the ECM.
2. This should turn "ON” the Shift light.
 TRANSMISSION CONTROLS 10-9

MANUAL TRANSMISSION SHIFT

LIGHT CHECK
ALL ENGINES

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8-19-86
* 7S 3864-6EA
 10-10 TRANSMISSION CONTROLS

DIAGNOSIS ON-VEHICLE SERVICE

TCC SYSTEM TCC SYSTEM
If the converter clutch is applied at all times, the • Refer to Section 3, for repair of wiring.
engine will stall immediately, just as in a manual • Refer to Section 3, for replacement of the ECM.
transmission with the clutch applied. • For replacement of the TCC solenoid, Vehicle Speed
If the converter clutch does not apply, fuel Sensor, or Brake Switch, refer to the appropriate
economy may be lower than expected. If the Vehicle series Service Manual, as listed in the forward.
Speed Sensor fails, the TCC will not apply. If the 4th
gear switch does not operate, the TCC will not apply at DOWNSHIFT CONTROL SYSTEM
the right time.
The Transmission Converter Clutch (TCC) system • Refer to Section 3, for repair of wiring.
has different operating characteristics th an an • Refer to Section 3, for replacement of the ECM.
automatic transmission without TCC. If the driver

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complains of a "chuggle" or "surge" condition, the Downshift Control Relay
vehicle should be road tested and compared to a
similar vehicle to see if a real problem exists. The |++[ Remove or Disconnect
Owner’s Manual section on TCC operation should be 1. Harness connector
reviewed with the driver. Another TCC complaint

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2. Retaining bolt(s).
may be a downshift felt when going up a grade,
especially with cruise control. This may not be a Install or Connect

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downshift, but a clutch disengagement due to the
change in TPS to maintain cruising speed. 1. Retaining bolt(s).
The electrical diagnosis of the TCC system is
covered in the appropriate "Transmission Converter
Clutch Electrical Diagnosis” chart.
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2. Harness connector.

SHIFT LIGHT SYSTEM

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If the ECM detects a problem in the VSS system, a
Code 24 should set. In this case see Code 24 Chart. • Refer to Section 3, for repair of wiring.
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• Refer to Section 3, for replacement of the ECM.

DOWNSHIFT CONTROL SYSTEM
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PARTS INFORMATION
If the downshift control system is "ON”, at all
times, the transmission will not upshift. PART NAME GROUP
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If the downshift control system is inoperative, a

forced downshift of the transmission will not occur. Sensor, VSS (1) ............................................ 9.761
In either case, refer to the "THM400 Transmission Valve, Clutch and Cruise Vac. Sw ..............3.885
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Downshift Control Electrical Diagnosis” chart. Solenoid, T C C .............................................. 4.122

SHIFT LIGHT SYSTEM
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If the manual transmission shift light does not

illuminate, or is "ON” all the time, while driving the
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vehicle, refer to "Manual Transmission Shift Light

Check” chart.
 POSITIVE CRANKCASE VENTILATION 11-1

SECTION 11
POSITIVE CRANKCASE VENTILATION (PCV)
CONTENTS
GENERAL DESCRIPTION................................. 11-1 FUNCTIONAL C H E C K .................................. 11-2
D IAG N O SIS.................................................... 11-1 ON-VEHICLE SERVICE...................................... 11-2
RESULTS OF INCORRECT OPERATION___ 11-1 PARTS INFORMATION .................................... 11-2

GENERAL DESCRIPTION DIAGNOSIS

A Positive Crankcase Ventilation (PCV) system is RESULTS OF INCORRECT OPERATION
used to provide more complete scavenging of
crankcase vapors. Fresh air from the air cleaner • A plugged valve or hose may cause:

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through a filter is supplied to the crankcase, mixed • Rough idle.
with blow-by gases and then passed through a positive • Stalling or slow idle speed.
• Oil leaks.

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crankcase ventilation (PCV) valve into the intake
manifold (Figure 11-1 or 11-2). • Oil in air cleaner.
The primary control is through the PCV valve • Sludge in engine.
(Figure 11-3), which m eters the flow at a rate

.
depending on manifold vacuum.

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To maintain idle quality, the PCV valve restricts
the flow when intake manifold vacuum is high. If
abnormal operating conditions arise, the system is
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designed to allow excessive amounts of blow-by gases
to back flow through the crankcase vent tube into the
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air cleaner to be consumed by normal combustion.
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=> CLEAN AIR

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—- V O LATILE OIL FUMES

MIXTURE OF AIR AND FUMES

<=c> CLEAN AIR

V O L A T IL E O IL FUMES
MIXTURE OF AIR AND FUMES

m PCV VALVE
m AIR CLEANER
n ~ l PCV VALVE [ T ] CRANKCASE VENT HOSE CRANKCASE
[ T ] AIR CLEANER [ T ] PCV VALVE HOSE VENT HOSE
4S1152 H PhC0VseV A LV E 45 0067

Figure 11-1 - PCV Flow(L-4) Figure 11-2 - PCV Flow (V6 and V8)
11-2 POSITIVE CRANKCASE VENTILATION

• A leaking valve or hose would cause:

• Rough idle.
• Stalling.
• High idle speed.

FUNCTIONAL CHECK
If an engine is idling rough, check for a clogged
PCV valve, dirty vent filter or air cleaner element, or
plugged hose. Replace as required. Use the following
procedure:
1. Remove PCV valve from rocker arm cover.
2. Run the engne at idle.
3. Place your thumb over end of valve to check for
vacuum. If there is no vacuum at valve, check for PH AIR CLEANER

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plugged hoses, manifold port at TBI unit, or PCV fTI CRANKCASE VENT FILTER
valve. Replace plugged or deteriorated hoses or IT] HOSE
plugged PCV valve. 7S 3854-6E

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4. Turn "OFF” the engine and remove PCV valve. Figure 11-4-Crankcase Vent Filter
Shake valve and listen for the rattle of check
needle inside the valve. If valve does not rattle,
ON-VEHICLE SERVICE

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replace valve.
With this system, any blow-by in excess of the
system capacity (from a badly-worn engine, sustained An engine can be damaged if it is operated without
heavy load, etc.) is exhausted into the air cleaner and
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crankcase ventilation. Therefore, it is important to
is drawn into the engine.
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perform the "Functional Check” at intervals shown in
Proper operation of the PCV system is dependent Section OB of the appropriate Service Manual or the
upon a sealed engine. If oil sludging or dilution is vehicle’s maintenance schedule.
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noted and the PCV system is functioning properly, Replace PCV components as diagnosis requires.
check engine for possible cause and correct to ensure The recommended replacement parts are listed in the
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that system will function as intended. Specifications section of the vehicle’s owners manual.
Periodically, inspect the hoses and clamps and
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replace any showing signs of deterioration.

PARTS INFORMATION
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PART NAME GROUP

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Air C le an e r..................................................... 1.150

Tube, C/Case V e n t.......................................... 2.383
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Hose, C/Case Vent V lv ................................... 2.170

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Figure 11-3 - PCV Valve Cross Section

 POSITIVE CRANKCASE VENTILATION 11-3

VIEW A

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m BOOT fTI CONNECTOR
m TUBE ASSEM BLY fTI GROMMET
fTI ELBOW m HOSE
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IT 1 CLAMP
Figure 11-5- PCV System (2.5L)
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fTI PCV VALVE

I 2 | GROMMET
[Tl TUBE ASSEM BLY
fTI TBI UNIT - PORT "C”
m AIR CLEANER FITTING -
I 6 [ MAP SENSOR 7 S 3630

Figure 11-6- PCV System (2.8L)

11-4 POSITIVE CRANKCASE VENTILATION

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fTl PCV VALVE [T] HOSE - ALTITUDE ONLY

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[~2~l GROMMET X I TUBE ASSEM BLY
f T l HOSE [ X AIR CLEANER EXTENTION
5.0L & 5.7L
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[~4~| TBI UNIT - PORT "C"
7S3631

Figure 11-7 - PCV System (4.3L. 5.0L & 5.7L)

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Figure 11-8- PCV System (7.4L)

 THERMOSTATIC AIR CLEANER 12-1

SECTION 12
THERMOSTATIC AIR CLEANER (THERMAC)
CONTENTS
GENERAL DESCRIPTION................................. ..12-1 TEMPERATURE SENSOR CHECK.................. ..12-3
PURPOSE.......................................................12-1 ON-VEHICLE SERVICE........................................12-3
OPERATION................................................ ..12-1 AIR CLEANER ELEM EN T............................. ..12-3
D IA G N O SIS.......................................................12-1 AIR CLEANER.............................................. ..12-4
RESULTS OF INCORRECT O PERATIO N ___ 12-1 VACUUM DIAPHRAGM M O TO R..................12-4
THERMAC AIR CLEANER SENSO R....................................................... ..12-4
FUNCTIONAL CHECK ...............................12-3 PARTS INFORM ATION......................................12-5
VACUUM MOTOR FUNCTIONAL CHECK . . 12-3

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GENERAL DESCRIPTION
PURPOSE

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A heated intake air system is used to give good
driveability under varying clim atic conditions.
Having a uniform inlet air temperature improves fuel

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vaporization.

OPERATION
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All Except S/T Series
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The THERMAC system (Figure 12-1) regulates
incoming air temperature without the use of vacuum. I 2 I WAX PELLET ACTUATOR
The air regulating damper is controlled by means of a fTl DAMPER ASSEM BLY
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self-contained, wax-pellet actuated assembly mounted 7S3810-6E

in the air cleaner. When incoming air is cold, the wax
m a te ria l sealed in the a ctu a to r is in a solid Figure 12-1 - THERMAC Air Cleaner
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(contracted) phase and the damper closes off the cold All Except S/T Series
air inelt. This causes all incoming air to be heated by
the exhaust manifold. As the incoming air warms, the
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wax material expands by changing to liquid phase DIAGNOSIS

which forces out a piston to reposition the damper
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allowing a cold and hot air mix or all cold air to enter RESULTS OF INCORRECT OPERATION
the engine.
All Except S/T Series
S/T Series
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• Hesitation during warm-up can be caused by:

The THERMAC system (Figure 12-2) uses a Heat stove tube disconnected.
sensor, vacuum motor, and damper to regulate intake Missing or damaged air cleaner-to-TBI gasket.
air temperature. The sensor monitors air temperature Loose air cleaner cover & air cleaner.
and controls the vacuum m otor which in tu rn Missing air cleaner cover seal.
positions the damper. When the incoming air is cold, Damper door does not close.
the sensor will apply manifold vacuum to the vacuum • Lack of power, sluggish, or spongy (on a hot
motor, cutting off the cold air supply. This causes all engine) can be caused by:
incoming air to be heated up by the exhaust manifold. Damper door does not open to outside air.
As the incoming air warms up, the sensor will reduce
the vacuum to the motor via an air bleed valve, thus
re-positioning the damper to allow a cold and hot air
mix or all cold air to enter the engine.
12-2 THERMOSTATIC AIR CLEANER

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n~| VACUUM DIAPHRAGM
MOTOR

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l~2~] TEM PERATU RE SENSOR
fT~] fTl
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VACUUM HOSE (TO SNORKEL
M ANIFOLD VACUUM)
WAX PELLET ACTUATOR
f T ] H EAT STO VE DUCT fTl PISTON

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f~5~l SN O R K EL FT] CALIBRATED SPRING
I 6 | LIN KA G E
f T ] HOT AIR INLET

08 14 84
PT| A IR B LEED V A LV E
IT] A IR C LEA N ER ASM.
[ T DAMPER DOOR 4S 0648-6E
arn n REGULATING DAMPER
ASSEM BLY
fTl COLD AIR INLET 7S3811-6E
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Figure 12-2 - THERMAC Air Cleaner - S/T Series Figure 12-3 - THERMAC Operation
All Except S/T Series
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f T l VACUUM DIAPHRAGM MOTOR

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DIAPHRAGM SPRING
GD TEMPERATURE SENSOR
AIR BLEED VALVE-CLOSED
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4B AIR BLEED V A LV E -
PARTIALLY OPEN
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l~4Cl AIR BLEED VALVE-OPEN

f in VACUUM HOSES
f~6~[ DIAPHRAGM
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l~7l HEAT STOVE

i~8 I HOT AIR (EXHAUST MANIFOLD)
l~9l DAMPER DOOR
fiQ l OUTSIDE INLET AIR
f i l l SNORKEL

A - HOT AIR DELIVERY MODE

B - REGULATING MODE
C - OUTSIDE AIR DELIVERY MODE

4S 0073-6E

Figure 12-4 - THERMAC Operation - S/T Series

 THERMOSTATIC AIR CLEANER 12-3

S/T Series VACUUM MOTOR FUNCTIONAL CHECK

• Hesitation during warm-up can be caused by: S/T Series

Heat stove tube disconnected.
Vacuum diaphragm motor inoperative (open 1. With engine off, disconnect vacuum hose at
to snorkel). vacuum diaphragm motor.
No manifold vacuum. 2. Apply at least 23 kPa (7 in. Hg.) of vacuum to the
Damper door does not move. vacuum diaphragm motor. Damper door should
Missing air cleaner to TBI seal. completely block off to outside air when vacuum is
Missing air cleaner cover seal or loose cover. applied. If not, check to see if linkage is hooked up
Loose air cleaner. correctly.
• Lack of power, sluggish, or spongy (on a hot 3. W ith vacuum still applied, tra p vacuum in
engine) can be caused by: vacuum diaphragm motor by bending hose.
Damper door does not open to outside air. Damper door should remain closed. If not, replace
Temperature sensor doesn’t bleed off vacuum. vacuum diaphragm motor assembly. (Failure of
the vacuum diaphragm motor assembly is more

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THERMAC AIR CLEANER FUNCTIONAL CHECK likely to be caused from binding linkage or a
corroded snorkel than from a failed diaphragm.

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All Except S/T Series This should be checked first, before replacing the
diaphragm.)
1. Remove air cleaner assembly and cool to below 4°C 4. If vacuum motor checks OK, check vacuum hoses
(40°F). The damper door should be closed to and connections. If OK, replace the temperature

.
outside air (cold air). sensor.

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2. Check for presence and condition of air cleaner to
throttle body gasket. TEMPERATURE SENSOR CHECK
3. Reinstall air cleaner assembly and be sure heat
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stove tube is connected at air cleaner snorkel and S/T Series
exhaust manifold.
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4. Start engine. Watch damper door in air cleaner 1. Start test with air cleaner temperature below 86°F
snorkel. As air cleaner warms up, damper door (30°C). If engine has been run recently, remove
should open slowly to outside air (cold air). air cleaner cover and place thermometer as close
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5. If air cleaner fails to operate as described, be sure as possible to the sensor. Let air cleaner cool until
calibrated spring is properly installed and damper thermometer reads below 86°F (30°C) about 5 to
is not binding. If OK, replace wax pellet actuator 10 minutes. Reinstall air cleaner on engine and
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assembly. continue to Step 2.

2. Start and idle engine. Damper door should move
S/T Series to close off outside air immediately, if engine is
cool enough. When damper door starts to open (in
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1. Inspect system to be sure all hoses and heat stove a few minutes), remove air cleaner cover and read
tube are connected. Check for kinked, plugged or thermometer. It must read about 131°F (55°C).
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deteriorated hoses. 3. If the damper door is not open to outside air at

2. Check for presence and condition of air cleaner to tem perature indicated, tem perature sensor is
throttle body gasket seal. malfunctioning and must be replaced.
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3. With air cleaner assembly installed, damper door

should be open to outside air. ON-VEHICLE SERVICE
4. Start engine. Watch damper door in air cleaner
snorkel. When engine is first started, damper door AIR CLEANER ELEMENT
should move and close off outside air. As air
cleaner warms up, damper door should open Remove or Disconnect
slowly to outside air. 1. Air cleaner cover.
5. If the air cleaner fails to operate as described
2. Old element.
above, perform vacuum m otor check. If it
3. Clean Housing.
operates, the door may not be moving at the right
temperature. If the driveability problem is during
+ 4- Install or Connect
warm-up, make the tem perature sensor check
below. 1. New element.
2. Air cleaner cover, Do not over-torque nuts (install
finger-tight).
12-4 THERMOSTATIC AIR CLEANER

AIR CLEANER WAX PELLET ACTUATOR

Refer to Figures 12-8 to 12-13 for repair or All Except S/T Series
replacement of air cleaner. (Figure 12-6)
VACUUM DIAPHRAGM MOTOR Remove or Disconnect
S/T Series 1. Air cleaner.
(Figure 12-5) 2. Spring.
3. Rivits retaining actuator
Remove or Disconnect 4. Actuator.

l. Air cleaner. Install or Connect

2. Vacuum hose from motor.
3. Drill out the two spot welds initially with a 1.6mm 1. Actuator.
(1/16” ) drill, then enlarge as required to remove 2. Spring.

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the retaining strap. Do not damage the snorkel 3. Rivits
tube. 4. Air cleaner.
Motor retaining strap.
Lift up motor, cocking it to one side to unhook the SENSOR

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motor linkage at the control damper assembly.
S/T Series
Install or Connect (Figure 12-7)
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1. Drill a 2.8mm (7/64”) hole in snorkel tube at Remove or Disconnect
center of vacuum motor retaining strap.
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1. Air cleaner.
2. Vacuum motor linkage into control dam per
assembly. 2. Hoses at sensor.
3. Pry up tabs on sensor retaining clip. Remove clip
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3. Use the motor retaining strap and sheet metal
screw provided in the motor service package to and sensor from air cleaner. Note position of
secure motor to the snorkel tube. Make sure the sensor for installation.
screw does not interfere with the operation of the
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damper assembly. Shorten screw if required. -►«- Install or Connect

4. Vacuum hose to motor and install air cleaner. 1. Sensor and gasket assembly in original position.
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2. Retainer clip on hose connectors.

3. Vacuum hoses and air cleaner on engine.
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-CD
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[~T| SPOT WELDS

|2 |
I3 |
MOTOR ASM.
RETA IN IN G STRAP
m WAX PELLET ACTUATOR [T] SNORKEL
cm RIVIT 7S 3812-6E
H IN S T A LL REPLACEM EN T SENSOR ASM.
IN SAME POSITION AS O R IG IN A L ASM.
Figure 12-6 - Replacing Wax Pellet Actuator
08 14 84 4S 0649-6E
All except S/T Series
Figure 12-5 - Replacing THERMAC Vacuum Motor
S/T Series
 THERMOSTATIC AIR CLEANER 12-5

f l | SENSOR RETA IN IN G CLIP

Figure 12-7 - Replacing THERMAC Sensor - S/T Series

PARTS INFORMATION

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PART NAME GROUP
Air C lean er......................................................3.402

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Element (Paper).............................................. .3.410 |~n AIR CLEANER [ T ] SUPPORT
Nut, A/Cl......................................................... .3.403 ------ASSEM BLY r y ] B 0 LT-TIGHTEN TO

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Seal, Air C leaner............................................ .3.403 1T1 NUT-TIGHTEN TO -------50 N m (37 FT. LBS.)
Sensor, A/Cl..................................................... .3.415 ■-------2 N m (18 IN‘ LBS') [ T ] BOLT-TIGHTEN TO
Motor, A/Cl Vac D iaph................................... .3.415
Tube, Eng Air Heat Stove............................... .3.417
Stove, Eng Air H e a t.........................................3.417
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I 3 I SEAL
fTl ADAPTER
30 N m (22 FT. LBS.)

7S3701-6E
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Figure 12-9 - Air Cleaner (2.5L - M Series)
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P T I NUT — TIGHTEN TO 6 N m (50 IN. LBS.) □3 AIR CLEANER ASSEM BLY

fTl AIR CLEANER m SEAL
|~3~| PCV FILTER m STUD
fTl GASKET — REMOVE PAPER FROM NEW SEAL m NUT-TIGHTEN TO 2 N m (18 IN. LBS.)
|~5~1 FULL MANIFOLD VACUUM HOSE g$ E TUBE ASSEM BLY 75 3702-6E

Figure 12-8 - Air Cleaner (2.5L - S/T Series) Figure 12-10 - Air Cleaner (2.8L - S/T Series)
12-6 THERMOSTATIC AIR CLEANER

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(4.3L, 5.0L & 5.7L - M & G Series)
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fTI AIR CLEANER ASSEM BLY

fTI SEAL
fTI EXTENSION
I T l STUD
HI NUT-TIGHTEN TO 2 N m (18 IN. LBS.) 7S 3704-6E

Figure 12-12 - Air Cleaner

(4.3L, 5.0L & 5.7L - Cf K, P, R & V Series)
 SPECIAL TOOLS 13-1

SECTION 13
SPECIAL TOOLS
CONTENTS
GENERAL......................................................... 13-1 IAC (Idle Air Control)............................... 13-3
"SCAN" TOOL .............................................. 13-1 Injector Pulse Width . . . . ...................... 13-3
"SCAN" TOOL M O D ES............................... 13-1 Integrator and Block Learn.................... 13-3
Normal (Open) Mode .......................... 13-1 Knock Retard.......................................... 13-3
ALDL Mode .......................................... 13-1 Knock S ig n a l.......................................... 13-3
Factory Test M o d e ................................. 13-1 MAT Sensor............................................ 13-3
"SCAN" TOOL LIMITATIONS AND USE___ 13-1 MAP Sensor............................................ 13-3
Intermittent Conditions........................ 13-2 Mode....................................................... 13-3
"SCAN" TOOL POSITIONS.......................... 13-2 MPH......................................................... 13-3
A/C Clutch................................................ 13-2 O xy ge n ................................................... 13-3

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A/C Request............................................ 13-2 Park/Neutral Sw itch ............................... 13-4
AD B a t..................................................... 13-2 Power Steering Pressure S w itc h ........... 13-3
Block Learn Memory (BLM) Cell............. 13-2 PPSW....................................................... 13-4
Closed Loop/Open Loop.......................... 13-2 PROM I D ................................................. 13-4
Codes....................................................... 13-2 RPM......................................................... 13-4

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Coolant Temperature............................. 13-3 Shift L ig h t ............................................... 13-4
Desired RPM............................................ 13-3 Throttle A n g le ........................................ 13-4

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EGR (Duty Cycle)..................................... 13-3 TPS ......................................................... 13-4
EGR Position............................................ 13-3 Transmission Convertor Clutch (TCC) . . 13-4
4th Gear.................................................. 13-3
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GENERAL In some cases, ’’S can ” tools w ill provide
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information that is either extremely difficult or
The special tools required to service the fuel and impossible to get with other equipment.
emission systems are illustrated in Figures 13-1
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through 13-3. A "SCAN" TOOL THAT DISPLAYS FAULTY

DATA SHOULD NOT BE USED AND THE
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You should know how to use a test light, how to

connect and use a tachometer, and how to use jumper PROBLEM SHOULD BE REPORTED TO THE
wires to by-pass components to test circuits. A test MANUFACTURER. THE USE OF A FAULTY
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light or voltmeter must be used when specified in the "SCA N " TO O L CA N R ESU LT IN
procedures. They must NOT be interchanged. Care MISDIAGNOSIS AND UNNECESSARY PARTS
should be taken to not deform terminals when testing. REPLACEMENT.
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You should be familiar with the Digital Volt-Ohm

Meter, particularly essential tool J-29125-A, J34029A Tree Code C h a rts in c o rp o ra te d ia g n o s is
or equivalent. You should be able to measure voltage, procedures using an ALDL ’’Scan” tool where possible.
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resistance, and current and know how to use the meter Some Electronic Control Modules have three
correctly. modes for transmitting information but some only
read data in the open mode.
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"SCAN" TOOL The following information will describe each of

the three modes where applicable and the affects they
The Computer Command Control ALDL connector may cause.
under the dash, has a variety of information available
on Serial Data line terminal "E” or "M” (depending on "SCAN" TOOL MODES
engine). There are several "Scan” tools available for
reading this information. Normal (Open) Mode
"Scan” tools do not make the use of diagnostic
charts unnecessary. They do not tell exactly where a Not all systems will transmit information on the
problem is in a given circuit. However, with an Serial Data Line while in this mode.
understanding of what each position on the equipment On systems that can be monitored in the open
measures, and knowledge of the circuit involved, the mode, it allows certain param eters to be obtained
tools can be very useful in getting information which w ithout c h an g in g th e e n g in e o p e ra tin g
would be more time consuming to get with other characteristics. The parameters capable of being read
equipment. vary from engine family to engine family. Most
 13-2 SPECIAL TOOLS

’’Scan” tools are programmed so that the system will The ’’Scan” tool is also a useful and quick way of
go directly into the special mode if the "open” mode is comparing operating parameters of a poorly operating
not available. engine with a known good one. For example; A sensor
may shift in value but not set a code. Comparing with
ALDL (10K ,or Special) Mode a known good vehicle may uncover the problem.
(not used on all engines) The ’’Scan” tool has the ability to save time in
diagnosis and prevent the replacement of good parts.
In this mode, all information incorporated into a The key to using the ’’Scan" tool successfully for
specific engine and ECM is obtainable. However, in diagnosis lies in the technicians ability to understand
this mode the system operating characteristics are the system he is trying to diagnose as well as an
modified as follows. understanding of the ’’Scan” tool’s lim itatio n s.
• Closed loop timers in ECM are bypassed Therefore, the technician should read th e tool
• EST (spark) is advanced operating manual to become familiar with the tool.
• IAC will control engine idle to 1000 rpm ± -50 The following information will describe most of the
RPM. ’’Scan" tool positions and how they can be helpful in

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• P/N restrict functions will be disabled diagnosis.

Factory Test (Back-up or 3.9 K) Mode "SCAN" TOOL POSITIONS

When in this mode, the ECM is operating on the The following positions may not be applicable to

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fuel back-up logic and calibrated by the Calpak MEM- all engines:
CAL. The Calpak MEM-CAL is used to control the

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fuel delivery if the ECM fails. This mode verifies that A/C Clutch
the back-up feature is OK. The parameters that can
be read on a ’’Scan” tool in this mode are not of much Displays "ON” when the ECM has commanded the
use for service.
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A/C Clutch "ON”.

"SCAN" TOOL LIMITATIONS AND USE A/C Request

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The ’’Scan” tool allows a quick check of sensors Displays the state of the A/C signal line to the
and switches which are inputs to the ECM. However, ECM. Should read "YES” whenever the A/C is
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on some applications the data update rate makes the requested.

tool not as effective as a voltmeter when trying to
detect an intermittent which lasts for a very short AD Bat
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time. However, the ’’Scan” tool allows manipulation of

wiring harnesses or components under the hood while Displays the battery voltage detected at the ECM
observing the ’’Scan” readout. This helps in locating ignition input.
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intermittents with the engine not running.

Block Learn Memory (BLM) Cell
Intermittent Conditions
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There are from two to sixteen different cells which

The ’’Scan” tool is helpful in cases of intermittent the ECM learns at depending on RPM and airflow or
operation. The tool can be plugged in and observed MAP. This parameter will display what cell the ECM
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while driving the vehicle under the condition where is using for the fuel calculation at the time.
the light comes "ON" momentarily, or the engine
driveability is poor momentarily. If the problem Closed Loop/Open Loop
seems to be related to certain areas th a t can be
checked on the ’’Scan” tool, then those are the This position will indicate whether the engine
positions that should be checked while driving the control system is operating in "Open” or "Closed
vehicle. If there does not seem to be any correlation Loop”. Most systems go "Closed Loop” after a certain
between the problem and any specific circuit, the amount of run time, when coolant tem perature is
’’Scan” tool can be checked on each position, watching high enough, and the oxygen sensor becomes active.
for a period of time to see if there is any change in the
readings that indicates intermittent operation.
 SPECIAL TOOLS 13-3

Codes The integrator is short term corrective action while

the block learn portion (which is a long term
Will display any code stored in the ECM memory. correction) will only change if the integrator has seen
a condition which lasts for a calibrated period of time.
Coolant Temperature
Knock Retard
D isplays engine te m p e ra tu re in d e g re es
centigrade. After engine is started the temperature Indicates the number of degrees the ECM is
should rise steadily to about 85-95° C then stabilize retarding the Electronic Spark Timing.
when the thermostat opens.
Knock Signal
Desired RPM
Displays a "YES” when knock is detected by the
Indicates the rpm to which the ECM is trying to ECM and displays a "NO” when knock is not detected.
control the idle.

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Manifold Air Temperature (MAT) Sensor
EGR (Duty Cycle)
Displays temperature of the intake manifold air.
The EGR system uses a valve to feed a small Should read close to ambient air temperature when
amount of exhaust gas back into the intake manifold the engine is cold, and rise as underhood and engine

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to control formation of NOx. Like all ECM outputs the temperature increases.
’’Scan” tool only indicates th a t the ECM has

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commanded the function and does not indicate that Manifold Absolute Pressure (MAP) Sensor
the function has really happened.
The MAP Sensor produces a low signal voltage
EGR Position
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high voltage when the pressure is high (low vacuum).
Indicates the position of the EGR pintle. With the ignition on and the engine stopped, the
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manifold pressure is equal to atmospheric pressure
4th gear and the signal voltage will be high. This information
is used by the ECM as an indication of vehicle altitude
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Displays state of the 4th gear switch. Yes = 4th and is referred to as BARO. Comparison of this BARO
gear. reading with a known good vehicle with the same
sensor ** is a good way to check accuracy of a
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IAC (Idle Air Control) "suspect” sensor. Readings should be the same ±.4
volt.
This system is used to control engine idle speed to
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the desired rpm, for different operating conditions. In ** MAP Sensors have a colored plastic insert visible in
this mode, the numbers will indicate what position the the connector cavity. Sensors with the same insert
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ECM thinks the valve is in. The ECM moves the IAC color are identical in calibration. The harness
in counts and these counts are are what is displayed electrical connector color should also be the same as
on a ’’Scan” tool. the sensor insert color.
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Injector Pulse Width Mode

In th is position, the re a d in g is given in Check with the manufacture to determine what
milliseconds which is the on time that the ECM is the function of this mode is. In most cases it allows the
commanding to the injector(s). user to place the ECM in different operating modes.

Integrator and Block Learn MPH

On Fuel Injected Engines, normal readings for Displays vehicle speed. Useful in Checking TCC
these positions are around 128, if higher, it indicates lock up speed or speedometer accuracy.
that the ECM is adding fuel to the base fuel
calculation because the system is lean, and if the
numbers are below 128 the ECM is taking out fuel
from the base calculation because the system is rich.
 13-4 SPECIAL TOOLS

Oxygen RPM
The reading will be read out in millivolts (mv) Displays engine rpm. Often useful if extra
with a range from 1 to 999 mv. If the reading is reference pulses are suspected. A sudden high RPM
consistently below 350 (350 mv), the fuel system is indication while at a steady throttle would indicate
running lean as seen by the ECM and if the reading is electrical interference (EMI) in the reference circuit.
consistently above 550 (550 mv), the system is This interference is usually caused by ECM wires too
running rich. close to ignition secondary w ires or an open
distributor ground circuit.
Park/Neutral Switch
Shift Light
The indication in this mode may vary with
manufacturer so the type of reading for a particular Displays "YES” when the ECM is commanding
tool should be checked in the operators manual. The the shift light to turn "ON”.
important thing is that the the reading changes state

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(switches) when the gear selector is moved from Throttle Angle
park/neutral to drive or reverse.
Displays in percent the amount the throttle is

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Power Steering Pressure Switch open.

Displays the state of switch. This reading may Throttle Position Sensor (TPS)

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vary with the tool used and the type of switch installed
on the vehicle. The important thing is that the reading Values read will be the voltage as seen by the
changes state (switches) when the steering is moved
against the stops.
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ECM. The voltage should be the TPS specification
with the throttle closed and go up to about 5 volts
with throttle wide open (WOT).
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PPSW
Transmission Convertor Clutch (TCC)
This is the voltage on the fuel pump feed circuit.
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In this position, the tool will indicate when the

PROM ID TCC has been commanded by the ECM to turn on.
This does not necessarily mean that the clutch was
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In this position, information is used for assembly engaged but only that the ECM grounded the circuit
verification only. PROM ID is useful only when the internally. The best way to determine if the clutch has
vehicle is equipped with the original ECM and PROM engaged is to monitor engine RPM when the TCC
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or MEM-CAL. comes ”ON”.

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 SPECIAL TOOLS 13-5

VOLTMETER - Voltage Position Measures amount of

voltage. When connected in parallel to an existing
circuit. A digital voitmeter with 10 meg ohm input
impedence is used because this type of meter will
not load down the circuit and result in faulty
readings.some circuits require accurate low voltage
readings, and some circuits in the ECM have a very
high resistance.

AMMETER - When used as ammeter, this meter also

accurately measures extremely low current flow.
Refer to meter instructions for more information.
• Selector must be set properly for both function

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and range. DC is used for most automotive
measurements.

OHMMETER - Measures resistance of circuit directly

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in ohms. Refer to meter for more information.
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Zero display in all ranges indicates a short
circuit.
Interm ittent connection in circu it may be
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indicated by d igital reading th at w ill not
stabilize on circuit.
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Range Switch.
200ft - Reads ohms directly
HIGH IMPEDANCE MULTIMETER 2K,20K,200Kft - Reads ohms in thousands
(DIGITAL VOLTMETER-DVM)
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2M and 20Mft - Reads ohms in millions

J34029-A/BT8623
VACUUM PUMP (20 IN. HG. MINIMUM)
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Use gage to monitor manifold engine vacuum and the

hand pump to check vacuum sensors, solenoids and
valves.
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J23738-A/BT8334
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UNPOWERED TEST LIGHT

Used to check wiring for complete circuit and short to
ground or voltage.
J34142-A
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TACHOMETER
Use inductive trigger signal pickup type to check RPM.
oSo
£-

CONNECTOR TEST ADAPTER KIT

Used to make electrical test connections in current
Weather Pack, Metri - Pack and Micro-Pack style
terminals.
J35616/BT8256 8-15-86
*7S 3534-6E
Figure 13-1 Special Tools (1 of 3)
13-6 SPECIAL TOOLS

OXYGEN SENSOR WRENCH

Used to remove or install the oxygen sensor.
J29533A/BT8127

IDLE AIR CONTROL WRENCH

Used to remove or install IAC valve on throttle body.

( ^ ^ 3 3 0 3 1 /BT8130

/ BT8320 \ INJECTOR TEST LIGHT

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Used to check electrical circuit to a TBI 220 fuel
H° °\J BT8320
injector

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INJECTOR TEST LIGHT
Used to check electrical circuit to a TBI 700 fuel
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J34730-2A/ injector.
BT8329A
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CIRCUIT TESTER
Used to check all relays and solenoids before
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connecting them to a new ECM. Measures the circuit
resistance and indicates pass or fail via green or red
LED. Amber LED indicates current polarity. Can also
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J34636/BT8405 be used as a non-powered continuity checker.

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OIL PRESSURE TRANSDUCER WRENCH

Used to remove or install oil pressure transducer on
^ J28687-A/BT8220
engine.
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METRI-PACK TERMINAL REMOVER

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Used to remove 150 series Metri-Pack "pull-to-seat"

terminals from connectors. Refer to wiring harness
service in Section 3 for removal procedure.
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J35689/BT8446
WEATHER PACK TERMINAL REMOVER
Used to remove Terminals from Weather Pack
v J28742/BT8234-A
connectors. Refer to wiring harness service in Section
3 for removal procedure.

ECM CONNECTOR TERMINAL REMOVER

Used to remove terminal from Micro-Pack connectors.
Refer to wiring harness service Section 6E for removal
procedure.
8-19-86
J33095/BT8234-A * 7S3535-6E
Figure 13-2 Special Tools (2 of 3)
 SPECIAL TOOLS 13-7

SPARK TESTER
Use to check available secondary ignition voltage. Also called an ST125.

.!!
J26792/BT7220-1

FUEL LINE WRENCH

Used to disconnect or connect fuel lines at TBI unit by holding fuel nut
at throttle body.

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J29698-A/BT8251

MINIMUM AIR RATE ADJUSTING WRENCH

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Used to adjust throttle stop screw on TBI unit.

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J33179-20

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FUEL PRESSURE GAGE
Used to check and monitor fuel line pressure.
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J29658A/BT8205
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FUEL PRESSURE GAGE

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Used to check and monitor fuel line pressure.

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J34020
s

FUEL TANK SENDING AND PUMP UNIT

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Used to remove and install cam lock nut on the fuel tank sending and
pump unit in Section 4.

J24187
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IGNITION MODULE TESTER

Used to test ignition module in Section 5.

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J24642-F/BT7220 7S 3536-6E

Figure 13-3 Special Tools (3 of 3)

13-8 SPECIAL TOOLS

SPECIFICATIONS
SPECIFICATION LOCATION OF INFORMATION
Engine Timing Vehicle Emission Control information label.

Idle Speed, ECM Not adjustable. ECM controls idle.

Controlled

Spark Plug Type See Owner's Manual, Section 7.

Spark Plug Gap Vehicle Emission Control Information Label.

Engine Code 8th digit of VIN number. See Section OA. Also Owner's Manual,
Section 7.

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Engine Family Vehicle Emission Control Information label.

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Filter Part Numbers See Owner's Manual, Section 7.

Part Numbers of WDD-GM Parts Book.

.
Major Components

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Replacement of WDD-GM Label Catalog.
Vehicle Emission
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Control Information
Label 6-4-86
7S 3536-6E
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 A BBREVIATIO N S-14-1

SECTION 14
ABBREVIATIONS AND GLOSSARY OF TERMS
Abbreviations used in this manual are listed CO - CARBON MONOXIDE - One of the pollutants
below in alphabetical order with an explanation of the found in engine exhaust.
abbreviation. There are some variations in the use of DIAGNOSTIC CODE - Pair of numbers obtained
periods and in capitalization (as mph, m.p.h., Mph, from flashing "Service Engine Soon” lig h t, or
and MPH) for abbreviations used in this Section but displaying on a "Scan” tool. This code can be used to
all types are acceptable. determine the system malfunction.
A/F-AIR/FUEL (A/F RATIO) - The amount of air-to- DIAGNOSTIC TERM. - Grounding terminal "B” of
fuel for combustion of fuel. Ideal ration is 14.7 parts of ALDL Connector will flash or display a code. When

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air to 1 part of fuel. grounded with the engine running will enter the
AIR - AIR INJECTOR REACTION SYSTEM - Air flow "Field Service Mode”.
from pump is directed into engine exhaust manifold

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DVM (10 Meg.) - Digital Voltmeter with 10 Million
and/or converter to reduce exhaust emissions.
ohms resistance - used for measurement in electronic
ALDL - ASSEMBLY LINE DIAGNOSTIC LINK - Used systems.

.
at assembly to evaluate Computer Command Control EAC - ELECTRIC AIR CONTROL- Used on AIR

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and for service to flash the "Service Engine Soon” System to direct air flow to Air Switching valve or
light if there are trouble codes. Also used by "Scan”
atmosphere.
tools to obtain ECM serial data.
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Bat + - Battery Positive Terminal (12 Volts)
A metal case (located in passenger compartment)
BLOCK LEARN - ECM memory that adjusts the air/fuel containing electronic circuitry which electrically
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ratio on a semipermanent basis. controls and monitors air/fuel and emission systems
on Computer Command Control, and turns on the
CALPAK - A device used with fuel injection to "Service Engine Soon” light when a m alfunction
allow fuel delivery in the event of a PROM or ECM
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occurs in the system.

malfunction.
ECU - ENGINE CALIBRATION UNIT - An electronic
CALIBRATOR - (PROM). An electronic component component which can be specifically programmed to
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which can be specifically programmed to meet engine the design of each vehicle model to control the M/C
operating requirements for each vehicle model. It
solenoid. The ECU plugs into the electronic control
plugs into the Engine Control Module (ECM). module (ECM). The ECU is usually called a PROM.
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CCC - COMPUTER COMMAND CONTROL - has an

EFI - ELECTRONIC FUEL INJECTION - Computer
electronic control module to control air/fuel and Command Control using throttle body fuel injection.
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emission systems.
EGR - EXHAUST GAS RECIRCULATION- Method of
CCP - CONTROLLED CANISTER PURGE - ECM
reducing NOx emission levels.
controlled solenoid valve th a t perm its manifold
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vacuum to purge the evaporative emissions from the EECS - EVAPORATIVE EM ISSIONS CONTROL
charcoal canister. SYSTEM - Used to prevent gasoline vapors in the fuel
tank from entering the atmosphere.
CID - CUBIC INCH DISPLACEMENT - Used to
describe engine size. ENERGIZE/DE-ENERGIZE - When current is passed
through a coil (energized) such as a solenoid, a plunger
C LOOP - CLOSED LOOP - Designed with feedback
is pulled or pushed. When the voltage to the solenoid
information to the ECM to maintain an optimum
is turned off, (de-energized), a spring raises or lowers
air/fuel ratio (14.7:1), output.
the plunger.
COOLANT TEMPERATURE SENSOR - Device that
ESC - ELECTRONIC SPARK CONTROL - Used to
senses the engine coolant temperature, and passes
sense detonation and retard spark advance when
that information to the electronic control module.
detonation occurs.
CONV. - CATALYTIC CONVERTER - Containing
EST - ELECTRONIC SPA RK TIM ING - ECM
platinum and palladium to speed up conversion of HC
controlled timing of ignition spark.
and CO.
14-2 ABBREVIATIONS

EVRV - ELECTRONIC VACUUM REGULATOR MAP - MANIFOLD ABSOLUTE PRESSURE SENSOR -

VALVE - Controls EGR vacuum. Reads pressure changes in intake manifold with
reference to zero pressure. It puts out a voltage which
FED - FEDERAL - Vehicle/Engine available in all
is highest when the pressure is h ig h est. The
states except California.
maximum voltage is between 4-5 volts.
FI - FUEL INJECTION - Computer Command Control
MAT - M anifold A ir T em p eratu re S en so r.
using throttle body fuel injection.
Measures temperature of air in the intake manifold.
GROUND - A Wire shorted to ground. A comon
MEM-CAL - Contains specific calibrations to meet
return for an eclectrical circuit.
the requirements of a specific engine..
HC - HYDROCARBONS - One of the pollutants
MODE - A particular state of operation.
found in engine exhaust. Hydrogen and carbon in
gasoline. MPH - MILES PER HOUR - A unit m easuring
distance (5280 feet) in one hour.
HIGH IMPEDANCE VOLTMETER - Has high

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opposition to the flow of electrical current. Good for N.C. - NORMALLY CLOSED. State of relay contacts
reading circuits with low current flow, such as found or solenoid plunger when no voltage is applied.
in electronic systems.

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N«m - NEWTON METERS (Torque) - A metric unit
HEI - HIGH ENERGY IGNITION - A distributor that which measures force.
uses an electronic module and pick-up coil in place of
N.O. - NORMALLY OPEN - State of relay contacts
contact points.

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or solenoid plunger when no voltage is applied.

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Hg - MERCURY a calibration material used as a
NOx - NITROGEN, OXIDES OF - One of the
standard for vacuum measurement.
pollutants found in engine exhaust. Nitrogen that
IAC - IDLE AIR CONTROL - installed in the throttle
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combines with oxygen to form oxdes of nitrogen.
body of a fuel injected system and controlled by the
O2 - OXYGEN (Sensor) - Monitors the oxygen
ECM to regulate idle speed.
content of the exhaust system and generates a voltage
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IDEAL MIXTURE - The air/fuel ratio which provides signal to the ECM.
the best performance, while maintaining maximum
O LOOP - OPEN LOOP - Describes ECM fuel
conversion of exhaust emissions, typically 14.7/1.
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control without use of oxygen sensor information.

IGN - IGNITION - Refers to ignition switch and
lock. OUTPUT - Functions, typically solenoids, that are
controlled by the ECM.
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INPUTS - Inform ation from sources (such

OXYGEN SENSOR, EXHAUST - Device that detects
as,coolant tem perature sensors, exhaust oxygen
the amount of oxygen (O2 ) in the exhaust stream.
sensor, etc.) that tell the ECM how the systems are
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performing. POSITIVE CRANKCASE VENTILATION - Prevent

fumes in crankcase from passing into atmosphere.
INTERMITTENT - Occurs now and then; not
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continuously. In electrical circ u its, refers to P/N - PARK/NEUTRAL - Refers to switch used to
occasional open, short, or ground. indicate to the ECM the position of the automatic
transmission.
I.P. - INSTRUMENT PANEL - Contains instrument
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gages and indicator lights to indicate performance of PORT - EXHAUST OR INTAKE PORT
the vehicle.
PROM - PROGRAMABLE READ ONLY MEMORY-
KM/H - KILOMETER PER HOUR - A metric unit an electronic term used to describe the engine
measuring distance (1000 meters) in one hour. calibration u n it.
L - LITER - A metric unit of capacity. RPM - REVOLUTIONS PER MINUTE - A measure of
rotational speed.
L4 - FOUR CYLINDER IN-LINE ENGINE
SELF-DIAGNOSTIC CODE - The ECM can detect
MALFUNCTION - A problem th a t causes the
malfunctions in the system. If a malfunction occurs,
system to operate incorrectly. Typical malfunctions
the ECM turns on the "Service Engine Soon” light. A
are; wiring harness opens or shorts, failed sensors, or
diagnostic code can be obtained from the ECM
circuit components.
through the "Service Engine Soon” light. This code
will indicate the area of the malfunction.
 ABBREVIATIONS-14-3

SES - SERVICE ENGINE SOON LIGHT - Lights when V - VOLT - A measurement of electrical pressure.
a malfunction occurs in Computer Command Control
V-6 - SIX CYLINDER ENGINE - Arranged in a "V".
system.
V-8 - EIGHT CYLINDER ENGINE - Arranged in a
TACH - TACHOMETER - A device for indicating
"V".
speed for rotation.
VACUUM - N eg ativ e p re s su re ; less th a n
TBI - THROTTLE BODY INJECTION (Unit) - is
atmospheric pressure.
controlled by the ECM to supply precise air/fuel
mixture into the intake manifold. VACUUM, M ANIFOLD - Vacuum source in
manifold below throttle plate.
TCC - TRANSMISSION / TRANSAXLE CONVERTER
CLUTCH - ECM controlled solenoid in transmission VACUUM, PORTED - A vacuum source above
which positively couples the transm ission to the (atmospheric side ) of closed throttle plate.
engine.
VIN - VEHICLE IDENTIFICATION NUMBER - Appears
THERMAC - THERMOSTATIC AIR CLEANER - on a plate attached to the windshield pillar.

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provides preheated air to intake manifold to provide
VSS - VEHICLE SPEED SENSOR - Sensor which
better driveability when engine is cold.
sends vehicle speed information to the ECM.

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TPS - THROTTLE POSITION SENSOR - Device that
WASTEGATE - A means of controlling the amount
tells the ECM the throttle position.
of boost available for a Turbo Charged engine.
TVS - THERMAL VACUUM SWITCH . Used to
WOT - WIDE OPEN THROTTLE.

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control vacuum in relationship to engine temperature.

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 INDEX

SECTION PAGE SECTION PAGE

A Chart A-4:
Injector Circuit Diagnosis - 2.5L.................. .3-20
Abbreviation.................................................. ..14-1 Injector Circuit Diagnosis-except 2.5L . . . 3-22
Acceleration Mode............................................4-3 Chart A-5:
Accelerator Control Cable ...............................4-41 Fuel Pump Relay Circuit-STM .................... .3-24
Accelerator Pedal..............................................4-42 Fuel Pump Relay Circuit - CKRVGP..............3-26
A/C Control Chart A-6:
General Description................................... ..3-6 Fuel System Pressure T e s t........................... .3-28
Diagnosis.................................................... ..3-10 Check Valve Diagnosis.....................................8-3
Service...........................................................3-100 Circuit Tester................................................... .13-6
Action Symbol U sage..................................... ..ii Clear Flood Mode..............................................4-3
Air Cleaner.........................................................12-1 Clearing Trouble Codes ...................................3-8
Air Cleaner Element..........................................12-3 Closed Loop System ........................................ .4-3

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Air Conditioning Electrical System Diagnosis. 4-76 Code System ................................................... .3-8
AIR Control Valve..............................................8-6 Code 1 3 .............................................................3-30
Code 1 4 .............................................................3-32

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Air Filter Element Replacem ent......................12-3
AIR Filter F a n .................................................. ..8-3 Code 1 5 .......................................... ................. 3-34
AIR Hoses and Pipes..........................................8-3 Code 2 1 .............................................................3-36
Air Injection Reaction..................................... ..8-1 Code 2 2 .............................................................3-38

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Air Management System .................................8-1 Code 2 3 .............................................................3-40
Diagnosis.................................................... ..8-2 Code 2 4 .............................................................3-42
Air Pump Diagnosis..........................................8-2
AIR S yste m -2.8 L..............................................8-1
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Code 2 5 .............................................................3-44
Code 32 - 2.8L................................................... .3-46
AIR Syste m -4.3 L& V 8 ..................................... 8-1 Code 32 - 2.5L, 4.3L, 5.0L, & 5.7L
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ALDL Connector.............................................. ..3-6 (Under 8500 GVW) .....................................3-48
Automatic Transmission................................. ..10-1 Code 32 - 7.4L & 5.7L (Over 8500 GVW) ------3-50
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Auxiliary Fuel Tank Control .......................... ..4-40 Code 3 3 .............................................................3-52

Code 3 4 .............................................................3-54
B Code 3 5 .............................................................3-56
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Code 4 2 .............................................................3-58
Backfire........................................................... ..2-2 Code 4 3 .............................................................3-60
Basic Electrical Circuits................................... ..1-2 Code 4 4 .............................................................3-62
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Battery Voltage Correction M ode..................4-3 Code 4 5 .............................................................3-64

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Before Starting .............................................. ..2-1 Code 5 4 .............................................................3-66

Bulb Check.........................................................3-6 Codes 51, 52, 55 ................................................3-68
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Cold Start Program Modifier ..........................3-6

c Compact Three Service.....................................3-86
Component Lo catio n s.....................................1-5
Component Systems ...................................... .1-4
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CALPAK
General Description................................... ..3-4 Computer Command C o n tro l..........................3-7
Diagnosis.......................................................3-9 Connector and Terminal Service.................... .3-85
Service...........................................................3-102 Connector Test Adapter K i t ........................... .13-5
Cautio n ........................................................... ..ii Coolant Sensor
Chart A-1: General Description.....................................3-4
No "Service Engine Soon" L ig h t ................3-12 Diagnosis..................................................... .3-9
Chart A-2: Service...........................................................3-104
No ALDL Data or Won't Flash Code 12 or Crankcase Vent Filter .....................................11-2
"Service Engine Soon" Light on Steady . . 3-14 Crank Signal.......................................................3-6
Chart A-3: Crank Signal Diagnosis.....................................3-72
Engine Crank But Will Not Run - 2.5L . . . . 3-16 Cut Out, Misses ................................................2-6
Engine Crank But Will Not Run - 2.5L . . . . 3-18
INDEX

SECTION PAGE SECTION PAGE

D F
Deceleration Mode ....................................... ..4-3 Factory Test M o d e.......................................... 3-2
Detonation.................................................... ..2-5 Field Service M ode.......................................... 3-8
Diagnostic M o d e ........................................... ..3-7 Filter Crankcase Ventilation ........................ 11-2
Diagnostic Tools................................................13-1 Forward........................................................... i
Dieseling, R u n -O n ......................................... ..2-2 Fourth Gear Switch.......................................... 10-4
Digital Voltmeter (DVM) .................................13-5 Fuel Control System ....................................... 4-1
Distributor Reference Signal ........................ ..3-6 Fuel Cutoff Mode............................................ 4-3
Downshift Control............. ........................... ..10-1 Fuel Filter Replacement................................. 4-31
Downshift Control Relay .................................10-1 Fuel Filters....................................................... 4-6
Draining the Fuel Tank.....................................4-34 Fuel Hoses and Vapor Pipes .......................... 4-6
Driveability.................................................... ..1-2 Service......................................................... 4-33

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Driveability Symptoms.....................................2-1 Fuel Injector.................................................... 4-4
Fuel Lines R e p a ir............................................ 4-34

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E Fuel Line W rench............................................ 13-1
Fuel Meter Assy. - TBI 700 ............................... 4-25

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EAC Valve ...................................................... 8-2 Fuel Meter Body-TBI 220 ............................... 4-18
E-Cell............................................................... 3-6 Fuel Module.................................................... 4-30

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E-Cell Replacement....................................... 3-109 Fuel Pressure G age.......................................... 13-7
ECM Code System............................................ 3-11 Fuel Pump D iagnosis..................................... 3-9
ECM Term inals-2.5L..................................... 3-98 Fuel Pump Operation..................................... 4-5
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ECM Term inal-2.8L....................................... 3-99 Fuel Pump Relay.............................................. 4-10
ECM Term inal-4.3L& V8............................... 3-100 Replacement.............................................. 4-29
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ECT Valve......................................................... 8-2 Fuel Pump Replacement................................. 4-29
EGR Control.................................................... 9-1 Fuel Pump Tests.............................................. 6C-6
EGR D iagnosis................................................9-3 Fuel System Cleaning..................................... 4-35
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EGR Filter Replacement.................................9-10 Fuel System Pressure Relief .......................... 4-7

EGR On-Vehicle Service ................................. 9-3 Fuel System Pressure T e s t............................... 3-28
EGR System Check............................................9-3 Fuel Tan k......................................................... 4-6
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EGR Vacuum Control....................................... 9-3 Fuel Tank Draining.......................................... 4-34

EGR Vacuum Diagnostic Switch and Solenoid 9-3 Fuel Tank Filler N e c k ..................................... 4-34
EGR Vacuum Solenoid................................... 9-10 Fuel Tank Leak T e s t ........................................ 4-35
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EGR Valves...................................................... 9-2 Fuel Tank Purging .......................................... 4-34

Elapsed Timer Module ................................. 3-6 Fuel Tank Replacement................................. 4-34
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Electronic Control Module Fuel Tank Selector Valve ............................... 4-40

General Description................................... 3-3 Fuel Tank Selector Valve Replacement . . . . 4-40
Diagnosis.................................................... 3-8
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Service......................................................... 3-87
Electronic Spark Control................................. 7-1
Electronic Spark T im in g ................................. 6-1 General Information ...................................... 1-1
Emissions......................................................... 1-2 Glossary of Terms............................................ 14-1
Emissions, Above Normal (Odors).................. 2-3
Engine Crank But Will Not R u n ...................... 3-16 H
EST Performance C h e c k ................................. 6-3
Evaporative Emission Control........................ 5-1 Hall Effect Switch............................................ ..6-2
Exhaust Gas Recirculation...............................9-1 Hard S t a r t .........................................................2-4
Exhaust System .............................................. 3-10 Hesitation.........................................................2-6
Restricted System....................................... 3-69
 INDEX

SECTION PAGE SECTION PAGE

I Minimum Air Rate Adjustment Wrench . . . . 13-7
Minimum Air Rate - TBI 220 .............................4-22
IAC Valve Flange-TBI 220 ..............................4-21 Minimum Air Rate - TBI 700 .............................4-28
IAC Valve Flange-TBI 700 ..............................4-21
Idle Air Control V alve..................................... .4-5 N
Idle Air Control W rench..................................13-6
Idle S p e e d ........................................................3-9 Negative Backpressure EGR Valve ................ 9-2
Ignition Module...............................................6-2 Normal (Open) M ode........................................13-1
Ignition System Diagnosis................................6-2
Ignition T im in g ...............................................6-3 o
Incorrect Id le .................................................. .2-3
Information Sensors ..................................... .3-3 Oil Pressure Sw itch.......................................... ..4-10
Injector Circuit Diagnosis - 2.5L...................... .3-20 Replacement.................................................4-31

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Injector Circuit Diagnosis-except 2.5 L ......... 3-22 Open Loop System .......................................... ..4-3
Injector Test Light ...........................................13-6 Oxygen Sensor
General Description......................................3-5

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In-Line Filter .................................................. .4-31
In-Tank Filte r.................................................. .4-32 Diagnosis..................................................... ..3-9
Intermittent Codes...........................................2-1 Service......................................................... ..3-106
Oxygen Sensor Wrench ................................. ..13-6

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K
P
Knock Sensor
General Description................................... .3-6
ar Park/Neutral Switch
Diagnosis.................................................... .3-60 General Description......................................3-6
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Service..........................................................3-109 Diagnosis..................................................... ..3-74
Service............................................................3-109
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L P a rts ................................................................ ..iv

PCV Valve ....................................................... ..11-2
Poor Fuel Economy.......................................... ..2-1
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Lack of Power ................................................ .2-5

Light, Manual Transmission S h if t ...................10-1 Port EGR V alve...................................................9-2
Light, Service Engine S o o n ..............................3-6 Positive Crankcase Ventilation .................... ..11-1
Power Steering Pressure Switch
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M General Description......................................3-6
Diagnosis..................................................... ..3-70
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Maintenance Schedule................................... .1-2 Service............................................................3-110

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Manual Transmission Shift Light ...................10-1 Pressure Regulator ........................................ ..4-4

MAP Sensor PROM
General Description................................... .3-4 General Description......................................3-4
Diagnosis..................................................... ..3-9
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Diagnosis......................................................3-9
Service......................................................... .3-104 Service............................................................3-87
MAT Sensor Pump, Fuel....................................................... ..4-5
General Description................................... ..3-5
Diagnosis.................................................... ..3-9 R
Service...........................................................3-109
MEM-CAL Relays
General Description................................... ..3-4 A/C Clutch Control - 2.5L ............................. ..3-76
Diagnosis.......................................................3-9 A/C Clutch Control - 2.8L............................. ..3-82
Service......................................................... ..3- Downshift Co n tro l...................................... ..10-1
Metri-Pack Service............................................3-86 Fuel P u m p ................................................... ..4-10
Metri-Pack Terminal Restricted Exhaust System ............................. ..3-69
Terminal Rem over..................................... ..13-6 Rough, Idle ..................................................... ..2-3
Micro-Pack Service............................................3-86 Run M o d e ....................................................... ..4-3
INDEX

SECTION PAGE SECTION PAGE

S TCC Pulse Switch ............................................ ..10-1
TCC Solenoid.....................................................10-1
Sag ................................................................. ..2-6 TCC System .......................................................10-1
"Scan" T o o l.................................................... ..13-1 Terminal Service ............................................ ..3-85
"Scan" Tool Positions...................................13-2 Test Light .........................................................13-5
Sensors Thermae Vacuum Diaphragm Motor................12-4
Co o lan t...................................................... ..3-4 Thermae Wax Pellet Actuator ...................... ..12-4
K n o c k ........................................................ ..3-6 Thermostatic Air Cleaner............................... ..12-1
MAP .......................................................... ..3-4 THM 400 ......................................................... ..10-1
MAT .......................................................... ..3-5 THM 700 ...........................................................10-1
O x y g e n ...................................................... ..3-5 Throttle Position Sensor
TPS ...............................................................3-5 General Description................................... ..3-5
V S S ...............................................................3-6 Diagnosis.......................................................3-9

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Serial Data L in e ................................................3-7 Service......................................................... ..3-108
Service Engine Soon Light ............................ ..3-6 Throttle Position Switch A d justm en t........... 4-23

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Shift Light, Manual Transmission....................10-1 TPS Output Check-TBI 220 .............................4-23
Solenoids Transmission Converter C lu tch ...................... ..10-1
Dow nshift....................................................10-1 Transmission Gear Position Signal ..................3-6

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E A C ...............................................................8-1
E G R ...............................................................9-4 u
T C C ...............................................................10-1
Spark Knock.................................................... ..2-5
Spark Tester ....................................................13-7
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Unstable Id le ....................................................2-3
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Special T o o ls ....................................................13-1 V
Specifications....................................................13-8
Speed Sensor-VSS Buffer A m p lifier............. ..10-1 Vacuum Pum p................................................ .13-5
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S ta llin g .............................................................2-3 Vapor P ip es......................................................4-6

Starting M o d e ..................................................4-3 Vehicle Emission Control
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Stumble.............................................................2-6 Information Label .......................................1-2

Surges and/or Chuggle.....................................2-4 Vehicle Speed Sensor
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Switches General Description................................... .3-7

Brake ...........................................................10-1 Diagnosis......................................................3-9
Fourth G e a r..................................................10-4 Service......................................................... .3-109
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Manual Clutch S ta rt.....................................10-1 Voltmeter, D ig ita l.......................................... .13-5

Oil Pressure..................................................4-10
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Park/Neutral ................................................3-6
Power Steering ......................................... ..3-6
System Check.................................................. ..3-6 Weather Pack Terminal Service .................... .3-86
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Terminal Rem over.......................................13-6

T Wiring Harness
General Description................................... .3-2
Table of Contents ............................................iii Service......................................................... .3-85
Tachometer.................................................... ..13-5 Wiring Diagram - 2.5 L .....................................3-88
TBI Model 220 ..................................................4-4 Wiring Diagram - 2.8 L ................................... .3-96
TBI Model 700 ................................................ .4-4 Wiring Diagram - 4.3L & V8 ........................... 3-94
TCC Brake Sw itch .............................................10-1
TCC Electrical Diagnosis
2.5L and 2 .8 L ...............................................10-2
4.3L and V 8 ................................................ .10-4
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B U S IN E S S R E P LY MAIL B U S IN ESS R E P LY MAIL
FIRST CLASS PERMIT NO. 102 PONTIAC, MICH. FIRST CLASS PERMIT NO. 102 PONTIAC, M ICH.

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Service Publications Service Publications
GMC Truck Operation GMC Truck Operation

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Truck & Bus Group Truck & Bus Group
General Motors Corporation General Motors Corporation
31 Judson Street 31 Judson Street

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Pontiac, Michigan 48058 Pontiac, Michigan 48058

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B U S IN E S S R E P LY MAIL B U S IN ESS R E P LY MAIL

FIRST CLASS PERMIT NO. 102 PONTIAC, MICH. FIRST CLASS PERMIT NO. 102 PONTIAC, M ICH.
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Service Publications Service Publications

GMC Truck Operation GMC Truck Operation
Truck & Bus Group Truck & Bus Group
General Motors Corporation General Motors Corporation
31 Judson Street 31 Judson Street
Pontiac, Michigan 48058 Pontiac, Michigan 48058
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