PleasureCraft Engine Group 5.0L Diagnostic Manual Download Page 1

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MEFI 4 / 4B

DIAGNOSTIC

MANUAL

5.0/5.7/6.0/8.1L

L510005P

11/05

Summary of Contents for 5.0L

Page 1: ...MEFI 4 4B DIAGNOSTIC MANUAL 5 0 5 7 6 0 8 1L L510005P 11 05...

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Page 3: ...ering System 5 0 5 7L Page 3A 1 Section 3B Fuel Metering System 6 0L Page 3B 1 Section 3C Fuel Metering System 8 1L Page 3C 1 Section 4A Ignition System 5 0 5 7L Page 4A 1 Section 4B Ignition System 6...

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Page 5: ...e Page 11 Wiring Harness Service Page 11 Wiring Connector Service Page 12 Metri Pack Series 150 Terminals Page 12 Weather Pack Connectors Page 13 Micro Pack 100 W Series Connectors Page 14 General Des...

Page 6: ...insulated shoes stands near a highly charged object and momentarily touches ground Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity Static char...

Page 7: ...ndicate exactly where the problem is in a particular circuit Some Diagnostic Procedures incorporate steps with the use of a scan tool scan diagnostics or with the DTC tool non scan diagnostics a hand...

Page 8: ...there does not seem to be any correlation between the problem and any specific circuit the scan tool can be checked on each position watching for a period of time to see if there is any change in the...

Page 9: ...5 Turn ignition OFF for at least 20 seconds 6 Turn ignition ON and read DTC s If DTC s are still present check Notice below and repeat procedure following from step 2 NOTICE When clearing DTC s with o...

Page 10: ...s are thoroughly clean 7 Never connect or disconnect the wiring harness at the ECM when the ignition is switched ON 8 Before attempting any electric arc welding on the vehicle disconnect the battery l...

Page 11: ...s for more information OL display in all ranges indicates open circuit Zero display in all ranges indicates a short circuit An intermittent connection in a circuit may be indicated by a digital readin...

Page 12: ...oving terminals from Weather Pack connectors Refer to wiring harness service in MEFI General Information Section for removal procedure DIAGNOSTIC TROUBLE CODE DTC TOOL A hand held diagnostic tool that...

Page 13: ...engine harness FUEL LINE QUICK CONNECT SEPARATOR Used to release fuel line quick connect fittings INJECTOR TESTER Separately energizes each injector to compare for equal fuel pressure drops over a con...

Page 14: ...GALLONS PER HOUR HVS HIGH VOLTAGE SWITCH IAC IDLE AIR CONTROL IAT INTAKE AIR TEMPERATURE IC IGNITION CONTROL IGN IGNITION INJ INJECTOR I O INPUT OUTPUT kPa KILOPASCAL ABBREVIATIONS KS KNOCK SENSOR SY...

Page 15: ...s certain components can be damaged Always use jumper wires with the corresponding mating terminals between connectors for circuit checking NEVER probe through connector seals wire insulation secondar...

Page 16: ...wire and terminal out through the connector If the terminal is being reused reshape the locking tang Wiring Connector Service Most connectors in the engine compartment are protected against moisture a...

Page 17: ...7 Figure 1 7 shows a Weather Pack connector and the tool J28742 or equivalent required to service it This tool is used to remove the pin and sleeve terminals If terminal removal is attempted without u...

Page 18: ...eries Connectors Figure 1 8 The harness connectors used with the ECM J1 and J2 connectors are Micro Pack 100 W Series It is used for its ruggedized construction capable of carrying more current and pr...

Page 19: ...1 3 4 5 6 7 8 9 10111213141516 18 17 1920212223242526272829303132 1 2 TAB B TAB C 3 4 TAB B TAB C TAB A TAB A TAB A TAB B TAB B FIGURE C STRAIN RELIEF OPENED FIGURE B STRAIN RELIEF CLOSED FIGURE A EXP...

Page 20: ...1 16 General Information 5 0 5 7 6 0 8 1L MEFI 4 PCM This page left intentionally blank...

Page 21: ...e 11 Engine Coolant Temperature ECT Sensor Page 12 Manifold Absolute Pressure MAP Intake Air Temperature IAT Sensor 5 0 5 7L Page 13 Manifold Absolute Pressure MAP Sensor 6 0 8 1L Page 14 Throttle Pos...

Page 22: ...ally charged particles that energizes solenoids closes relays and illuminates lamps Besides causing current flow in circuits voltage can be used as a signal Voltage signals can send information by cha...

Page 23: ...ariable but not continuously They can only be represented by distinct voltages within a range For example 1V 2V or 3V would be allowed but 1 27V or 2 56V would not Digital signals are especially usefu...

Page 24: ...e manufacturer with the calibration information that is specific to each marine application Engine Control Module ECM The Engine Control Module ECM located on the engine is the control center of the f...

Page 25: ...l warning 2 low oil pressure lamp control Speed Density System The Marine Electronic Fuel Injection MEFI system is a speed and air density system The system is based on speed density fuel management S...

Page 26: ...TEMPERATURE ECT SENSOR INTAKE AIR TEMPERATURE IAT 5 0 5 7L only KNOCK SENSOR 1 DIAGNOSTIC ENABLE GENERAL WARNING 2 OIL PRESSURE CRANKSHAFT POSITION SENSOR RPM FUEL INJECTORS MULTIPLE IGNITION CONTROL...

Page 27: ...a wide open throttle would produce a high MAP output voltage This high output voltage is produced because the pressure inside the manifold is almost the same as outside the manifold so you measure al...

Page 28: ...pe input creates the timing signal for the pulsing of the fuel injectors as well as the IC functions This signal is used for a number of control and testing functions within the ECM Throttle Position...

Page 29: ...on Purpose To control spark knock detonation a knock sensor KS system is used This system is designed to retard spark timing when excessive spark knock is detected in the engine The KS system allows t...

Page 30: ...present at the time the system is being checked In this case refer to the Symptoms portion of the manual and make a careful physical inspection of all portions of the system involved Shorted relay co...

Page 31: ...ve the retainer 3 Disconnect the system relay electrical connector 4 Remove the system relay Important The system relay is an electrical component Do Not soak in any liquid or solvent as damage may re...

Page 32: ...1 Turn OFF the ignition 2 Drain the cooling system below the level of the ECT sensor if necessary 3 Disconnect the ECT electrical connector 4 Remove the ECT sensor Installation Procedure Important Co...

Page 33: ...nd replace as necessary map rr map rr Installation Procedure Important Lightly coat the MAP sensor seal with rubber lubricant before installing the sensor The lubricant should be applied with a sponge...

Page 34: ...ake manifold 2 4 Inspect the MAP sensor seal for wear or damage and replace as necessary 684801 684801 1 Installation Procedure Important Lightly coat the MAP sensor seal with rubber lubricant before...

Page 35: ...5 0 5 7 6 0L 8 1L ECM and Sensors 2 15 MEFI 4 PCM 3 Connect the MAP sensor electrical connector 1 684798 1...

Page 36: ...actuator lever 3 TP sensor attaching screws Torque to 2 N m 18 lb in 4 TP sensor electrical connector 5 Flame arrestor 2 1 PS19190 Throttle Position TP Sensor Remove or Disconnect 1 Flame arrestor 2 T...

Page 37: ...this type of deposit Shiny spots on the pintle or seat are normal and do not indicate misalignment or a bent pintle shaft Important If installing a new IAC valve be sure to replace with an identical...

Page 38: ...n identical part number When installing knock sensor be sure to install in the same location removed from If installing knock sensor in water jacket use Teflon sealer 1 Knock sensor into engine block...

Page 39: ...installing knock sensor be sure to install in the same location removed from 1 Knock sensors into engine block Be sure threads are clean Torque to 20 N m 15 lb ft 4 Remove the knock sensors 2 Connect...

Page 40: ...r 12 108 MAP IAT Sensor Attaching Stud 5 7 44 62 TP Sensor Attaching Screws 2 18 IAC Valve Attaching Screws 3 2 28 Knock Sensor 15 22 11 16 Fastener Tightening Specifications 6 0 8 1L Application N m...

Page 41: ...bly Page 8 Quick Connect Fitting s Service Metal Collar Page 9 Fuel Rail Assembly Page 11 Fuel Injectors Page 13 Fuel Pressure Regulator Assembly Page 14 Fuel Control Cell FCC Page 15 Low Pressure Fue...

Page 42: ...ow the maximum OEM RPM specification Rev Limit Power Reduction Mode Power reduction mode is a function of the ECM that reduces engine power under certain conditions Power reduction will disable one fu...

Page 43: ...ure 3 2 Typical Fuel Control Cell FCC Figure 3 1 Fuel Metering System Typical Figure 3 3 Low Pressure Fuel Pump FUEL TANK PRESSURE REGULATOR FUEL FILTER LOW PRESSURE FUEL PUMP FUEL CONTROL CELL FUEL R...

Page 44: ...n injector that is stuck partly open would cause loss of pressure after engine shut down Consequently long cranking times would be noticed Dieseling could also occur because some fuel could be deliver...

Page 45: ...ow control is handled by the Idle Air Control IAC valve described below The throttle body also provides the location for mounting the TP sensor and for sensing changes in engine vacuum due to throttle...

Page 46: ...plates Figure 3 7 By moving a conical valve known as a pintle IN towards the seat to decrease air flow or OUT away from the seat to increase air flow a controlled amount of air moves around the thrott...

Page 47: ...Install or Connect 1 Flame arrestor to throttle body 2 Flame arrestor retaining clamp to flame arrestor Fuel Control On Board Service The following is general information required when working on the...

Page 48: ...battery cable 2 Flame arrestor 3 Electrical connectors from TP sensor and IAC valve 4 Throttle cable 5 Throttle body attaching bolts 6 Throttle body assembly and flange gasket Discard gasket Clean Not...

Page 49: ...ve the retainer from the quick connect fitting Caution Wear safety glasses in order to avoid eye damage 3 Blow dirt out of the fittig using compressed air 12776 4 Choose the correct tool from the tool...

Page 50: ...lean engine oil to the male pipe end 12784 2 Push both sides of the fitting together in order to snap the retaining tabs into place 12786 3 Once installed pull on both sides of the fitting in order to...

Page 51: ...ck Connect Fittings outlined in this section 5 Vacuum line to fuel pressure regulator 6 Electrical connectors from injectors 7 Move wire harness out of way 8 Four attaching screws for fuel rail 9 Fuel...

Page 52: ...uel Rail Attaching Stud 2 Fuel Pressure Connection Cap 3 Fuel Rail Assembly 4 Fuel Injector O Ring 5 Fuel Injector Assembly 6 Fuel Injector Retaining Clip 7 Fuel Pressure Regulator 8 Fuel Pressure Reg...

Page 53: ...tor O ring seal grooves for nicks burrs or corrosion Replace injector if damaged Clean with spray cleaner and wipe groove clean with lint free cloth Do Not use abrasive materials or wire brush on inje...

Page 54: ...If dirty use a pick to remove filter screen and discard Replace with new filter screen supplied in service package Fuel Pressure Regulator Install or Connect 1 Lubricate new fuel pressure regulator O...

Page 55: ...let fuel line fittings 4 Fuel Control Cell FCC attaching bolts 5 Fuel Control Cell FCC Install or Connect 1 Fuel Control Cell FCC 2 Fuel Control Cell FCC attaching bolts 3 Inlet and outlet fuel line f...

Page 56: ...y hand thread the bowl into the FCC mounting head Tighten the bowl firmly back into the head with an oil filter wrench 10 Apply pipe sealant suitable with gasoline to the 3 16 allen plug 11 Install an...

Page 57: ...ine to the threads fo the 7 16 plug 10 Install and tighten the 7 16 plug securely 11 Install the bowl firmly back onto the FCC head 12 Install the canister retaining clamp and tighten securely 13 Reco...

Page 58: ...let and outlet fuel line fittings 4 Fuel pump electrical connector 5 Negative battery cable Inspect Turn ignition switch to the ON position for 2 seconds then turn to the OFF position for 10 seconds T...

Page 59: ...19 MEFI 4 PCM Torque Specifications Fastener Tightening Specifications Application N m Lb Ft Lb In Throttle Body Attaching Screws 15 11 IAC Valve Attaching Screws 3 2 28 Fuel Pressure Connector 13 115...

Page 60: ...3A 20 Fuel Metering System 5 0 5 7L MEFI 4 PCM This page left intentionally blank...

Page 61: ...ly Page 8 Quick Connect Fitting s Service Metal Collar Page 9 Fuel Rail Assembly Page 12 Fuel Injectors Page 15 Fuel Control Cell FCC Page 17 Fuel Pressure Regulator Page 19 Low Pressure Fuel Pump Pag...

Page 62: ...ll resume after engine RPM drops below the maximum OEM RPM specification Rev Limit Power Reduction Mode Power reduction mode is a function of the ECM that reduces engine power under certain conditions...

Page 63: ...Control Cell FCC Figure 3 1 Fuel Metering System Typical Figure 3 3 Low Pressure Fuel Pump M4054P 2 12 04 FUEL TANK PRESS REG FUEL FILTER LOW PRESSURE FUEL PUMP FUEL CONTROL CELL FUEL RAIL ASSEMBLY E...

Page 64: ...d integrates the fuel pressure regulator 2 into the fuel metering system Figure 3 3 Fuel Rail Assembly Figure 3 4 Fuel Injector Assembly Typical 380659 351198 Fuel Injectors The Multec 2 fuel injector...

Page 65: ...dled by the Idle Air Control IAC valve described below The throttle body also provides the location for mounting the TP sensor and for sensing changes in engine vacuum due to throttle plates position...

Page 66: ...ng allows enough air flow by the throttle plates to cause the IAC valve pintle to be positioned at a calibrated number of steps counts from the seat during controlled idle operation This minimum air r...

Page 67: ...s warnings and cautions before proceeding 1 Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is made to start the engine 2 Loosen fuel filler cap to relieve...

Page 68: ...tighten the clamp 6 Reconnect the negative battery cable Throttle Body Assembly Replacement Remove or Disconnect 1 Disconnect the negative battery cable 2 Remove the flame arrestor clamp and flame ar...

Page 69: ...re before servicing any fuel system connection Refer to Fuel Pressure Relief Procedure 2 Remove the retainer from the quick connect fitting 1238589 4 Choose the correct tool from the tool set for the...

Page 70: ...ale pipe end 12784 2 Push both sides of the fitting together in order to snap the retaining tabs into place 12786 5 Pull the connection apart 6 Use a clean shop towel in order to wipe off the male pip...

Page 71: ...Fuel Metering System 3B 11 MEFI 4 PCM 3 Once installed pull on both sides of the fitting in order to make sure the connection is secure 12787 1238589 4 Install the retainer on to the quick connect fit...

Page 72: ...sure Refer to Fuel Pressure Relief Procedure 2 Remove the engine cover 3 Before removal clean the fuel rail assembly with a spray type engine cleaner GM X 30A or equivalent if necessary Follow the pac...

Page 73: ...emoved in order to avoid damaging the fuel rail components Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes a...

Page 74: ...ct Fitting procedure in this section 8 Connect the injector electrical connectors Install each connector on the proper injector in order to ensure correct injector firing order Rotate the injectors as...

Page 75: ...build date code 3 indicates the month 4 day 5 year 6 and the shift 7 that built the injector 351185 351196 Fuel Injector Replacement Remove or Disconnect Important The engine oil may be contaminated...

Page 76: ...njector 3 Install a new retainer clip 1 on the injector 351185 4 Push the fuel injector 5 into the fuel rail injector socket with the electrical connector facing outwards The retainer clip 4 locks on...

Page 77: ...t fuel line fittings 4 Fuel Control Cell FCC attaching bolts 5 Fuel Control Cell FCC Install or Connect 1 Fuel Control Cell FCC 2 Fuel Control Cell FCC attaching bolts 3 Inlet and outlet fuel line fit...

Page 78: ...hand thread the bowl into the FCC mounting head Tighten the bowl firmly back into the head with an oil filter wrench 10 Apply pipe sealant suitable with gasoline to the 3 16 allen plug 11 Install and...

Page 79: ...e to the threads fo the 7 16 plug 10 Install and tighten the 7 16 plug securely 11 Install the bowl firmly back onto the FCC head 12 Install the canister retaining clamp and tighten securely 13 Reconn...

Page 80: ...clamps 1 3 Remove the fuel pressure regulator 2 Install or Connect 4 Install the fuel pressure regulator 2 5 Install two new clamps 1 6 Push on a new filter element over the electric pump 7 Install th...

Page 81: ...nlet and outlet fuel line fittings 4 Fuel pump electrical connector 5 Negative battery cable Inspect Turn ignition switch to the ON position for 2 seconds then turn to the OFF position for 10 seconds...

Page 82: ...MEFI 4 PCM Torque Specifications Fastener Tightening Specifications Application N m Lb Ft Lb In Throttle Body Attaching Screws 15 11 IAC Valve Attaching Screws 3 2 28 Fuel Pressure Connector 13 115 F...

Page 83: ...ge 8 Quick Connect Fitting s Service Metal Collar Page 9 Fuel Rail Assembly Page 11 Fuel Pressure Regulator Assembly Page 16 Fuel Injectors Page 17 Fuel Control Cell FCC Page 20 Low Pressure Fuel Pump...

Page 84: ...the maximum OEM RPM specification Rev Limit Power Reduction Mode Power reduction mode is a function of the ECM that reduces engine power under certain conditions Power reduction will disable one fuel...

Page 85: ...igure 3 2 Fuel Control Cell FCC Figure 3 1 Fuel Metering System Typical Figure 3 3 Low Pressure Fuel Pump FUEL TANK PRESSURE REGULATOR FUEL FILTER LOW PRESSURE FUEL PUMP FUEL CONTROL CELL FUEL RAIL AS...

Page 86: ...s and integrates the fuel pressure regulator 2 into the fuel metering system Figure 3 3 Fuel Rail Assembly Figure 3 4 Fuel Injector Assembly 341661 351198 Fuel Injectors The Multec 2 fuel injector ass...

Page 87: ...ides the location for mounting the TP sensor and for sensing changes in engine vacuum due to throttle plates position Pressure Regulator Assembly The pressure regulator is a diaphragm operated relief...

Page 88: ...ng allows enough air flow by the throttle plates to cause the IAC valve pintle to be positioned at a calibrated number of steps counts from the seat during controlled idle operation This minimum air r...

Page 89: ...s warnings and cautions before proceeding 1 Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is made to start the engine 2 Loosen fuel filler cap to relieve...

Page 90: ...tighten the clamp 6 Reconnect the negative battery cable Throttle Body Assembly Replacement Remove or Disconnect 1 Disconnect the negative battery cable 2 Remove the flame arrestor clamp and flame ar...

Page 91: ...e the retainer from the quick connect fitting Caution Wear safety glasses in order to avoid eye damage 3 Blow dirt out of the fitting using compressed air 12776 4 Choose the correct tool from the tool...

Page 92: ...engine oil to the male pipe end 12784 2 Push both sides of the fitting together in order to snap the retaining tabs into place 12786 3 Once installed pull on both sides of the fitting in order to mak...

Page 93: ...equivalent if necessary Follow the package instructions Do not soak fuel rails in liquid cleaning solvent 3 Remove the engine cover 4 Disconnect the TP sensor harness connector 5 Disconnect the IAC v...

Page 94: ...nector in order to release the connector from the injector 9 Repeat step 9 and step 10 for each injector connector 10 Disconnect the fuel feed and return from the fuel rail Refer to Quick Connect Fitt...

Page 95: ...assembly 14 Remove the injector lower O ring seal 4 from the spray tip end of each injector 3 15 Discard the O ring seals Install or Connect 1 Lubricate the new lower injector O ring seals 4 with clea...

Page 96: ...dlock or equivalent to the threads of the fuel rail attaching bolts 5 Install the fuel rail attaching bolts Tighten Tighten the fuel rail attaching bolts to 12 N m 106 lb in 6 Connect the fuel pressur...

Page 97: ...njectors as required in order to avoid stretching the wire harness 9 Reconnect the TP sensor harness connector 10 Reconnect the IAC valve harness connector 11 Install the engine cover 12 Connect the n...

Page 98: ...essure regulator 8 from the fuel pressure regulator housing Install or Connect 1 Install the backup ring 10 on the fuel pressure regulator 8 2 Install the new large O ring 11 on the fuel pressure regu...

Page 99: ...l leaks Fuel Injector Replacement Remove or Disconnect Important The engine oil may be contaminated with fuel if the fuel injectors are leaking 1 Remove the fuel rail assembly Refer to Fuel Rail Assem...

Page 100: ...be sure to order the correct injector for the application being serviced The fuel injector assembly 1 is stamped with a part number identification 2 A four digit build date code 3 indicates the month...

Page 101: ...or 5 into the fuel rail injector socket with the electrical connector facing outwards The retainer clip 4 locks on to a flange on the fuel rail injector socket 5 Install the fuel rail assembly Refer t...

Page 102: ...t fuel line fittings 4 Fuel Control Cell FCC attaching bolts 5 Fuel Control Cell FCC Install or Connect 1 Fuel Control Cell FCC 2 Fuel Control Cell FCC attaching bolts 3 Inlet and outlet fuel line fit...

Page 103: ...hand thread the bowl into the FCC mounting head Tighten the bowl firmly back into the head with an oil filter wrench 10 Apply pipe sealant suitable with gasoline to the 3 16 allen plug 11 Install and...

Page 104: ...e to the threads fo the 7 16 plug 10 Install and tighten the 7 16 plug securely 11 Install the bowl firmly back onto the FCC head 12 Install the canister retaining clamp and tighten securely 13 Reconn...

Page 105: ...nlet and outlet fuel line fittings 4 Fuel pump electrical connector 5 Negative battery cable Inspect Turn ignition switch to the ON position for 2 seconds then turn to the OFF position for 10 seconds...

Page 106: ...pplication N m Lb Ft Lb In Throttle Body Attaching Screws 15 11 IAC Valve Attaching Screws 3 2 28 Fuel Pressure Connector 13 115 Fuel Pressure Regulator Attaching Screw 9 5 84 Fuel Pressure Regulator...

Page 107: ...Page 3 Ignition System Overview Page 3 Crankshaft Position CKP Sensor and Reluctor Wheel Page 3 Camshaft Position CMP Sensor and Reluctor Wheel Page 4 Ignition Coil Page 4 Noteworthy Ignition Informa...

Page 108: ...p 1 52 mm 060 in Spark Plug Type R030010 Fastener Tightening Specifications Specifications Application Metric English Camshaft Position CMP Sensor Bolt 9 N m 72 lb in Crankshaft Position CKP Sensor Bo...

Page 109: ...it to trigger the ignition coil The distributor used on the MEFI equipped engines is designed for the marine industrial environment The base plate of the distributor is equipped with two special vents...

Page 110: ...MUST be used There is a parameter on the data stream called Cam Retard Cam retard must be set to 43 47 degrees or driveability problems will exist The design construction of the ignition coil affects...

Page 111: ...way the CKP sensor may be destroyed Extreme care must be exercised during removal and installation procedures The ignition timing is not adjustable Moving the distributor changes the Cam Retard Cam Re...

Page 112: ...l to calculate an average voltage Then the ECM assigns a voltage range above and below the average voltage value The ECM checks the KS and related wiring by comparing the actual knock signal to the as...

Page 113: ...bolts Tighten Tighten the ignition coil mounting bolts to 12 N m 106 lb in 3 Connect the ignition coil harness connector 4 Connect the coil wire at the ignition coil Refer to Spark Plug Wire Replacem...

Page 114: ...f cracks or splits in the wires 3 Inspect each boot for the following conditions Tearing Piercing Arcing Carbon tracking Corroded terminal If corrosion carbon tracking or arcing are indicated on a spa...

Page 115: ...causes driveability conditions Ensure that the spark plug has the correct heat range An incorrect heat range causes the following conditions Spark plug fouling colder plug Pre ignition causing spark...

Page 116: ...pect the spark plug recess area of the cylinder head for moisture such as oil coolant or water A spark plug boot that is saturated causes arcing to ground Inspect the insulator 2 for cracks All or par...

Page 117: ...electrodes 3 4 Deposits on the electrodes 3 4 reduce or eliminates the gap Inspect for worn or missing platinum pads on the electrodes 3 4 if equipped Inspect for excessive fouling Inspect the spark...

Page 118: ...l not effect spark intensity unless they form into a glazing over the electrode Installation Procedure 1 Properly position each spark plug washer 2 Inspect each spark plug gap Adjust each plug as need...

Page 119: ...all the NEW CKP sensor O ring 387759 Installation Procedure Important Ensure that the crankshaft position sensor is fully seated and held stationary in the engine front cover bore A crankshaft positio...

Page 120: ...retaining screws 5 Remove the distributor rotor 6 Remove the CMP sensor retaining screws 7 Align the notch 1 in the reluctor wheel with the CMP sensor 8 Remove the CMP sensor M4090 678815 1 2 1 1 Inst...

Page 121: ...der to read serial data 2 Start the engine 3 Look at the Cam Retard parameter 1 2 6 Install the distributor cap 7 Install the distributor cap bolts 1 Tighten Tighten the distributor cap bolts to 2 4 N...

Page 122: ...the wiring harness connector from the knock sensor 2 2 Remove the knock sensor 2 from the engine block 1 20272 Installation Procedure 1 Install the knock sensor 2 into the engine block 1 Tighten Tigh...

Page 123: ...ft Position CMP Sensor and Reluctor Wheel Page 4 Ignition Coils Page 4 Noteworthy Ignition Information Page 5 Engine Control Module ECM Page 5 Knock Sensor KS System Description Page 6 Purpose Page 6...

Page 124: ...030011 Spark Plug Type 8 1L R030009 Fastener Tightening Specifications Application Metric English Camshaft Position CMP Sensor Bolt 6 0L 29 N m 21 lb ft Camshaft Position CMP Sensor Bolt 8 1L 25 N m 1...

Page 125: ...shaft position or engine speed The 1X signal The 1X camshaft position sensor sends a signal to the ECM The ECM uses this signal to quickly determine what cylinder to fire the ignition coil on The igni...

Page 126: ...lustrates the type of coil used Camshaft Position CMP Sensor and Reluctor Wheel The camshaft position CMP sensor works in conjunction with a 1X reluctor wheel mounted at the rear of the camshaft The C...

Page 127: ...oot from the plug or coil tower before pulling the boot from the spark plug or the ignition coil tower Engine Control Module ECM The ECM is responsible for maintaining proper spark and fuel injection...

Page 128: ...nal to calculate an average voltage Then the ECM assigns a voltage range above and below the average voltage value The ECM checks the KS and related wiring by comparing the actual knock signal to the...

Page 129: ...ghten Tighten the ignition coil mounting bolts to 12 N m 106 lb in 3 Connect the ignition coil harness connector 4 Connect the spark plug wires at the ignition coils Refer to Spark Plug Wire Replaceme...

Page 130: ...signs of cracks or splits in the wires 3 Inspect each boot for the following conditions Tearing Piercing Arcing Carbon tracking Corroded terminal If corrosion carbon tracking or arcing are indicated...

Page 131: ...g causes driveability conditions Ensure that the spark plug has the correct heat range An incorrect heat range causes the following conditions Spark plug fouling colder plug Pre ignition causing spark...

Page 132: ...ect the spark plug recess area of the cylinder head for moisture such as oil coolant or water A spark plug boot that is saturated causes arcing to ground Inspect the insulator 2 for cracks All or part...

Page 133: ...electrodes 3 4 Deposits on the electrodes 3 4 reduce or eliminates the gap Inspect for worn or missing platinum pads on the electrodes 3 4 if equipped Inspect for excessive fouling Inspect the spark...

Page 134: ...not effect spark intensity unless they form into a glazing over the electrode Installation Procedure 1 Properly position each spark plug washer 2 Inspect each spark plug gap Adjust each plug as needed...

Page 135: ...Important Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine 2 Remove the CKP sensor retaining bolt 3 Remove the CKP sensor 1239292 Installation Pro...

Page 136: ...moved and installed three times Exceeding three installations with the same sensor may result in engine driveability problems or a possible no start Important The crankshaft position sensor bolt has a...

Page 137: ...in order to avoid debris from entering the engine 2 Remove the CMP sensor retaining bolt 3 Remove the CMP sensor 260128 Installation Procedure Important Inspect the CMP sensor O ring for wear or damag...

Page 138: ...ion Procedure Important Inspect the CMP sensor O ring for wear or damage If a problem is found replace the O ring Lubricate the new O ring with clean engine oil before installing 1 Install the CMP sen...

Page 139: ...nock sensor be sure to install in the same location removed from 1 Knock sensors into engine block Be sure threads are clean Torque to 20 N m 15 lb ft 4 Remove the knock sensors 2 Connect the knock se...

Page 140: ...ne block Tighten Tighten the knock sensor to 20 N m 15 lb ft 2 Connect the knock sensor harness connector 1 to the knock sensor 2 678815 Knock Sensor KS 1 Replacement 8 1L Removal Procedure 1 Remove t...

Page 141: ...ove the wiring harness connector from the knock sensor 2 2 Remove the knock sensor 2 from the engine block 1 20272 Installation Procedure 1 Install the knock sensor 2 into the engine block 1 Tighten T...

Page 142: ...4B 20 Electronic Ignition 6 0 8 1L MEFI 4 PCM This Page Left Intentionally Blank...

Page 143: ...C 44 Knock Sensor 1 Circuit Scan Page 116 DTC 44 Knock Sensor 2 Circuit Scan Page 118 DTC 51 Calibration Checksum Failure Scan Page 120 DTC 81 Exhaust Temperature Switch Fault Page 122 DTC 81 Cranksha...

Page 144: ...tput circuits depend upon good continuity between circuit connectors It is important before component replacement and or during normal troubleshooting procedures that a visual inspection of any questi...

Page 145: ...90 194 241 80 176 332 70 158 467 60 140 667 50 122 973 45 113 1188 40 104 1459 35 95 1802 30 86 2238 Engine Controls Speci cations Ignition System Speci cations 5 0 5 7L Speci cations Application Metr...

Page 146: ...72 lb in Engine Control Module ECM Mounting Screws 10 14 N m 88 124 lb in Engine Coolant Temperature ECT Sensor 17 N m 13 lb ft Fuel Rail Attaching Bolts 10 N m 89 lb in Idle Air Control IAC Valve At...

Page 147: ...r comparison with the engine you are diagnosing The Engine Scan Tool Data List represents values that would be seen on a normal running engine Typical Diacom Preferred Screen Data List Idle Operating...

Page 148: ...5 6 Diagnosis 5 0 5 7 6 0 8 1L MEFI 4 PCM 6 0L MPI...

Page 149: ...5 0 5 7 6 0 8 1L Diagnosis 5 7 MEFI 4 PCM 8 1L MPI...

Page 150: ...of the idle air control pintle in counts A larger number of counts means that more air is being commanded through the idle air passage Idle air control should respond fairly quickly to changes in eng...

Page 151: ...00 msec Indicates the amount of time the ECM is commanding the injectors ON during each engine cycle A larger injector pulse width will cause more fuel to be delivered Inj Pulse Width should increase...

Page 152: ...nsor Voltage Low High Temperature Indicated DTC 21 Throttle Position TP Sensor Circuit Throttle Position Sensor Skewed High DTC 21 Throttle Position TP Sensor Circuit Throttle Position Sensor Voltage...

Page 153: ...voltage low No action set when voltage 10v General Warning 1 Telltale Set J1 19 Transmission Over temp 235 F Enabled when trans sw closes General Warning 2 Telltale Set J1 4 Low Oil Pressure if using...

Page 154: ...gs Using Diacom these warnings will be displayed under the Codes tab They can be cleared the same as the trouble codes Unlike trouble codes these warnings do not turn on the MIL nor can they be ashed...

Page 155: ...methylcyclopentadlenyl manganese tricarbonyl MMT ask your service station operator whether or not this fuel contains MMT General Motors does not recommend the use of such gasoline If fuels containing...

Page 156: ...To DLC Connector Term G Engine Control Module ECM To DLC Connector Term E To System Relay Term 86 To Fuse Block Term A To System Relay Term 30 14 B A S108 S107 S101 S106 Coolant Temperature Sender Alt...

Page 157: ...2 BLU WHT 4 J1 J1 From DLC Connector Term A From Ignition Coil Connector odd cyl Term A From System Relay Term 85 From Ignition Coil Connector even cyl Term A From Ignition Coil Connector even cyl Ter...

Page 158: ...86 87A 87 85 87A 87 1 2 Not Used Fuel Pump Relay Fuse 20A Low Pressure Fuel Pump Fuel Control Cell A B PNK BLK 339 Fuel Pump Relay DK GRN 485 85 86 30 Fuse Block M4003_8 1LP 2 14 04 ECM Fuse 20A Fuse...

Page 159: ...M BRN WHT 419 BLK WHT 451 ORN 440 DLC Connector F G H J K E D C B A From S120 B To Pin 10 10 pin Boat Harness From S116 ignition From S112 ground 10 J2 27 2 J1 ORN BLK 461 ORN BLK 461 Diagnostic Test...

Page 160: ...Map Sensor Signal Sensor Ground ECT Sensor Signal Engine Control Module ECM B A S125 S123 TP Sensor Signal DK BLU 417 23 Knock Sensor 1 Signal J2 M4005p_8 1L 7 29 05 C B A GRY 416 5 Volt Reference Coi...

Page 161: ...e 17 18 16 32 J2 A A C C B B Crankshaft Position CKP Sensor Solid State PNK BLK 632 PNK BLK 632 RED 631 RED 631 LT GRN 634 BRN WHT 633 S105 S104 CMP Sensor Signal Depspower CKP Sensor Signal DepsLo Ca...

Page 162: ...Injector Cylinder 1 B A Fuel Injector Cylinder 4 B A Fuel Injector Cylinder 6 B A Fuel Injector Cylinder 7 DK BLU 467 C A 11 J1 Fuel Injector Cylinder 2 B B A Fuel Injector Cylinder 3 B A Fuel Injecto...

Page 163: ...Fuel Injector Driver B 11 J1 Fuel Injector Driver A 26 DK BLU DK BLU DK BLU DK BLU DK BLU 467 DK GRN DK GRN DK GRN DK GRN DK GRN 468 PNK PNK A C E G B D F H J K Engine Control Module ECM From S122 Fro...

Page 164: ...inder 3 Engine Control Module ECM BLK 151 BLK 151 BLK 151 BRN 2129 BRN 2129 BLK 450 LT BLU 2123 LT BLU 2123 PPL 2121 PPL 2121 PPL 902 PNK 439 PNK 39 PNK 39 PNK 39 PNK 39 C109 S132 S111 S128 S130 S121...

Page 165: ...linder 7 Engine Control Module ECM BLK 151 BLK 151 BLK 151 BRN 2129 BRN 2129 BLK 450 RED 2127 RED 2127 DK GRN 2125 DK GRN 2125 PPL 902 PNK 439 PNK 39 PNK 39 PNK 39 PNK 39 C109 S132 S111 S128 S130 S121...

Page 166: ...der 4 Engine Control Module ECM BLK 151 BLK 151 BLK 151 BRN 2129 BRN 2129 BLK 450 DK GRN WHT 2124 DK GRN WHT 2124 RED 2122 RED 2122 PPL 902 PNK 439 PNK 39 PNK 39 PNK 39 PNK 39 C110 S133 S111 S129 S131...

Page 167: ...er 8 Engine Control Module ECM BLK 151 BLK 151 BLK 151 BRN 2129 BRN 2129 BLK 450 PPL WHT 2124 PPL WHT 2124 BLU WHT 2126 BLU WHT 2126 PPL 902 PNK 439 PNK 39 PNK 39 PNK 39 PNK 39 C110 S133 S111 S129 S13...

Page 168: ...trol Module ECM Ignition Control C 30 Ignition Control F Ignition Control E Ignition Control B Ignition Control D Ignition Control G 13 29 15 J2 J1 J1 J2 J2 14 28 Not Used Not Used Ignition Coil Conne...

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Page 170: ...7 8 9 10 To DLC Connector Term G Engine Control Module ECM To DLC Connector Term E To System Relay Term 86 To System Relay Term 30 To Alternator Connector Term A To Starter Relay Term 86 To Starter R...

Page 171: ...Y GRN YEL GRN YEL PNK BLK BLK 450 BLK 450 M4002_5 7P 2 10 04 S113 S117 S119 S116 13 28 29 B A 1 2 General Warning 2 BLU WHT 4 J1 From Pin 1 10 pin Boat Harness From DLC Connector Term A From System Re...

Page 172: ...n 1 2 Not Used Fuel Pump Relay Fuse 20A Low Press Fuel Pump Fuel Control Cell A B PNK 339 Fuel Pump Relay DK GRN WHT 485 85 86 30 Fuse Block M4003_5 7P 2 12 04 INJ ECM Fuse 20A Fuse Block C D B A To I...

Page 173: ...M BRN WHT 419 BLK WHT 451 ORN 440 DLC Connector F G H J K E D C B A From S120 B To Pin 10 10 pin Boat Harness From S116 ignition From S113 ground 10 J2 27 2 J1 ORN BLK 461 ORN BLK 461 Diagnostic Test...

Page 174: ...TP Sensor Engine Control Module ECM Map Sensor Signal Sensor Ground ECT Sensor Signal Engine Control Module ECM 2 B A S125 S123 TP Sensor Signal DK BLU 417 23 Knock Sensor 1 Signal PPL 472 J2 M4005p_5...

Page 175: ...Wire Ignition Coil Distributor Ignition Control Module ICM High Voltage Switch Distributor M4006_5 7L Solid State 17 18 16 32 31 J2 C A A A B C C D C A B B Crankshaft Position CKP Sensor Located Righ...

Page 176: ...Fuel Injector Cylinder 2 B A Fuel Injector Cylinder 3 B A Fuel Injector Cylinder 5 B A Fuel Injector Cylinder 8 BLU 467 C A 11 J1 Fuel Injector Cylinder 1 B B A Fuel Injector Cylinder 4 B A Fuel Injec...

Page 177: ...5 0 5 7 6 0 8 1L Diagnosis 5 35 MEFI 4 PCM This Page Was Intentionally Left Blank...

Page 178: ...N BLK BUZZER J1 9 TAN WHT CHECK GAUGES LAMP ENGINE OVER TEMP J1 10 J1 11 468 DK GRN FUEL INJECTOR B DRIVER J1 12 J1 13 450 BLK ECM GROUND J1 14 GRY TACHOMETER OUTPUT 1 J1 15 444 GRN BLK IDLE AIR CONTR...

Page 179: ...2 2 416 GRY 5 VOLT REFERENCE J2 3 814 BLK SENSOR GROUND J2 4 J2 5 J2 6 J2 7 410 YEL ECT SENSOR SIGNAL J2 8 432 LT GRN MAP SENSOR SIGNAL J2 9 J2 10 461 ORN BLK SERIAL DATA J2 11 J2 12 J2 13 J2 14 J2 15...

Page 180: ...ELAY CONTROL J1 7 J1 8 BUZZER J1 9 CHECK GAUGES LAMP ENGINE OVER TEMP J1 10 J1 11 468 DK GRN FUEL INJECTOR B DRIVER J1 12 J1 13 450 BLK ECM GROUND J1 14 GRY TACHOMETER OUTPUT 1 J1 15 444 GRN BLK IDLE...

Page 181: ...2122 PPL WHT IGNITION CONTROL D J2 15 2128 RED WHT IGNITION CONTROL B J2 16 634 LT GRN CRANK SENSOR SIGNAL J2 17 631 RED DEPSPOWER J2 18 632 PNK BLK DEPSLO J2 19 439 PNK IGNITION FEED J2 20 BRN EXHAUS...

Page 182: ...B YEL BLK 1868 DEPSLO Low Ref C DK BLU WHT 1869 CKP Sensor Signal Connector Part Information 12129140 2 Way F Metri Pack 280 1 P2S BLK Connector Part Information 12129140 2 Way F Metri Pack 280 1 P2S...

Page 183: ...K 439 Ignition Voltage Wire Circuit Pin Color No Function A DK BLU 467 Fuel Injector 6 Control B PNK 439 Ignition Voltage 684833 Fuel Injector 3 6 0 8 1L 684833 Fuel Injector 4 6 0 8 1L Connector Part...

Page 184: ...ction A DK GRN 468 Fuel Injector 8 Control B PNK 439 Ignition Voltage Wire Circuit Pin Color No Function A BLK 151 Ground B BRN 2129 Low Reference C PPL 2121 IC 1 Control D PNK 39 Ignition Voltage 684...

Page 185: ...854 Connector Part Information 12162144 4 Way F Metri Pack 150 Series Sealed BLK Ignition Coil Driver Cylinder 7 6 0 8 1L Wire Circuit Pin Color No Function A BLK 151 Ground B BRN 2129 Low Reference C...

Page 186: ...ay F Metri Pack 150 Series Sealed BLK Ignition Coil Driver Cylinder 8 6 0 8 1L Wire Circuit Pin Color No Function A BLK 151 Ground B RED 2127 IC 7 Control C DK GRN 2125 IC 5 Control E BRN 2129 Low Ref...

Page 187: ...15355362 1 Way F Metri Pack 150 Series Sealed NAT 35437 Knock Sensor RH Even 6 0 8 1L Wire Circuit Pin Color No Function A LT BLU 468 KS 2 Signal Connector Part Information 15355362 1 Way F Metri Pac...

Page 188: ...Table 1 Conditions of the starting system that require repair before proceeding are no crank or slow crank conditions Always verify battery condition and connections prior to troubleshooting starter...

Page 189: ...r Lamp ash DTC 12 Go to Step 4 Go to Step 5 1 Verify a known good Diacom scan tool 4 2 Check CKT 451 for a short to ground 3 If a problem is found repair as necessary Repeat OBD Was a problem found Sy...

Page 190: ...to DTC typical scan tool data values page Refer to Procedure for 9 Are the displayed values normal or close to the typical Symptoms the Circuit that values Section 7 is Out of Range 1 Ignition ON Eng...

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Page 192: ...e DTC Tool Installed If the engine runs OK check for a faulty light bulb or an open in the MIL driver circuit CKT 419 If the engine cranks but will not run check for an open ECM ignition or battery fe...

Page 193: ...Go to Step 13 6 Check the ECM BAT fuse Is the fuse good Go to Step 7 Go to Step 14 1 Ignition OFF 2 Disconnect both ECM connectors 7 3 Using a test light connected to ground probe ECM harness connect...

Page 194: ...System Check Locate and repair open in CKT 440 Go to OBD 15 Is action complete System Check 16 Locate and repair open or short to ground in CKT 439 Was a problem found Verify Repair Go to DP A 6 17 Re...

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Page 196: ...Tool Installed Diagnostic Aids An intermittent may be caused by a poor connection rubbed through wire insulation or a wire broken inside the insulation Check for the following items Poor connection o...

Page 197: ...uminate brightly Go to Step 4 Go to Step 6 1 Verify correct operation of DTC tool on a known 4 good system 2 If a problem is found repair as necessary Go to OBD Is action complete System Check Go to S...

Page 198: ...an cause a no start A defective MAP sensor may cause a no start or a start and stall condition If above are all OK refer to Hard Start in Symptoms section Circuit Description In the Ignition system an...

Page 199: ...ition coil secondary wire 3 While cranking the engine observe the timing light Go to DP A 7B Is the timing light ashing indicating spark Go to Step 7 6 0 8 1L 1 Using a known good timing light check f...

Page 200: ...spark plugs for being gas fouled If the spark plugs are gas fouled determine what caused the rich condition Inspect for an engine mechanical failure that causes an engine not to start i e timing chai...

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Page 202: ...spring inside the fuel pressure regulator When this happens the result is lower fuel pressure The fuel pressure at idle will vary slightly as the barometric pressure changes but the fuel pressure at i...

Page 203: ...wing procedure 1 Remove the fuel rail Refer to Fuel Rail Assembly Replacement 2 Reinstall the crossover pipe to the right fuel rail Refer to Fuel Rail Assembly Replacement 3 Connect the fuel feed pipe...

Page 204: ...t the following items for a restriction 6 The fuel lter The fuel feed pipe Did you nd a restriction Go to Step 24 Go to Step 7 1 Remove the fuel sender assembly 2 Visually and physically inspect the f...

Page 205: ...pipe 2 Pressurize the fuel system using a scan tool 11 3 Wait for the fuel pressure to build 4 Close the valve in the fuel pipe shut off adapter that is connected to the fuel return pipe Does the fuel...

Page 206: ...cation that is connected to the fuel return pipe Sheet end of Does the fuel pressure rise above the maximum value this section Go to Step 21 Go to Step 7 Turn ON the fuel pump using a scan tool Go to...

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Page 208: ...on Excess fuel returns to the fuel tank on the FCC system When the engine is stopped a scan tool in the output controls function can turn ON the fuel pump Improper fuel system pressure results in one...

Page 209: ...sing the scan tool Does the test lamp illuminate for 2 seconds Go to Step 6 Go to Step 11 Important Ignition must be ON before performing this step 6 Jumper the fuel pump relay battery feed circuit te...

Page 210: ...e action complete Go to Step 26 15 Repair the open fuel pump ground circuit Is the action complete Go to Step 26 Repair the short to ground in the fuel pump relay load 16 circuit between the relay and...

Page 211: ...spect for poor electrical connections at the 25 fuel pump harness before replacing the fuel pump Replace the faulty fuel pump and replace the fuse Is the action complete Go to Step 26 1 Select the Dia...

Page 212: ...Term A To Fuel Inj Connector Term K To Fuse Block Term A To Fuel Pump Relay Term 86 Diagnostic Procedure DP A 6 System Relay Diagnosis Test Description Number s below refer to the step number s on th...

Page 213: ...the resistance less than the speci ed value 0 5 ohms Go to Step 5 Go to Step 10 1 Turn OFF the ignition 2 Jumper system relay terminal 30 and system relay terminal 87 together using a fused jumper 5...

Page 214: ...t ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connection Corrosion Mis routed harness Rubbed t...

Page 215: ...connect the ECM J2 connector 4 3 Using a DMM measure resistance between terminal C of the CKP sensor and ECM harness connector J2 16 Does the DMM display the speci ed value 0 ohms Go to Step 5 Go to S...

Page 216: ...easure above the speci ed value 10 0 volts Go to Step 13 Go to Step 24 Using a test lamp connected to B probe the IC module 13 harness connector ground circuit terminal C Does the test lamp illuminate...

Page 217: ...repair as necessary Was a problem found Verify Repair Go to Step 27 Locate and repair an open or short to ground on the ignition 24 voltage circuit at the IC module Is action complete Verify Repair Ch...

Page 218: ...complete Verify Repair 34 Repair the circuit as necessary Is action complete Verify Repair 35 Replace the faulty ignition coil Is action complete Verify Repair 36 Replace the coil wire Is action compl...

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Page 220: ...e following conditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connecti...

Page 221: ...ECM connector J2 5 3 Test the continuity from the IC circuit at the ignition coil harness connector to the ECM connector using the DMM J 39200 Does the DMM indicate continuity Go to Step 6 Go to Step...

Page 222: ...rmines if the circuitry or the IAC valve is faulty Circuit Description The ECM controls idle speed to a calibrated desired RPM based on sensor inputs and actual engine RPM The ECM uses four 4 circuits...

Page 223: ...peci ed value 200 RPM Go to Step 4 Go to Step 5 1 Reinstall IAC harness connector 4 2 Idle speed should gradually return within 75 RPM of the original recorded RPM within 30 seconds Does RPM return to...

Page 224: ...F the voltage will measure about 1 5 2 0 volts Diagnostic Aids Check for the following conditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken lock...

Page 225: ...CKT 410 4 Turn ignition ON leaving engine OFF Does scan tool display a coolant temperature above the speci ed value 130 C 266 F Go to Step 6 Go to Step 5 DTC 14 is intermittent Locate and repair inte...

Page 226: ...improperly formed or damaged terminals and poor terminal to wire connection Damaged harness Inspect the wiring harness for damage If the harness appears to be OK observe the ECT display on the scan t...

Page 227: ...e OFF Does scan tool display a coolant temperature below the speci ed value 30 C 22 F Go to Step 6 Go to Step 5 DTC 15 is intermittent Locate and repair intermittent faulty 4 connections Refer to Diag...

Page 228: ...2 If the ECM recognizes the low voltage signal the ECM and wiring are OK 4 Using DMM from harness terminal A CKT 416 harness terminal B CKT 814 checks the sensor ground circuit A faulty sensor ground...

Page 229: ...han the speci ed value 36 volt Go to Step 4 Go to Step 6 Connect DMM from harness terminal A CKT 416 to 4 harness terminal B CKT 814 Does DMM indicate a voltage greater than the speci ed value 4 volts...

Page 230: ...hrottle cable adjustment or for bent or binding linkage 3 This test simulates a DTC 21 If the ECM recognizes the high signal voltage the ECM and wiring are OK 4 This test checks for the 5 volt referen...

Page 231: ...value 4 volts Go to Step 8 Go to Step 4 1 Turn ignition OFF 2 Connect DMM from harness terminal A CKT 416 4 to a known good ground 3 Turn ignition ON leaving engine OFF Does DMM indicate a voltage gr...

Page 232: ...re is cold the sensor thermistor resistance is high As the intake air temperature warms up the sensor resistance becomes less See intake air temperature sensor table under Diagnostic Aids Diagnostic A...

Page 233: ...sor harness connector 3 Connect a jumper wire from harness terminal 2 3 CKT 472 to harness terminal 1 CKT 814 4 Turn ignition ON leaving engine OFF Does scan tool display a coolant temperature above t...

Page 234: ...is cold the sensor thermistor resistance is high As the intake air temperature warms up the sensor resistance becomes less See intake air temperature sensor table under Diagnostic Aids Diagnostic Aids...

Page 235: ...ep 4 1 Turn ignition OFF 2 Disconnect IAT sensor harness connector 3 3 Turn ignition ON leaving engine OFF Does scan tool display an intake air temperature below the speci ed value 30 C 22 F Go to Ste...

Page 236: ...information as a signal voltage that will vary from about 1 0 1 5 volts at idle to about 4 0 4 5 volts at Wide Open Throttle WOT If the MAP sensor fails the ECM will substitute a default MAP value tha...

Page 237: ...ensor voltage less than the speci ed value 1 volt Go to Step 5 Go to Step 8 1 Turn the ignition OFF 2 Connect DMM from CKT 814 to CKT 416E 5 0 5 7L harness terminal 1 to harness terminal 3 5 6 0 8 1L...

Page 238: ...n manifold pressure vacuum The ECM receives this information as a signal voltage that will vary from about 1 0 1 5 volts at idle to about 4 0 4 5 volts at Wide Open Throttle WOT If the MAP sensor fail...

Page 239: ...terminal C 4 Turn the ignition ON leaving the engine OFF Does scan tool indicate MAP sensor voltage greater than the speci ed value 4 volts Go to Step 10 Go to Step 5 1 Turn OFF the ignition 2 Connec...

Page 240: ...inal to wire connection Corrosion Mis routed harness Rubbed through wire insulation Broken wire inside the insulation Test Description 2 This step veri es the fault is present 4 This step tests the in...

Page 241: ...ty from the IC circuit at the ignition control module connector Pin B to the ECM connector terminal J2 31 using the DMM J 39200 Does the DMM indicate continuity Go to Step 6 Go to Step 9 Test the resi...

Page 242: ...onditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connection Corrosion...

Page 243: ...ector J2 5 3 Test the continuity from the IC circuit at the ignition coil harness connector to the ECM connector using the DMM J 39200 Does the DMM indicate continuity Go to Step 6 Go to Step 9 Test t...

Page 244: ...nditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connection Corrosion M...

Page 245: ...ector J2 5 3 Test the continuity from the IC circuit at the ignition coil harness connector to the ECM connector using the DMM J 39200 Does the DMM indicate continuity Go to Step 6 Go to Step 9 Test t...

Page 246: ...g conditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connection Corrosi...

Page 247: ...ector J2 5 3 Test the continuity from the IC circuit at the ignition coil harness connector to the ECM connector using the DMM J 39200 Does the DMM indicate continuity Go to Step 6 Go to Step 9 Test t...

Page 248: ...wing conditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connection Corr...

Page 249: ...ector J2 5 3 Test the continuity from the IC circuit at the ignition coil harness connector to the ECM connector using the DMM J 39200 Does the DMM indicate continuity Go to Step 6 Go to Step 9 Test t...

Page 250: ...g conditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connection Corrosi...

Page 251: ...ector J2 5 3 Test the continuity from the IC circuit at the ignition coil harness connector to the ECM connector using the DMM J 39200 Does the DMM indicate continuity Go to Step 6 Go to Step 9 Test t...

Page 252: ...g conditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connection Corrosi...

Page 253: ...ector J2 5 3 Test the continuity from the IC circuit at the ignition coil harness connector to the ECM connector using the DMM J 39200 Does the DMM indicate continuity Go to Step 6 Go to Step 9 Test t...

Page 254: ...onditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connection Corrosion...

Page 255: ...ector J2 5 3 Test the continuity from the IC circuit at the ignition coil harness connector to the ECM connector using the DMM J 39200 Does the DMM indicate continuity Go to Step 6 Go to Step 9 Test t...

Page 256: ...g conditions Poor connection at ECM Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connection Corrosi...

Page 257: ...ector J2 5 3 Test the continuity from the IC circuit at the ignition coil harness connector to the ECM connector using the DMM J 39200 Does the DMM indicate continuity Go to Step 6 Go to Step 9 Test t...

Page 258: ...timing based on the KS signal coming into the ECM DTC 44 will set only if the ECM does not see any activity on the KS signal circuit s Diagnostic Aids Check for the following conditions Poor connecti...

Page 259: ...und Verify Repair Go to Step 4 Check knock sensor for being loose in the engine 4 block If a problem is found repair as necessary Was a problem found Verify Repair Go to Step 5 1 Install scan tool 2 S...

Page 260: ...d spark timing based on the KS signal coming into the ECM DTC 44 will set only if the ECM does not see any activity on the KS signal circuit s Diagnostic Aids Check for the following conditions Poor c...

Page 261: ...problem found Verify Repair Go to Step 4 Check knock sensor for being loose in the engine 4 block If a problem is found repair as necessary Was a problem found Verify Repair Go to Step 5 1 Install sc...

Page 262: ...n failure by comparing the calibration value to a known value stored in the EEPROM This test is also used as a security measure to prevent improper use of calibration or changes to these calibrations...

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Page 264: ...round in the circuit Circuit Description The Exhaust Temperature Switch ETS circuit monitors for a high exhaust temperature due to a lack of raw water cooling The switch is a normally open device and...

Page 265: ...d value 0 ohms Go to Step 5 Go to Step 10 1 Disconnect the starboard exhaust temp switch harness connector 5 2 Using a DMM measure resistance between the switch terminal and the exhaust elbow riser Do...

Page 266: ...e engine does not start and DTC 81 is not present refer to DP A 3 3 This test checks for the 12 volt supply voltage to the CKP sensor 4 This test veri es the ground circuit to the CKP sensor Circuit D...

Page 267: ...circuit at the CKP sensor harness Does the DMM display the speci ed value 11 13 volts Go to Step 4 Go to Step 9 Using a DMM measure the voltage between the Depspower 4 circuit and the Depslo circuit a...

Page 268: ...found Verify repair Go to Step 15 Locate and repair an open short to ground or short to 11 voltage in the CKP sensor signal circuit If a problem is found repair as necessary Was a problem found Verify...

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Page 270: ...EL 632 RED 631 RED 631 BRN 633 S105 S104 Engine Control Module ECM M4080 2 13 04 To CKP Sensor To CKP Sensor CMP Sensor Signal Depspower DepsLo Camshaft Position CMP Sensor 8 1L Engine Control Module...

Page 271: ...KP sensor 24X 6 0 8 1L or 4X 5 0 5 7L signal the engine will start The ECM can determine top dead center for all cylinders by using the CKP sensor 24X 6 0 8 1L or 4X 5 0 5 7L signal alone The CMP sens...

Page 272: ...roblem found Verify Repair Go to Step 8 1 Jump terminal A 8 1L or C 5 0 5 7 6 0L of the CMP sensor harness connector to terminal A 8 1L or C 5 0 5 7L of the CMP sensor using a fused jumper wire 2 Jump...

Page 273: ...blem found Verify Repair Go to Step 13 Inspect for poor connections at the CMP sensor If a problem 13 is found repair as necessary Was a problem found Verify Repair Go to Step 14 14 Replace the faulty...

Page 274: ...Aids If the condition is suspected to be intermittent refer to Intermittent Conditions Test Description 3 The Depspower circuit may be shorted to another ECM circuit The shorted circuit may not be ap...

Page 275: ...the ECM J2 harness connector Do any of the circuits indicate a resistance within the speci ed range 0 2 ohms Go to Step 7 Go to Step 9 1 Turn OFF the ignition 2 Disconnect the ECM connector J2 4 3 Us...

Page 276: ...The shorted circuit may not be apparent when the ECM harness connector is disconnected Circuit Description The Engine Control Module ECM uses a common 5 volt reference circuit as a sensor feed This c...

Page 277: ...ector Do any of the circuits indicate a resistance within the speci ed range 0 2 ohms Go to Step 7 Go to Step 9 1 Turn OFF the ignition 2 Disconnect the ECM connector J2 4 3 Using a test lamp connecte...

Page 278: ...Identify and test the relay coil terminals in order to avoid improper diagnosis 12 If no trouble is found in the control circuit or the connection at the ECM the ECM may be faulty However this is an...

Page 279: ...isconnect the fuel pump relay connector 4 3 Using a DMM measure the resistance from the relay control circuit in the ECM harness connector to ground Does the DMM display in nite resistance or OL out o...

Page 280: ...erify Repair Go to Step 12 9 Locate and repair faulty connections at the ECM Was a problem found Verify Repair Go to Step 13 10 Repair the faulty relay control circuit 485 Is action complete Verify Re...

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Page 282: ...jector Cylinder 1 6 0 8 1L B A Fuel Injector Cylinder 4 6 0 8 1L B A Fuel Injector Cylinder 6 6 0 8 1L B A Fuel Injector Cylinder 7 6 0 8 1L DK BLU 467 C 26 J1 Hot in Run And Start S122 S126 S109 To E...

Page 283: ...detects an incorrect voltage for the commanded state of the driver a fuel injector control DTC sets Diagnostic Aids Performing the Fuel Injector Coil test may help isolate an intermittent condition Re...

Page 284: ...s Go to Step 7 Go to Step 4 4 Does the test lamp remain illuminated at all times on any of the four fuel injector harness connectors Go to Step 6 Go to Step 5 Locate and repair an open or short to vol...

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Page 286: ...linder 2 6 0 8 1L B A Fuel Injector Cylinder 3 6 0 8 1L B A Fuel Injector Cylinder 5 6 0 8 1L B A Fuel Injector Cylinder 8 6 0 8 1L DK GRN 468 C 11 J1 Hot in Run And Start S122 S127 S110 To ECM Term J...

Page 287: ...tects an incorrect voltage for the commanded state of the driver a fuel injector control DTC sets Diagnostic Aids Performing the Fuel Injector Coil test may help isolate an intermittent condition Refe...

Page 288: ...to Step 7 Go to Step 4 4 Does the test lamp remain illuminated at all times on any of the four fuel injector harness connectors Go to Step 6 Go to Step 5 Locate and repair an open or short to voltage...

Page 289: ...0 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa at Idle at Idle at Idle at Idle at Idle Spark Plug P N R030010 R030010 R030009 R030009 R030011 Spark Plug Gap 0 060 in 0 060 in 0 060 in 0 060 in...

Page 290: ...y Fuel Pressure 49 54 psi idle 49 54 psi idle 37 43 psi idle 37 43 psi idle 49 52 psi idle STD FCC 57 62 psi WOT 57 62 psi WOT 44 48 psi WOT 44 48 psi WOT 57 60 psi WOT MY 04 Fuel Pressure FCC 59 61 p...

Page 291: ...172 552 kPa Minimum Oil Pressure 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa at Idle at Idle at Idle Spark Plug P N R030010 R030010 R030011 Spark Plug Gap 0 060 in 0 060 in 0 060 in Firing Order 1 8 4...

Page 292: ...Warning 1 Gen Warning 1 Gen Warning 1 Switch Trans Temp Lamp Trans Temp Lamp Trans Temp Lamp Optional Power Reduction Power Reduction Power Reduction Low Oil 10 psi 10 psi 10 psi Pressure Gen Warning...

Page 293: ...172 552 kPa Minimum Oil Pressure 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa at Idle at Idle at Idle Spark Plug P N R030010 R030010 R030011 Spark Plug Gap 0 060 in 0 060 in 0 060 in Firing Order 1 8 4...

Page 294: ...220 F 104 8 C 220 F 104 8 C Over Temperature Water Temp Lamp Water Temp Lamp Water Temp Lamp Sensor Power Reduction Power Reduction Power Reduction Low Oil 10 psi 10 psi 10 psi Pressure Gen Warning 1...

Page 295: ...ting conditions arise the system is designed to allow excessive amounts of blow by gases to back flow through the crankcase vent tube into the engine air inlet to be consumed by normal combustion Resu...

Page 296: ...led engine If oil sludging or dilution is noted and the PCV system is functioning properly check engine for possible cause and correct to ensure that the system will function as intended Functional Ch...

Page 297: ...n Page 21 Backfire Page 22 ECM Connector J1 Symptom Table Page 24 ECM Connector J2 Symptom Table Page 26 Fuel Injector Coil Test Page 28 Fuel Injector Balance Test Page 30 Symptoms Page 2 Important Pr...

Page 298: ...ition Control IC module wiring should kept away from the alternator Check all wires from the ECM to the ignition control module for poor connections If problem has not been found go to ECM Connector S...

Page 299: ...If a problem is found repair as necessary Go to OBD Was a problem found System Check Go to Step 6 1 Check for contaminated fuel 6 2 Check fuel filters and water separator 3 If a problem is found repa...

Page 300: ...ace the ECT sensor Go to OBD Is action complete System Check 1 Check for intermittent opens or shorts to ground in the 15 MAP sensor circuits 2 If a problem is found repair as necessary Go to OBD Was...

Page 301: ...is procedure 2 If all steps have been completed and no malfunctions have been found review inspect the following 19 Visual physical inspection Scan tool data All electrical connections within a suspec...

Page 302: ...hile the condition exists 6 Refer to Table A 4 2 If a problem is found repair as necessary Go to OBD Was a problem found System Check Go to Step 7 1 Check for intermittent opens or short to grounds in...

Page 303: ...nnectors are connected to an incorrect cylinder correct as necessary Go to OBD Was a prob3nd System Check Go to Step 15 1 Check ECM grounds for being clean tight and in the 15 proper locations 2 If a...

Page 304: ...Check fuel filters 3 If a problem is found repair as necessary Go to OBD Was a problem found System Check Go to Step 7 1 Check for proper fuel pressure while the condition exists 7 Refer to Table A 4...

Page 305: ...found System Check Go to Step 17 1 Check for proper alternator voltage output 17 2 The voltage should be between specified values 3 If a problem is found repair as necessary Go to OBD Was a problem f...

Page 306: ...ary Go to OBD Was a problem found System Check Go to Step 6 1 Check for contaminated fuel 6 2 Check for poor fuel quality and proper octane rating 3 If a problem is found repair as necessary Go to OBD...

Page 307: ...on chambers for excessive carbon build up 2 If a problem is found repair as necessary Go to OBD Was a problem found System Check Go to Step 14 1 Remove excessive carbon buildup with a top engine clean...

Page 308: ...5 Refer to Table A 4 2 If a problem is found repair as necessary Go to OBD Was a problem found System Check Go to Step 6 1 Check fuel injectors Refer to Injector Coil Test and Injector Balance 6 Test...

Page 309: ...es 3 If a problem is found repair as necessary Go to OBD Was a problem found 11 16V System Check Go to Step 13 1 Check for faulty or incorrect thermostat 13 2 If a problem is found repair as necessary...

Page 310: ...connectors and install an injector test light J 34730 2 between the harness terminal connector of each injector 2 Crank engine and note light on each connector If test 5 light fails to blink at any o...

Page 311: ...dition can be caused by EMI on the reference circuit EMI can usually be detected by monitoring engine RPM 11 with a scan tool or tachometer A sudden increase in RPM with little change in actual engine...

Page 312: ...Check condition of IC module CKP sensor distributor cap rotor and spark plug wires 4 If a problem is found repair as necessary Go to OBD Was a problem found System Check Go to Step 7 1 Check ignition...

Page 313: ...n their proper locations 14 2 Also check that battery cables and ground straps are clean and secure 3 If a problem is found repair as necessary Go to OBD Was a problem found System Check Go to Step 15...

Page 314: ...within this procedure 2 If all steps have been completed and no malfunctions have been found review inspect the following 21 Visual physical inspection Scan tool data All electrical connections within...

Page 315: ...fuel leaks 3 If a problem is found repair as necessary Go to OBD Was a problem found System Check Go to Step 6 1 Check for proper fuel pressure 6 Refer to Table A 4 2 If a problem is found repair as n...

Page 316: ...roper propeller size and pitch for that application 3 If a problem is found repair as necessary Go to OBD Was a problem found System Check Go to Step 13 1 Review all diagnostic steps within this proce...

Page 317: ...s found repair as necessary Go to OBD Was a problem found System Check Go to Step 5 1 Check for obvious overheating problems Loose water pump belt Faulty or incorrect water pump 5 Restriction in cooli...

Page 318: ...ngine is going into RPM reduction 6 2 If a problem is found repair as necessary Go to OBD Was a problem found System Check Go to Step 7 Check the injector connections If any of the injectors are 7 con...

Page 319: ...TC 3 If a problem is found repair as necessary Go to OBD Was a problem found System Check Go to Step 15 1 Check engine mechanical for the following conditions Low compression Sticking or leaking valve...

Page 320: ...or all symptoms J1 14 Tachometer Output gry In Line Boat None Loss of tachometer reading Signal Harness J1 15 IAC B Low 444 grn blk IACValve None Rough Unstable or Incorrect Idle J1 16 IAC A High 441...

Page 321: ...Circuit J1 29 ECM Ground 450 blk Engine Block None An open ground or high resistance ground may cause any or all symptoms J1 30 Knock Sensor 1 496 dk blu Knock 44 Poor Fuel Economy Signal Sensor 1 Poo...

Page 322: ...Ignition Control D 2122 ppl wht Ignition Coil 41 Poor Performance Poor Fuel Inline Connector cyl 2 Fuel Economy engine misfire J2 15 Ignition Control B 2128 red wht Ignition Coil 41 Poor Performance P...

Page 323: ...n Control C 2127 red Ignition Coil 41 Poor Performance Poor Fuel Inline Connector cyl 7 Fuel Economy engine misfire J2 31 Ignition Control A 2121 ppl Ignition Coil 41 Poor Performance Poor Fuel Inline...

Page 324: ...ns included with the tools used to perform this test procedure 3 The engine coolant temperature affects the ability of the Fuel Injector Tester to detect a faulty Fuel Injector If the engine coolant t...

Page 325: ...Go to Step 3 Allow the engine to warm or cool as necessary 3 Is the Engine Coolant Temperature within the specified 10 C 35 C limits 50 F 95 F Go to Step 4 1 Connect the Fuel Injector Tester to a fuel...

Page 326: ...ICLE BATTERY READY TO TEST TEST IN PROGRESS AMPERAGE SUPPLY SELECTOR SWITCH Coil Test 4 amp 2 5 amp 0 5 amp Balance Test 4 amp 0 5 2 5 amp PUSH TO START TEST INJECTOR CONNECTOR FUEL PRESSURE GAUGE FUE...

Page 327: ...p value for each injector by subtracting the second pressure reading from the first pressure reading Refer to the illustration above 1 Was the On Board Diagnostic OBD System Check Go to OBD performed...

Page 328: ...or 11 Subtract the 2nd pressure reading from the 1st pressure reading for one fuel injector The result is the pressure drop value 12 Obtain a pressure drop value for each fuel injector 13 Add all of t...

Page 329: ...connect all harnesses and fuel lines 4 Install a scan tool 5 Ignition ON engine OFF 10 6 Check for fuel leaks 7 Using the scan tool clear any DTC s that are present 8 Start the engine 9 Idle the engi...

Page 330: ...7 34 Symptoms 5 0 5 7 6 0 8 1L MEFI 4 PCM This page left intentionally blank...

Page 331: ...kPa 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa at Idle at Idle at Idle at Idle at Idle Spark Plug P N R030010 R030010 R030009 R030009 R030011 Spark Plug Gap 0 060 in 0 060 in 0 060 in 0 0...

Page 332: ...ure 57 62 psi WOT 57 62 psi WOT 44 48 psi WOT 44 48 psi WOT 57 60 psi WOT STD FCC MY 04 Fuel Pressure FCC 59 61 psi Returnless to Rail WOT Fuel Pressure LPFP 4 7 psi 4 7 psi 4 7 psi 4 7 psi 4 7 psi AL...

Page 333: ...4 kPa 172 552 kPa Minimum Oil Pressure 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa at Idle at Idle at Idle Spark Plug P N R030010 R030010 R030011 Spark Plug Gap 0 060 in 0 060 in 0 060 in Firing Order 1...

Page 334: ...ing 1 Gen Warning 1 Gen Warning 1 Switch Trans Temp Lamp Trans Temp Lamp Trans Temp Lamp Optional Power Reduction Power Reduction Power Reduction Low Oil 10 psi 10 psi 10 psi Pressure Gen Warning 2 Ge...

Page 335: ...4 kPa 172 552 kPa Minimum Oil Pressure 10 psi 69 kPa 10 psi 69 kPa 10 psi 69 kPa at Idle at Idle at Idle Spark Plug P N R030010 R030010 R030011 Spark Plug Gap 0 060 in 0 060 in 0 060 in Firing Order 1...

Page 336: ...104 8 C 220 F 104 8 C Over Temperature Water Temp Lamp Water Temp Lamp Water Temp Lamp Sensor Power Reduction Power Reduction Power Reduction Low Oil 10 psi 10 psi 10 psi Pressure Gen Warning 1 Gen W...

Page 337: ...5 0 5 7 6 0 8 1L Master Specifications 8 7 MEFI 4 PCM This page left intentionally blank...

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PleasureCraft Engine Group 5.0L, Diagnostic Manual

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