1988 GMC Light Duty Truck Fuel and Emissions Including Driveability

1988 Light Duty Truck
Fuel and Emissions

Including Driveability
Service Manual
(Fuel Injected GM C
TRU CK
Gas Engines Only)

FOREWORD
This Service Manual replaces Section 6C and 6E for 2.5L, 2.8L, 4.3L, 5.0L, 5.7L, and 7.4L
gasoline engines w ith throttle body injection and supplements the follow ing shop manuals:
X-8832 10-30 Series R-V-G-P Light Duty Truck Service Manual

X-8829 10 Series S-T Light Duty Truck Service Manual
X-8830 10 Series M-Van Light Duty Truck Service Manual
X-8731-B 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 w ith a throttle body
injection fuel control system.
Wiring diagrams for the above vehicles are also published in a separate "Truck W iring
Diagram" booklet.
This manual should be kept in a handy place for ready reference. If properly used, it w ill
meet the needs of technicians and vehicle owners.
CAUTION:
These vehicles contain some parts dimensioned in the metric system as w ell as in the customary
system. Some fasteners are metric and are very close in dimension to fam iliar customary fasteners in the
inch system. It is im portant to note that, during any vehicle maintenance procedures, replacem ent
fasteners must have the same measurements and strength as those rem oved, w h e th e r m etric or
customary. (Numbers on the heads of metric bolts and on surfaces of metric nuts indicate their 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 removed from the vehicle should be saved for re-use in the same
location whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to
seiect a replacement th at matches the original. For information and assistance, see your authorized
dealer.
GMC TRUCK DIVISION

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 w ith 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 w ho intends to use a replacement part, service procedure or tool, which is not
recommended by the vehicle manufacturer, must first determine that neither his safety nor the safe
operation of the vehicle w ill be jeopardized by the replacement part, service procedure or tool selected.
It is important to note that this manual contains various Cautions and Notices that must be carefully
observed in order to reduce the risk of personal injury during service or repair, or the possibility that
improper service or repair may damage the vehicle or render it unsafe. It is also im portant 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.
ACTION SYMBOL USAGE
The general narrative w riting style has been replaced in

some procedures w ith action symbols. To improve readability
and to provide emphases w h en needed, th e fo llo w in g
symbols are used in the text.
Remove or Disconnect Inspect
-4- Install or Connect 1 Measure
Disassemble [jp] Tighten
Assemble | 9 [ important
IJJI Clean 1^1 Adjust

1988 TABLE OF CONTENTS SECTION
LIGHT DUTY TRUCK
FUEL AND EMISSIONS
GENERAL INFORMATION 1 S
SERVICE MANUAL
DRIVEABILITY SYMPTOMS
2 I
li
FOR GASOLINE ENGINES COMPUTER COMMAND
CONTROL (WITH "SCAN"
WITH TOOL)

THROTTLE BODY INJECTION FUEL CONTROL

* I
C,K,P,R,V,S,T TRUCK
AND
EVAPORATIVE EMISSION
CONTROL
5 !
M-VAN, G-VAN IGNITION SYSTEM/EST
i
MODELS
10/ 1500 - 20/ 2500 - 30/3500
ELECTRONIC SPARK CONTROL
i
SERIES AIR MANAGEMENT
8 i
EXHAUST GAS
The Table of Contents on this page indicates the
RECIRCULATION 9 I
sections covered in this manual. At the beginning
AUTOMATIC TRANSMISSION
of each individual section is a Table of Contents
CONVERTER CLUTCH OR
which gives the page number on which each major
10
subject begins. DOWN-SHIFT CONTROL AND
MANUAL TRANSMISSION
W hen reference is made in this manual to a SHIFT LIGHT
brand name, number, or specific tool, an equivalent
product may be used in place of the recommended POSITIVE CRANKCASE
item.
11
VENTILATION
All information, illustrations, and specifications

contained in this Manual are based on the latest THERMOSTATIC AIR CLEANER
product in fo rm a tio n a v a ila b le at th e tim e of
publication approval. The right is reserved to make SPECIAL TOOLS AND
changes at any tim e w ithout notice. SPECIFICATIONS
i
ABBREVIATIONS 14
COMPUTER COMMAND
P R IN T E D IN C A N A D A
1987 General Motors Corporation Aug.,1987
All Rights Reserved
CONTROL (WITHOUT "SCAN"
TOOL)
ALPHABETICAL INDEX
5 l
in
He knows
quality parts
make a difference
even on
simplejobs.
Mr. Goodwrench wants you to have the right parts for So keep that great GM feeling with genuine GM parts
your truckwhether you see him for service or whether at participating independent Mr. Goodwrench dealers
you do the work yourself. selling Chevrolets, Pontiacs, Oldsmobiles, Buicks,
Cadillacs, GMC and Chevy Trucks.
Thats why Mr. Goodwrench wants to have a good
stock of genuine GM Parts available. Everything from
exclusive GM Goodwrench replacement engines and
transmissions to GM Goodwrench Motor Oil that meets
M N M A l MOT** O O W O ttfW N
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
iv
GENERAL INFORMATION 1-1
SECTION 1
GENERAL INFORMATION
CONTENTS
GENERAL.............................................................. 1-1 Thermostatic A ir Cleaner (THERMAC) . . . . 1-4
VISUAL/PHYSICAL UNDERHOOD INSPEC____ 1-2 Special T o o ls ................................................... 1-4
BASIC ELECTRIC CIRCUITS.................................. 1-2 A b b re v ia tio n s ................................................. 1-4
EMISSIONS............................................................ 1-2 Com puter Command Control
MAINTENANCE SCHEDULE............................... 1-2 (W ith o u t Using "Scan" Tool Diagnosis) . 1-4
VEHICLE EMISSION CONTROL INFO. LABEL . . 1-2 COMPONENT LOCATIONS.................................. 1-4
SECTION DESCRIPTION....................................... 1-2 2 .5 L -M S e rie s ................................................. 1-5
D rivea bility Sym ptom s.................................... 1-2 2.5L-ST S e rie s ................................................. 1-6
C om puter Command Control 2.8L-ST S e rie s ................................................. 1-7
(Using "Scan" Tool Diagnosis) ............... 1-2 4.3 L-ST Series................................................... 1-8
Fuel Control S y s te m ....................................... 1-2 4.3L - CK S eries................................................. 1-9
Evaporative Emission Control ................... 1-2 4.3L-G Series ................................................. 1-10
Ignition/E le ctronic Spark T im ing ............... 1-2 4.3L- M S e rie s ................. .............................. 1-11
Electronic Spark C o n tr o l............................... 1-4 4.3L- RV S eries................................................ 1-12
A ir M anagem ent ......................................... 1-4 5.0L75.7L-CK S e rie s ....................................... 1-13
Exhaust Gas Recirculation ........................... 1-4 5.0L/5.7L-G Series ....................................... 1-14
Transmission Converter Clutch, D ow nshift 5.7L- RV S eries................................................ 1-15
Control and M anual Transmission Shift 5.0L- P Series.................................................... 1-16
Light C o n tr o l.............................................. 1-4 7.4L-C K RV S e rie s ......................................... 1-17
Positive Crankcase V e n tila tio n (PCV) . . . 1-4 7.4L-G Series ......................................... 1-18
ALL NEW GENERAL MOTORS VEHICLES ARE CERTIFIED BY THE U NITED STATES
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 ADJUSTMENTS BEING SET TO FACTORY
STANDARDS. IN MOST CASES, THESE ADJUSTMENT 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.
GENERAL
A ll engines in this manual have a Computer This section has a brief description o f systems
Command Control system with electronic control used to control fuel and emissions.
module (E C M ) to control the throttle body injection Abbreviations that are used in driveability and
(TB I) fuel system. The ECM varies the air/fuel ratio. emissions are listed at the end of the manual.
In addition, the ECM controls the ignition timing W irin g harness service information for harnesses
system as well as other emission control systems such used with the E C M is also p r o v id e d in the
as the exhaust gas recirculation system. computer command control section.
It is important to review the emission sections Special tools used to diagnose and repair a system
and ECM wiring diagrams for a specific engine to are illustrated at the end of the manual.
determine what is controlled by the ECM and what
systems are non-ECM controlled.
1-2 GENERAL INFORMATION
VISUAL/PHYSICAL UNDERHOOD INSPECTION SECTION DESCRIPTION
One of the most important checks that must Section "2"

be done as part of any diagnostic procedures or Driveability Symptoms
finding the cause of an emissions test failure, is a
c a re fu l visual/physical u n d e r h o o d in sp e ction . The fuel and emissions d riv ea b ility d ia g n o s is
This can often lead to fixing a problem without further procedures apply to various systems in current G M
steps. Inspect all vacuum hoses for correct routing, vehicles. The procedures assume that the vehicle
pinches, cuts, or disconnects. Be sure to inspect hoses worked right at one time and the problem is due to
that are difficult to see beneath the a ir clean er, time, wear, dirt or other causes. Start with the EC M
compressor, generator, etc. Inspect all the wires in diagnosis in Section "3 and then to Section "2 which
the e n g in e c o m p a r t m e n t fo r c o r r e c t and good references driveability symptoms.
connections, burned or chafed spots, pinched wires, or
contact with sharp edges or hot exhaust manifolds. Section "3"
This visual/physical inspection is very important. It Computer Command Control
must be done carefully and thoroughly. (With "Scan" Tool)
BASIC ELECTRIC CIRCUITS Th is is an e le c t r o n ic a ll y co n tr o lle d e x h a u s t

emission system that uses an e le ctro n ic co n trol
Y ou should understand the ba sic t h e o r y o f module (E X M ) to control fu el d e liv e r y , ig n it io n
electricity, and know the meaning of voltage, amps, tim in g , a ir m a n a g e m e n t and e x h a u s t gas
and ohms. You should understand what happens in a recirculation. It also controls the engagement of the
circuit with an open or a shorted wire. You should be transm ission c o n v e r t e r clu tch and the m a n u a l
able to read and understand a w irin g diagram. A transmission shift light. This section diagnoses the
short to ground is r e f e r r e d to as a g rou n d to system with the use of a "Scan tool.
distinguish it from a short between wires.
Section "4"
EMISSIONS Fuel Control System
The exhaust emission control systems used on The ECM controls the air/fuel d e live ry to the
General Motors engines perform a specific function to combustion chamber by co n trollin g the fuel flo w
lower exhaust emissions while maintaining good fuel through the injector(s). The ECM also controls idle
economy and driveability. speed. The in-tank fuel pump is controlled by the
ECM. When ignition is turned " O N , the pump will
MAINTENANCE SCHEDULE run for 2 seconds for most systems, then stop unless
the engine is cranking or running. On some vehicles,
R e fe r to the G e n e r a l M o to r s M a in t e n a n c e the fuel pump will run for 20 seconds. The fuel control
Schedule in Section "OB of the Truck Service Manual system is used on all engines. The ECM may control
or in the glove box for the maintenance service that the A/C clutch of the compression and maintain idle
should be p e rfo rm ed to r e ta in em ission control speed to improve idle quality.
performance.
Section "5"
VEHICLE EMISSION CONTROL INFORMATION Evaporative Emission Control
LABEL
This system has a canister which stores fuel vapor
from the fuel tank. The fuel vapor is removed from the
The Vehicle Emission Control Information label
canister and consumed in the normal combustion
( F i g u r e 1-1) c o n t a i n s i m p o r t a n t e m i s s i o n
process when the engine is running. This system is
specifications and setting procedures. In the upper
used on all engines and is not controlled by the ECM.
left corner is exhaust emission information which
identifies the year, the manufacturing division of the
Section "6"
engine, the displacement in liters of the engine, the
Ignition/Electronic Spark Timing
class o f vehicle and type o f fuel metering. Also there is
an illustrated emission component and vacuum hose
This system is controlled by the ECM which
schem atic. T h is label is located in the en gin e
controls ignition timing and is used on all engines.
compartment of every General Motors Corporation
vehicle. I f the label has been removed, it can be
ordered from the parts division, ( W D I ) G M )
E N G IN E A D J U S T M E N T
S P E C IF IC A T IO N S
ADJU STM EN T
PROCEDURE
LA B E L C O D E
E N G IN E SIZE
E M IS S IO N C O M P O N E N T
A N D V A C U U M HO SE S C H E M A T IC
LABEL P A R T N U M B E R
A R E A OF C E R T IF IC A T IO N
"A L W A Y S REFER TO THE VEHICLE EM ISS IO N CONTROL INFOR M ATIO N LABEL

FOR THE CORRECT AN D M O S T CURRENT SP EC IFIC ATIO N S .
E V A P O R A T IV E E M IS S IO N S Y S T E M
EXHAUST EMISSION SYSTEM

J 3 G 4.3 T 5 T A A 7
CERT YEAR C H EC K SUM

J = 1988 DIGIT
D IV IS IO N DISPLA C EM ENT VEHICLE CLASS AND STA N D A R D S

1G = CPC Liters Largest
T = GASOLINE TRUCK CATALYST D ES IG N A TO R
2G = BOC if m ore than one
K = DIESEL TRUCK
3G = T&B
FUEL METERING
7S 3236 6E
Figure 1-1 Vehicle Emission Control In fo rm atio n Label

Section "7" Section "12"

Electronic Spark Control (ESC) Thermostatic Air Cleaner (THERMAC)
This system uses a knock sensor in connection The T H E R M A C system reg u la te s heated a ir
with the ECM to control spark timing to allow the through the air cleaner to provide uniform inlet air
engine to have maximum spark advance w ithout temperature which gives good d r iv e a b ilit y under
spark knock. This im proves d r iv ea b ility and fuel various clim atic conditions. T h is system is not
economy and is used on all engines except the 2.5L & controlled by the ECM and is used on all engines.
7.4L.
Section "13"
Section "8" Special Tools
Air Management
R e fe r to Section " 1 3 for s p e c ia l to o ls and
This system provides additional oxygen to the equipment needed to diagnose the fuel control and
exhaust gases to continue the combustion process. emissions systems.
This system is on all engines except the 2.5L.
Section "14"
Section "9" Abbreviations
Exhaust Gas Recirculation (EGR)
Refer to Section "14 for abbreviations used in this
Th? EGR system uses a va lve to feed a small manual.
amount of exhaust gas back into the intake manifold
to control formation o f NOx. This system is used on all
Section "15"
engines and is controlled by the ECM.
Computer Command Control
(W ithout "Scan" Tool)
Section "10"
T h is is an e le c t r o n ic a lly co n tr o lle d ex h a u s t
Transmission Converter Clutch (TCC),
emission system that uses an ele c tr o n ic co n trol
Downshift Control and Manual
module (E C M ) to control fuel d e liv e r y , ig n it io n
Transmission Shift Light Control
tim in g , a ir m a n a g e m e n t and e x h a u s t gas
recirculation. It also controls the engagement o f the
The TCC is ECM controlled and is used on all
tra n s m is sion c o n v e r t e r clu tch and the m a n u a l
engines with a T H M 700R4 automatic transmission.
transmission shift light. This section diagnoses the
This system reduces slippage losses in the torque
system without use of a "Scan tool.
convertor by coupling the engine flyw heel to the
output shaft of the transmission.
The ECM controls the downshift solenoid in the
COMPONENT LOCATIONS
T H M 400 a utom atic tra n s m is sion for wide-open
T h ere are many com p onent system s used to
throttle downshift.
control fuel and emissions. Each system is divided in
The ECM controls the shift light on all engines
a section which includes general description o f the
with manual transmission to indicate the best shift
system, diagnosis and on-vehicle service. Component
point for maximum fuel economy on vehicles below
locations for all series vehicles and all engines are
8500 GVW.
illustrated in Figures 1-2 through 1-15. Below is a
Section "11" brief description of each component system:
Positive Crankcase Ventilation (PCV)
The P C V system passes crankcase vapors into the

intake manifold. This system is not controlled by the
ECM and is used on all engines.
Figure 1-2 - C om ponent Locations 2.5L (M Series)

'S / T ' series r p o :L N 8 engine c o d e : E 2 . 5 L L4
COMPUTER COMMAND Q ECM INFORMATION : : EMISSION COMPONENTS

CONTROL SENSORS (NOT ECM CONTROLLED)
C1 Electronic Control M odule (E.C.M.) A M anifold pressure (M.A.P.) N1 Crankcase went valve (PCV)
C2 ALDL diagnostic connector B Exhaust oxygen N15 Fuel Vapor Canister
C3 "SERVICE ENGINE SOON" light c Throttle position (T.P.S.)
C5 ECM harness ground D Coolant tem perature
C6 Fuse panel F Vehicle speed (V.S.S.)
C8 Fuel pum p test connector G Power Steering Pressure
T M anifold Air Tem perature (M .A.T.)
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
12 Exhaust Gas Recirculation Vacuum Solenoid
7S 3 3 1 0
13 A/C relay
6-2-86
Figure 1-3 - Com ponent Locations 2.5L (ST Series)

' S / T ' series r p o :LL2 e n g i n e c o d e :R 2 . 8L V 6
COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

C1 Electronic Control M odule (E.C.M.) A M anifold 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.)
C6 Fuse panel D Coolant tem peratu re
C8 Fuel pump test connector F Vehicle speed (V.S.S.)
C9 Elapsed Timer M odule J Electronic Spark Control Knock (E.S.C.)
U EGR vacuum diagnostic switch
ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pump relay
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 7S 3 2 9 8
13 A/C Relay 4-23-86
Figure 1-4 - C om ponent Locations 2.8L (ST Series)

'S/T' SERIES r p o :LB4 ENGINE CODE:Z 4 .3 L V 6
C2
\ : N15
COMPUTER COMMAND O e c m in f o r m a t io n '"! EMISSION COMPONENTS

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
C5 ECM harness ground D Coolant tem perature
C8 Fuel pump test connector J Electronic Spark Control Knock (E.S.C.)
ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pump relay
8S 4 3 2 9
4-7-87
Figure 1-5 - C om ponent Locations 4.3L (ST Series)

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

C2 ALOL diagnostic connector B Exhaust oxygen N9 Air Pump
C5 ECM harness ground D Coolant tem peratu re
ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pump relay
9 Electric Air Control solenoid (E.A.C.
12 Exhaust Gas Recirculation Vacuum Solenoid 7S 3 3 0 0
5-19-87
Figure 1-6 - C om ponent Locations - 4.3L (CK Series)

' G ' SERIES r p o :LB4 ENGINE CODE:Z 4 .3 L V 6
Cl

C5 ECM harness ground 0 Coolant tem perature
ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pump relay
6 Electronic Spark Timing Distributor (E.S T.)
12 Exhaust Gas Recirculation Vacuum Solenoid 7S3301
14 Transmission dow nshift relay (THM -400 only) 4-15-87
Figure 1-7 - Component Locations 4.3L (G Series)

'M ' series rpo:LB 4 engine c o d e : Z 4.3L V6
COMPUTER COMMAND O ECM INFORMATION r EMISSION COMPONENTS

C5 ECM harness ground D Coolant tem peratu re
ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pum p relay
7S 3299
4-23-86
Figure 1-8 - Com ponent Locations 4.3L (M Series)

'R/V' series rpo:LB4 en g in e c o d e :Z 4.3L V6

C1 Electronic Control M odule (E.C.M.) M anifold Absolute Pressure (M.A.P.) N1 Crankcase vent valve (PCV)
C2 ALDL diagnostic connector Exhaust oxygen N9 Air Pump
C3 "SERVICE ENGINE SOON" light Throttle position (T.P.S.) N15 Fuel Vapor Canister
C5 ECM harness ground Coolant tem peratu re
C6 Fuse panel Vehicle speed (V.S.S.)
C8 Fuel pum p test connector Electronic Spark Control Knock (E.S.C.)
ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pump relay
7S3302
4-15-87
14 Transmission d ow nshift relay (THM -400 only)
Figure 1-9 - Com ponent Locations 4.3L (RV Series)

'C /K ' series r p o :L 0 3 /L 0 5 engine co d e :H /K 5 .0 / 5 . 7 L V 8

C2 ALDL diagnostic connector Exhaust oxygen N2 Fuel M odule (5.7LH .D . only)
C3 "SERVICE ENGINE SOON" light Throttle position (T.P.S.) N9 Air Pump
C5 ECM harness ground Coolant tem peratu re N15 Fuel Vapor Canister
C8 Fuel pum p test connector Electronic Spark Control Knock (E.S.C.)
ECM CONTROLLED
COMPONENTS
Fuel injector
Idle air control
Fuel pum p relay
Transmission Converter Clutch Connector
Electronic Spark Timing Distributor (E.S.T.)
Remote ignition coil
Electronic Spark Control module (E.S.C.)
Oil pressure switch
Electric Air Control solenoid (E.A.C.)
7S 3303
Exhaust Gas Recirculation Vacuum Solenoid
5-19-87
Transmission dow nshift relay (TH M -400 only)
Figure 1-10 - C om ponent Locations - 5.0L/5.7L (CK Series)

'G 's e rie s r p o :L 0 3 /L 0 5 engine co d e :H /K 5 . 0 /5 . 7 L V 8
Cl
N2 7
.....
C2 ALDL diagnostic connector B Exhaust oxygen N2 Fuel M odule (5.7L only)
C3 "SERVICE ENGINE SOON" light C Throttle position (T.P.S.) N9 Air Pump
C5 ECM harness ground D Coolant tem perature N15 Fuel Vapor Canister
C8 Fuel pump test connector ) Electronic Spark Control Knock (E.S.C.)
ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pump relay
14 Transmission dow nshift relay (TH M -400 only)
Figure 1-11 - C om ponent Locations 5.0L/5.7L (G Series)

'R/V' SERIES rpo :L03/L05 engine code: H/K 5.0/5.7L V8
C3 C2
C6
"V N2 : ----^
C8 3 14 /
--- C5
o I2
Lii

: N< :
N1 :
C5
4-

C2 ALDL diagnostic connector B Exhaust oxygen N2 Fuel M odule (5.7L H.D. only)
C5 ECM harness ground D Coolant tem peratu re N15 Fuel Vapor Canister
ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pump relay
12 Exhaust Gas Recirculation Vacuum Solenoid * 7S3305
14 Transmission dow nshift relay (THM -400 only) 4-15-87
Figure 1-12 - Com ponent Locations 5.0L/5.7L (RV Series)

'P' SERIES r p o :L05 ENGINE CODElK 5.7L V8
| Cl | C2 |j N2 | C3 | C6
3
C8
t r
3
+

C2 ALDL diagnostic connector Exhaust oxygen N2 Fuel Module
C3 "SERVICE ENGINE SOON" light Throttle position (T.P.S.) N9 Air Pump
C5 ECM harness ground Coolant tem perature N15 Fuel Vapor Canister
ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pump relay
7S3307-6E
14 Transmission dow nshift relay (THM -400 only)
4-15-87
Figure 1-13 - C om ponent Locations 5.7L (P Series)

' C / K & R / V ' series rp o:L19 e n g in e c o d e :N 7 .4 L V 8

C2 ALDL diagnostic connector B Exhaust oxygen N2 Fuel Module
C8 Fuel pump test connector
ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pump relay
14 Transmission d ow nshift relay (THM -400 only) 7S 3 3 0 6
5-19-87
Figure 1-14 - C om ponent Locations - 7.4L (CK & RV Series)

' G ' series rp o:L19 e n g in e c o d e :N 7 .4 L V 8

C2 ALDL diagnostic connector B Exhaust oxygen N2 Fuel Module
C6 Fuse panel F Vehicle speed (V S.S.)
C8 Fuel pump test connector
ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle air control
3 Fuel pump relay
14 Transmission d ow nshift relay (THM -400 only) 8S4330-6E
4-15-87
Figure 1-15 - C om ponent Locations 7.4L (G Series)

DRIVEABILITY SYMPTOMS 2-1
SECTION 2
DRIVEABILITY SYMPTOMS
CONTENTS
Before S ta r tin g ............................................................................................................................................................ ..2-1
Poor Fuel E c o n o m y .......................................................................................................................................................2-1
ECM In te rm itte n t Codes or P e rfo rm a n c e .................................................................................................................2-2
Dieseling, R u n -O n ....................................................................................................................................................... ..2-2
Backfire ..........................................................................................................................................................................2-2
Rough, Unstable, or Incorrect Idle, Stalling .......................................................................................................... ..2-3
Above Normal Emissions (O d o rs )............................................................................................................................. ..2-3
Hard S ta r t ........................................................................................................................................................................2-4
Surges and / or C h u g g le .............................................................................................................................................. ..2-4
Lack o f Power, Sluggish, or S p o n g y ........................................................................................................................ ..2-5
D etonation /S park K n o c k ......................................................................................................................................... ..2-5
Hesitation, Sag, S tu m b le ..............................................................................................................................................2-6
Cuts Out, Misses ............................................................................................................................................................2-6
BEFORE STARTING
Before using this section, you should have Vacuum hoses for splits, kinks, and prop er
performed the S Y S T E M C H E C K in Section " 3 connections, as shown on V eh ic le E m is sio n
Diagnosis. Control Information label.
Verify the customer complaint, and locate the A ir leaks at throttle body mounting and intake
co rrect S Y M P T O M b e lo w . C h e c k the ite m s manifold. See Section "4 .
indicated under that symptom. Ignition wires for cracking, hardness, proper
I f the E N G I N E C R A N K S B U T W I L L N O T routing, and carbon tracking.
R U N , see C H A R T A-3, in Section "3 . W ir in g for proper connections, pinches, and
Refer to the related Chassis Service Manual for cuts.
corrective action of driveability symptoms that are T h e im p o r t a n c e o f this s t e p c a n n o t be
not fuel or emission related. stressed too strongly - it can lead to correcting
a p roblem without furth er checks a n d can save
Careful Visual Check valu able time.
The following symptoms cover several engines.
Several o f the following symptom procedures To determine if a particular system or component is
call for a careful visual (physical) check. This check used, r e fe r to the E C M w i r i n g d i a g r a m s fo r
should include: application.
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 Em ission Control
or for wrong heat range. Information label for procedure.
- Fuel pressure. See C H A R T A-5 in Section "3 . - TC C for proper operation. See Section 10 .
2-2 DRIVEABILITY SYMPTOMS
ECM INTERMITTENT CODES OR PERFORMANCE

Problem may or may not turn " O N the "Service Engine Soon light, or store a code.
The ECM code charts, in Section "3 or Section Loss of code memory: To check, disconnect TPS,
"15 , determine i f there is a fault with a circuit, or, if and idle engine until "Service Engine Soon light
there is an intermittent problem. An intermitent comes " O N . Code 22 should be stored, and kept
means that a code is stored in the ECM memory, but in memory when ignition is turned " O F F , for at
the circuit is OK. Refer to Section "3 for wiring least 10 seconds. If not, the ECM is faulty.
diagrams.
CHECK:
Most intermittent problems are caused by faulty
electrical connections or wiring. Perform careful - E le c tr ic a l system in t e r fe r e n c e caused by a
check of the suspected circuits for: defective relay, ECM driven solenoid, or switch.
Poor m ating o f the connector halves, or T h e y can cause a s h a rp e l e c t r i c a l s u r g e .
terminals, not fully seated in the connector N orm ally, the problem w ill occur when the
body (backed out). faulty component is operated.
Improperly formed or damaged terminals. - Improper installation of electrical options, such
A l l connector term in a ls , in a p ro b lem as lights, 2-way radios, etc.
circuit, should be c a r e fu lly refo rm e d to - EST wires should be kept away from spark plug
increase contact tension. wires, distributor wires, distributor housing, coil,
Poor te r m in a l to w ire connection. Th is and generator. W ire from C K T 453 to distributor
requires rem oving the term inal from the should have a good contact to ground.
connector body as outlined in Section "3 . - Ignition secondary shorted to ground.
I f a visual (physical) check does not find the - C K T s 419 and 451 in te rm itten tly shorted to
cause of the problem, the vehicle can be driven ground.
with a v o ltm e t e r connected to a suspected - E C M po w e r grounds. See S e c t io n " 1 fo r
circuit. An abnormal voltage reading, when the location.
problem occurs, indicates the problem may be in
that c ir c u it.
DIESELING, RUN-ON
Definition: Engine continues to run, after key is turned
" O F F , 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 T B I assem bly for
fuel pump test terminal to turn " O N fuel pump fuel leakage. See Section "4 .
and prime fuel system. See C H A R T A-5 in
Section "3 .
BACKFIRE
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 E n gin e t im in g - See V e h ic le E m is s i o n
EGR diagnosis in Section "9 . Control Information label.
- Output voltage o f ignition coil. See Section 6 . 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.
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 ). Esther condition may be severe enough
to cause stalling. Engine idles at incorrect speed.
Perform careful visual check as described at - Minimum idle air rate. See Section 4 .
start of this section. - Check A.I.R. system. There should be no A.I.R.
to ports while in "Closed Loop . See Section " 8 .
CHECK:
- EGR valve: There should be no E2GR at idle. See
- Throttle linkage for sticking or binding. See Section "9 .
Section "4 . Run a cylinder compression check.
- Ignition timing. See Vehicle Emission Control Inspect oxygen sensor for silicon contamination
Information label. from fuel, or use of improper R T V sealant. The
- EC M ground circuits. See Section " 1 for sensor will have a white, powdery coating, and
location. will result in a high but false signal voltage (rich
- IA C system. See Code 35 in Section " 3 . exhaust indication). The E.CM will then reduce
Diagnosis in Section "4 . the amount of fuel d e liv e re d to the e n g in e ,
- Generator output voltage. Repair if less than 9, causing a severe driveability problem.
or more than 16, volts. Check for fuel in pressure reg u lator hose. If
- P/N switch circuit. See diagnosis in Section "3 , present, replace regulator assembly. See Section
or use "Scan tool. "4 .
- P C V valve for proper op eration , by p la cin g Check ignition system: wires, plugs, rotor, etc.
finger over inlet hole in valve end several times. Monitoring block learn w ill help identify the
Valve should snap back. I f not, replace valve. cause of the problem. If the system is running
See Section "11 . lean (block learn grea te r than 138), refer to
- E v a p o r a t iv e em ission control system. See "Diagnostic A id s on facing page o f Code 44 in
diagnosis in Section "5 . Section "3 . I f the system is running rich (block
- A/C signal to ECM terminal "B8 . "Scan tool learn less than 118), refer to "Diagnostic A ids
should indicate A/C is being requested whenever on facing page of Code 45 in Section "3 .
A/C is selected and the pressure cycling switch is Stalling may be due to an incorrect idle air rate.
closed. See diagnosis in Section "3 . Refer to Code 35 in Section "3 or "Idle Speed
- Controlled idle speed. See Section "4 . Error in Section " 4 for diagnosis.
EXCESSIVE EXHAUST EMISSIONS OR ODORS

Definition: Vehicle fails an emission test. May also have excessive "rotten e g g smell
(hydrogen sulfide). Excessive odor does not necessarily indicate excessive emissions.
Perform "System Check in Section "3 . - Check for improperly installed fuel cap. See
IF T E S T SH O W S EX C ESSIVE CO A N D HC, (or Section "4 .
also has excessive odors): If the system is running rich, (block learn less
Check items which cause engine to run RICH. than 118), refer to "Diagnostic A id s on facing
Make sure engine is at normal operating page of Code 45 in Section "3 .
temperature. IF T E S T S H O W S E X C E S S IV E N O x:
CHECK: Check items which cause engine to run L E A N ,
- Fuel pressure. See C H A R T A-6, in Section "3 . or to run too hot.
- Incorrect timing. See Vehicle Emission Control - EGR vale for not opening. See "E1GR System
Information label on vehicle. Check in Section "9 .
- Canister for fuel loading. See Section "5 . - Vacuum leaks.
- P C V valve for being plugged or stuck, or blocked - Remove carbon with top engine cleaner. E'ollow
P C V hose. See Section "11 . instructions on can.
- S p a r k p lu g s , p l u g w i r e s , a nd i g n i t i o n - Check i g n i t i o n t i m i n g for e x c e s s i v e base
components. advance. See V e h i c l e E m i s s i o n C o n t r o l
- Check for lead c o n ta m in a tio n o f c a t a l y t i c Information label on vehicle.
converter (look for removal o f fuel fille r neck If the system is ru n n in g lean, (block learn
restrictor). greater than 138), refer to "Diagnostic A ids on
facing page of Code 44 in Section "3 .
HARD START
Definition: Engine cranks OK, but does not start for a long
time. Does eventually run, or may start but immediately dies.
CHECK:
- For water contaminated fuel. Long cranking time but eventually runs. Refer to
- Fuel pressure. See Section "3 , C H A R T A-6. Section "3 , C H A R T A-3, Engine Cranks but W ill
* T P S for sticking or binding. See Section "4 . Not Run.
- 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 " O N , for 2 seconds, following ignition Bare and shorted wires.
" O N . See C H A R T A-5 in Section "3 . Pickup coil resistance and connections.
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 " O N . If this circuit is not S p ark p lu g s, w e t p lu g s , cr a c k s , w e a r ,
functioning, this may cause a hot, hard start improper gap, burned electrodes, or heavy
condition. See Section "3 , C H A R T A-5A. deposits.
- For a faulty in-tank fuel pump, check valve, If engine starts, but then im m ed ia tely stalls,
which would allow the fuel in the lines to drain open distributor bypass line. I f engine then
back to the tank after the engine is stopped. To starts, and runs O K, replace distributor pickup
check for this condition: coil.
1. Ignition " O F F . Hard start, with engine at norm al o p era tin g
2. Disconnect fuel line at the filter. See Section temperature. See Crank Signal Diagnosis, in
"4 . Section "3 .
3. Remove the tank filler cap. See Section "4 .
4. Connect a radiator test pump to the line and
apply 103 kPa (15 psi) pressure. I f the
pressure will hold for 60 seconds, the check
valve is OK.
SURGES AND/OR CHUGGLE

Definition: Engine power variation under steady throttle or
cruise. Feels like the vehicle speeds up and slows down with no
change in the accelerator pedal.
I f a tool is available which plugs in to the A L D L Inspect Oxygen sensor for silicon contamination
connector, make sure reading o f VSS matches from fuel, or use of improper R T V sealant. The
vehicle speedometer. See Code 24 in Section sensor may have a white, powdery coating and
"3 . result in a high but false signal voltage (rich
CHECK: exhaust indication). The ECM will then reduce
the amount o f fuel delive re d to the en gin e,
- For intermittent EGR at idle. See Section "9 .
causing a severe driveability problem.
- Ignition timing. See Vehicle Emission Control
Remove spark plugs. Check for cracks, wear,
Information label.
improper gap, burned ele c tr o d e s , or h e a v y
- Inline fuel filter for dirt or restriction. See
deposits. Also, check condition o f distributor
C H A R T A-6 in Section "3 .
cap, rotor, and spark plug wires.
- Fuel pressure. See C H A R T A-6 in Section "3 .
- Generator output voltage. Repair, if less than 9
volts or more than 16 volts.
- TC C Operation. See Section "10 .
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 customers vehicle to sim ila r unit. Check Exhaust system for restriction:
Make sure the customers vehicle has an actual 1. W i t h e n g i n e a t n o r m a l o p e r a t i n 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 i s c o n n e c t E G R s o l e n o i d e l e c t r i c a l
Refer to Section "12 . connector or connect EGR va lve directly to
vacuum source bypassing any switches or
CHECK:
solenoids.
- Ignition timing. See Vehicle Emission Control 3. Run engine at 1000 rpm and record vacuum
Information label. reading.
- For restricted fuel filter, contaminated fuel or 4. Increase rpm slow ly to 2500 rpm. N ote
improper fuel pressure. See C H A R T A-6 in vacuum reading at steady 2500 rpm.
Section "3 . 5. I f vacuum at 2500 rpm decreases more than
- ECM Grounds. Refer to Section "1 . 3", from reading at 1000 rpm, the exhaust
- EGR operation for being open or partly open all system should be inspected for restrictions.
the time. See Section "9 . 6. Disconnect exhaust pipe from engine and
- Generator output voltage. Repair if less than 9 repeat steps 3 & 4. If vacuum still drops,
or more than 16 volts. more than 3" with exhaust disconnected,
- Engine valve timing and compression. check valve timing.
- Engine for proper or worn camshaft.
DETONATION / SPARK KNOCK

Definition: A mild to severe ping, usually worse under acceleration.
The engine makes sharp metallic knocks that change with throttle opening.
Check for obvious overheating problems. Check EGR system for not opening. See Section
- Low coolant. "9 .
- Loose water pump belt. For proper transmission shift points.
- Restricted air flow to radiator, or restricted Check TC C operation. See Section "10 .
water flow thru radiator. For incorrect basic engine parts such as cam,
CHECK: heads, pistons, etc.
Remove carbon with top engine cleaner.
- For poor fuel quality, proper octane rating.
Follow instructions on can.
- For correct PROM. (See Service Bulletins).
- T H E R M A C for staying closed. See Section On vehicles with 7.4L or 5.7L (over 8500 G V W )
" 12 . engine and a dual ca talytic c o n ve rter system,
- Ignition timing. See Vehicle Emission Control check for an exhaust r e s tr ic t io n in the rea r
Information label. converter area. See Figure 3-13.
- Fuel system for low pressure. See C H A R T A-6
in Section "3 .
HESITATION, SAG, STUMBLE

Definition: Momentary lack o f 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, i f severe enough.
P e r fo r m c a r e fu l vis u a l (p h y s ic a l) check as - Fuel pump cycle system. See C H A R T A-5 in

described at start o f Section "2 . Section "3 .
CHECK: - T P S for binding or sticking.
- Generator output voltage. Repair if less than 9 or
- Fuel pressure. See C H A R T A-6 in Section "3 .
more than 16 volts.
- W ater contaminated fuel.
- For open HEI ground, C K T 453. See Section "6 .
- Ignition timing. See Vehicle Emission Control
- Canister purge system for proper operation. See
Information label.
Section "5 .
- EGR valve operation. See Section "9 .
CUTS OUT, MISSES

Definition: Steady pulsation or je r k in g that follows engine
speed, usually more pronounced as engine load increases. The
exhaust has a steady spitting sound at idle or low speed.
Check for missing cylinder by: CHECK:

1. Disconnecting I A C motor. Start engine.
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).
2. I f there is an rpm drop on all cylinders
- Ignition coil and secondary voltage using spark
(equal to within 50 rpm), go to " R O U G H ,
tester J-26792 (ST-125), or equivalent.
U N S T A B L E , OR IN C O R R E C T ID L E ,
- For restricted fuel filter. Also check fuel tank
S T A L L I N G sym ptom . R e c o n n e c t I A C
for water. See Section "4 for location.
motor.
- For low fuel pressure. See C H A R T A-6 in
3. I f there is no rpm drop on one or more
Section "3 .
cylinders, or excessive variation in drop,
- Check for proper valve timing.
check for spark on the suspected cylinder(s)
P erform compression check on q u e stio n a b le
with J 26792 (ST-125) Spark Gap Tool or
cylinder(s) found above. If compression is low,
equivalent. I f no spark, see Ignition Section
repair as necessary.
"6 . I f there is spark, remove spark plug(s) Visually check distributor cap and rotor for
in those cylinders and check for:
moisture, dust, cracks, burns, etc. Spray cap and
Cracks
plug wires with fine water mist to check for
W ear
shorts.
Improper Gap
Remove rocker covers. Check for bent pushrods,
Burned Electrodes worn rocker arms, broken valve springs, worn
H eavy Deposits
camshaft lobes.
COMPUTER COMMAND CONTROL (WITH "SCAN") 3-1
SECTION 3
COMPUTER COMMAND CONTROL
(USING "SCAN" TOOL DIAGNOSIS)
TABLE OF CONTENTS
GENERAL DESCRIPTION .................................... 3-2 Checking Fuel Gage (Two Fuel Tanks) . . 3-11
ALDL C o n n e c to r......................................... 3-2 COOLANT TEMPERATURE SENSOR............. 3-12
W irin g Harness and C o n n e c to rs ............ 3-3 MAP SENSOR................................................... 3-12
Inform ation Sensors.................................. 3-3 OXYGEN SENSOR............................................ 3-12
ELECTRONIC CONTROL MODULE ............... 3-3 THROTTLE POSITION SENSOR .................... 3-12
Mem-Cal ..................................................... 3-4 TPS O u tp u t................................................... 3-13
PROM .......................................................... 3-4 TBI 220 ( 4 . 3 L &V8 Engine) .................... 3-13
C a lP a k.......................................................... 3-4 TBI 220 (2.8L Engine) ............................. 3-13
FUEL CONTROL .............................................. 3-4 TBI 700 ........................................................ 3-13
INPUT INFORMATION.................................... 3-4 VEHICLE SPEED SENSOR................................ 3-13
Coolant Tem perature S e n s o r................. 3-4 MAT SENSOR................................................... 3-13
MAP S e n s o r................................................ 3-5 EGR SYSTEM ................................................... 3-13
Oxygen S ensor........................................... 3-5 IDLE SPEED........................................................ 3-13
T hrottle Position S e n s o r........................... 3-5 ELECTRONIC SPARK T IM IN G ......................... 3-14
M anifold A ir Tem perature S ensor.......... 3-6 ELECTRONIC SPARK C O N T R O L.................... 3-14
E -C ell............................................................ 3-6 SYSTEM OVERVOLTAGE ............................. 3-14
Vehicle Speed S e n s o r................................ 3-6 PARK/NEUTRAL SW ITCH................. .............. 3-14
Knock S e n s o r.............................................. 3-7 CRANK SIGNAL................................................. 3-14
Park/Neutral Switch S ig n a l...................... 3-7 POWER STEERING PRESSURE S W IT C H ____ 3-14
Crank S ig n a l................................................ 3-7 DISTRIBUTOR REFERENCE SIGNAL............... 3-14
D istribu tor Reference S ig n a l.................... 3-7 A/C CLUTCH C O N TR O L.................................. 3-14
Power Steering Pressure Switch Signal . 3-7 A/C "O N " SIG N AL............................................ 3-14
A/C Control S ig n a l....................................... 3-7 EXHAUST S Y S TE M .......................................... 3-14
Transmission Gear Position Signal . . . . 3-7 ON-VEHICLE SERVICE.......................................... 3-92
D IA G NO SIS .......................................................... 3-7 WIRE HARNESS................................................. 3-92
BULB CHECK ................................................... 3-7 CONNECTORS AND TE R M IN A LS .................. 3-92
SYSTEM CHECK .............................................. 3-7 3-93
Diagnostic M o d e ....................................... 3-8 M e tri-P a c k ................................................... 3-93
Field Service M o d e .................................... 3-8 W eather-Pack ............................................ 3-93
"Scan" T o o l................................................ 3-8 Compact T h re e ............................................ 3-94
Engine Does Not Start ............................. 3-8 W irin g Diagram - 2 .5L .............................. 3-95
Code System .............................................. 3-8 W irin g Diagram - 2.8L .............................. 3-98
Clearing Codes ......................................... 3-9 W irin g Diagram - 4.3L & V 8 ...................... 3-101
ELECTRONIC CONTROL MODULE ............... 3-9 ELECTRONIC CONTROL M O D U L E ............... 3-94
ECM Quad Driver (QDR) C h e c k ............... 3-9 ECM Connector T e rm in a ls -2.5 L ............. 3-105
PROM .......................................................... 3-10 ECM Connector Terminals - 2.8 L ............. 3-106
Mem-Cal ..................................................... 3-10 ECM Connector Term inals - 4.3L & V8 . . 3-107
C a lP a k .......................................................... 3-10 COOLANT TEMPERATURE SENSOR............. 3-112
FUEL CONTROL .............................................. 3-10 MAP SENSOR................................................... 3-112
Fuel Injector................................................ 3-10 OXYGEN SENSOR............................................ 3-113
Pressure Regulator .................................. 3-10 THROTTLE POSITION SENSOR...................... 3-116
Idle Air Control ......................................... 3-10 MAT SENSOR................................................... 3-117
Fuel Pump C ir c u it....................................... 3-10 E CELL ............................................................... 3-117
Fuel M o d u le................................................ 3-10 VEHICLE SPEED SENSOR................................ 3-117
Fuel Module Check.................................... 3-10 KNOCK SENSOR.............................................. 3-117
Fuel Pump Circuit (Two Fuel Tanks) . . . . 3-11 PARK/NEUTRAL SW ITCH................................ 3-117
Fuel Tank Selector Diagnosis POWER STEERING PRESSURE S W IT C H ------- 3-118
(Two Fuel Tanks)....................................... 3-11 A/C CONTROL................................................... 3-118
PARTS INFORMATION ....................................... 3-118
3-2 COMPUTER COMMAND CONTROL (WITH "SCAN")
GENERAL DESCRIPTION
The Computer Command Control system has a
F E C B A
computer (electronic control module) to control the
fuel delivery, ignition timing, some emission control
o GH M *
o, /
s y s te m s and e n g a g e m e n t o f the t r a n s m is s i o n TERMINAL IDENTIFICATION
converter clutch, downshift control or the manual
H GROUND |7 J TC<; (lfu s E D )
transmission shift light.
Th e system , through the E le ctro n ic C on trol 0
H AGNOSTIC TERMiNAL Q FUELPUM P(CK )
Module (E C M ), monitors a number of engine and [c ~ | A.I.R. (IF USED)
ve h icle functions (F i g u r e 3-1) and co n tro ls the
following operations: 0 SERIAL DATA (V6/V8)
0 BRAKE SENSE
SPEED INPUT (CK)
(SEE SPECIAL TOOLS) M SERIAL DATA (L4)
Fuel control (SEE SPECIAL TOOLS)
Ignition/electronic spark timing *7S 3541-6E
6-2-87
Electronic spark control
Figure 3-2 ALDL Connector
A ir management
Exhaust gas recirculation ALDL Connector
Transmission converter clutch, downshift control Figure 3-2
or manual transmission shift light The A ssem bly Line D ia g n o stic Link ( A L D L )
The diagnosis in this section is provided when a twelve terminal connector is wired to the ECM and is
"Scan tool to interface with the Computer Command located under the instrument panel in the passenger
Control system is available. I f a "Scan tool is not compartment.
available, refer to Section "15 for diagnosis. This connector has term in als that are used to
diagnose the system either with jum per wires or a
"Scan tool.
* OPERATING CONDITIONS SENSED * SYSTEMS CONTROLLED
A/C "O n" or "O ff"

Air M anagem ent
Engine Coolant "T em p erature"
Exhaust Gas Recirculation (EGR)
Engine Crank Signal
Electronic Spark Timing (EST)
Exhaust 0 x y g e n (0 2) Sensor
Fuel Control
Distributor Reference
Idle Air Control (IAC)
Crankshaft Position
Electric Fuel Pump
Engine Speed (RPM)
Transmission Converter Clutch (TCC),
M anifold Absolute Pressure (M AP) ELECTRONIC
D ow nshift Control or M anual
Park Neutral Switch (P/N) Position (ENGINE)
Transmission Shift Light
System Voltage CONTROL
Air Conditioning
Throttle Position (TPS) MODULE
Diagnostics
Transmission Gear Position (ECM)
"Service Engine Soon" Light
Vehicle Speed (VSS)
Diagnostic Terminal (ALDL)
Fuel Pump Voltage
Data O utput (ALDL)
Power Steering Pressure
Electronic Spark Control (ESC)
EGR Vacuum
E-Cell-2.8L
Engine Knock (ESC)
* All systems not used on all engines.
M anifold Air Tem perature (M A T)
6-25-87
*7S 3537-6E
Figure 3-1 Computer Command Control System

The following terminals are used: Crank signal

A - This terminal provides a ground circuit to other Distributor reference signal
terminals. Power steering pressure switch signal
B- This terminal is the "diagnostic terminal for the A/C control signal
ECM. W hen grounded to " A term in a l, the Transmission gear position signal
"Service Engine Soon light will flash codes (key EGR vacuum signal
" O N and engine " O F F ) entering the diagnostic
mode or flashes a field service mode (engine ELECTRONIC CONTROL MODULE
running) to determine if system is in a "Closed (Figure 3-3 or 3-4)
or "Open Loop operation. The Electronic Control Module (E C M ) is located in
C - This terminal, on some air management systems, the passenger compartment and is the control center
is wired to the ground side o f the electric air of the Computer Command Control system.
control valve. It can be used to diagnose the air The ECM constantly looks at the information from
management system. Refer to Section "8 . various sensors, and controls the systems that affect
E - This term inal is the s e r ia l data line on all v e h ic le p e r fo r m a n c e . T h e E C M p e r f o r m s th e
engines except 2.5L and is used by a "Scan tool diagnostic function o f the system. It can recognize
to read various system data information. operational problems, a lert the d r iv e r through the
F - Th is term inal is used to d ia g n ose the T C C "Service Engine Soon light, and store a code or codes
system and is wired to the ground side o f the TC C which identify the problem areas to aid the technician
solenoid. Refer to Section "10 . in making repairs. See diagnosis section for more
G - This terminal is used to diagnose the fuel pump information.
circuit on all C K series. On other engines the The ECM is designed to process the various input
fuel pump test lead is in the engine compartment information (Figure 3-1) and then sends the necessary
near the fuel pump relay. Refer to C H A R T A-5 electrical responses to control fuel d e liv e ry , spark
or A-5A. timing and other emission control systems. The input
H - Th is term inal is used to diagnose the brake information has an interrelation to more than one
system on C K trucks. Refer to " C K Light Duty output, therefore, if the one input failed it could effect
Service Manual for additional information. more than one systems operation.
M - This terminal is the serial data line for the 2.5L The ECM has a "learn ing ability which allows it
engines and is used by a Scan tool to read to make corrections for minor variations in the fuel
various system data information. system to im prove d riv ea b ility . I f the ba tte ry is
d iscon nected to cle a r codes, or fo r r e p a i r , the
Wiring Harness and Connectors "learn ing process has to begin all over again.
A wiring harness electrically connects the ECM to

various sensor, solenoid and relays within the system.
M any connectors in the engine co m p artm en t are
environmentally protected because o f the systems low
voltages and current levels.
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
|T] ACCESS COVER [T] MEM/CAL
and the following input signals: _____________________________________________ 6S2548-6E
Park/neutral switch signal Figure 3-3 Electronic Control Module (L4)

PROM (V 6& V 8)
(Figure 3-5)
Inform ation for specific engine and ve h ic le is
program m ed using an integrated c irc u it c a lle d a
PROM, (Programmable Read-Only Memory). In the
parts book, it is listed as a calibrator. This allows one
model o f controller to be used for many d iffe re n t
vehicles. The PROM is located inside the ECM and
has inform ation on the v e h ic le s w e ig h t, e n g in e ,
transmission, axle ratio, and several others. W h ile
one ECM part number can be used by many vehicle
lines, a P R O M is very specific and must be used for the
right vehicle. For this reason, it is very important to
check the latest parts book and S e rv ice B u lle tin
in fo r m a t io n for the co rrect p a r t n u m b er w hen
replacing a PROM.
CalPak ( V 6 &V 8 )
(Figure 3-5)
A c h a n g e m a y be n o t e d in th e v e h i c l e s
A CalPak is used to allow fuel delivery if other
performance. To "teach the vehicle, make sure the
parts o f the E C M are damaged. I f the C a lP a k is
engine is at operating temperature, and drive at part
missing, it will result in a no start and run condition.
th r o tt le , w it h m o d e r a t e a c c e l e r a t i o n and id le
conditions, until normal performance returns.
NOTICE: T h e E C M m ust be m a in t a in e d at a
tem perature below 185F (85C) at all
times. This most essential i f the vehicle is
put through a paint baking process. The
E C M w i l l b e c o m e i n o p e r a t i v e i f its
t e m p e r a t u r e e x c e e d s 18 5F (8 5 C ) .
T h e r e f o r e , it is r e c o m m e n d e d t h a t
temporary insulation be placed around the
ECM during the time the vehicle is in a
paint oven or other high t e m p e ra tu r e
processes.
There are two types of E C M s used in light duty

trucks. FUEL CONTROL
A vehicle equipped with a 4 cylinder engine has an
ECM (referred to as G M P 4) with two parts for service. Fuel delivery is controlled by the Computer Command
A controller (an ECM without a Mem-Cal) and a Mem- Control system. Th e general d e sc rip tio n o f fu el
Cal (Memory and Calibration unit). control is in Section " 4 . This includes the fu el
A ll vehicles with a V6 or V8 cylinder engine have injector, pressure regulator, idle air control valve and
an ECM (referred to as G M C M ) with three parts for the fuel pump electrical circuit.
service. A controller (an EC M without a PR O M ), a
PR O M with specific progra m in fo r m a t io n for an INPUT INFORMATION
en g in e and v e h ic le and a C a lP a k w ith s p e c ific
calibration information.
Coolant Temperature Sensor
(Figure 3-6)
The coolant temperature sensor is a thermistor (a
Mem-Cal (L4)
resistor which changes value based on temperature)
(Figure 3-3)
mounted in the engine coolant stream. Low coolant
This assembly contains both the functions of the
temperature produces a high resistance (100,000 ohms
PROM and CakPak. Like the PROM, it contains the
at -40C/-40F) while high tem perature causes low
calibrations needed for a specific vehicle as well as the
resistance (70 ohms at 130C/266F).
back-up fuel control circuitry required if the rest o f the
ECM becomes damaged or faulty.
The M A P sensor reading is the opposite o f what you

would measure on a vacuum gage. When manifold
pressure is high, vacuum is low. The M A P sensor is
also used to measure ba rom etric pressu re u nder
c e r t a i n c o n d it io n s , w h ic h a l l o w s the E C M to
automatically adjust for different altitudes.
The ECM sends a 5 volt reference signal to the
M A P sensor. As the manifold pressure changes, the
electrical resistance of the sensor also changes. By
monitoring the sensor output voltage, the ECM knows
1 ENGINE COOLANT TEMPERATURE SENSOR the manifold pressure. A h ig h e r pressu re, low
2 HARNESS CONNECTOR TO ECM vacuum (high voltage) requires more fuel, w h ile a
4-2-85 3 LOCKING TAB lower pressure, higher vacuum (low voltage) requires
5S 1640-6EA less fuel.
Figure 3-6 Coolant Temperature Sensor The ECM uses the M A P sensor to control fuel
delivery and ignition timing.
The ECM supplies a 5 volt signal to the coolant
temperature sensor through a resistor in the ECM and Oxygen (O2) Sensor
measures the voltage. The voltage will be high when (Figure 3-8)
the engine is cold, and low when the engine is hot. By The exhaust oxygen (O 2) sensor is mounted in the
measuring the voltage, the ECM knows the engine exhaust system where it can monitor the o x y g e n
coolant temperature. Engin e coolant tem perature content o f the exhaust gas strea m . T h e o x y g e n
affects most systems the ECM controls. content in the exhaust reacts with the oxygen sensor
to produce a voltage output. This voltage ranges from
MAP Sensor approximately .1 volts (high oxygen - lean mixture) to
(Figure 3-7) .9 volts (low oxygen - rich mixture).
The Manifold Absolute Pressure ( M A P ) sensor By monitoring the voltage output of the oxygen
m easu res the c h a n g e s in the in t a k e m a n ifo ld sensor, the E C M w ill know w hat fu el m i x t u r e
pressure, which result from engine load and speed command to give to the injector (lean m ixture-low
changes, and converts this to a voltage output. voltage-rich command, rich mixture-high voltage-lean
A closed throttle on engine coastdown will produce command).
a r e la tiv e ly low M A P output, w h ile a w ide-open
throttle will produce a high output. This high output Throttle Position Sensor
is produced because the pressure inside the manifold (Figure 3-9 or 10)
is the same as outside the manifold, so 100% o f the The Throttle Position Sensor (TP S) is connected to
outside air pressure is measured. the t h r o t t l e s h a f t on th e T B I u n it. It is a
potentiometer with one end connected to 5 volts from
the ECM and the other to ground.
Figure 3-7 M AP Sensor Figure 3-8 O xygen Sensor

[T 1 THROTTLE BODY ASSEM BLY

m THROTTLE POSITION SENSOR - NON-ADJUSTABLE
m THROTTLE POSITION SENSOR - NON-ADJUSTABLE
rT l M ANIFOLD AIR TEMPERATURE (MAT) SENSOR
fT I THROTTLE POSITION SENSOR - ADJUSTABLE
[~2~1 ENGINE INTAKE M ANIFOLD
m SCREW ASSEM BLY
FTI RETAINER 7S 3652-6E
7S3545-6E
Figure 3-9 Throttle Position Sensor - V6/V8 Figure 3-11 Manifold Air Temperature Sensor - L4
A third wire is connected to the ECM to measure Low temperature produces a high resistance (100,000
the voltage from the TPS. As the throttle valve angle ohms at -40C/-40F) while high temperature causes
is changed (accelerator pedal moved), the output of the low resistance (70 ohms at 130C/266F).
T P S also changes. A t a closed throttle position, the The ECM supplies a 5 volt signal to the sensor
output o f the T P S is low (approximately .5 volts). As through a resistor in the EC M and measures the
the throttle valve opens, the output increases so that, voltage. The voltage will be high when the manifold
at wide-open throttle, the output voltage should be air is cold, and low when the air is hot. By measuring
approximately 5 volts. the v o lta g e , the E C M k n ow s the m a n ifo ld a ir
By monitoring the output voltage from the TPS, temperature.
the ECM can determine fuel delivery based on throttle The M A T sensor signal is used by the EC M to
valve angle (driver demand). delay EGR until the manifold air temperature reaches
about 5C (40F).
Manifold Air Temperature (MAT) Sensor The ECM uses the signal to slightly retard the
(Figure 3-11) timing during high ambient air temperatures.
The Manifold A ir Temperature (M A T ) sensor is a
thermistor (a resistor which changes value based on E-Cell-2.8L
te m p e r a t u r e ) mounted on a 2.5L e n gin e in the (Federal Only)
manifold. The E-Cell located next to the ECM, is also known
as an elapsed timer module or a cold start program
modifier. The E-Cell is an emission device that is an
enrichment signal to the ECM for about 4 seconds
during cold start. After an elapsed time of operating
hours, the signal is no longer required and becomes
inoperative.
Vehicle Speed Sensor
The Vehicle Speed Sensor (VSS) located behind

the speedometer or on the transmission on C K or P
series, sends a pulsing voltage signal to the ECM ,
which the ECM converts to miles per hour. Th is
sensor m ainly controls the op eration o f the T C C
system, shift light, and cruise control.
Figure 3-10 Throttle Position S en so r-L 4

Knock Sensor Power Steering Pressure Switch Signal
Located in the engine block, the knock sensor The power steering pressure switch is used with
retards ig n it i o n t i m i n g d u r i n g a s p a r k knock the 4-cylinder engine and is located near the power
condition to allow the ECM to m aintain maximum steering gear. When steering is to the extrem e left or
timing advance under most conditions. right, the switch is closed and this signal will increase
the idle air rate and retard the spark for a stable idle.
Park/Neutral Switch Signal
A/C Control Signal
The Park/Neutral (P/N) switch, located on the
steering column, is used on an automatic transmission This signal indicates that the A/C control switch is
vehicle to indicate to the ECM when the transmission turned " O N and the pressure switch is closed. The
is in park or neutral. This inform ation is used to ECM uses this signal to adjust the idle speed and on
control the operation o f the transmission converter 2.5L and 2.8L engines, engages the A/C compressor
clutch and idle air control. clutch.
Crank Signal Transmission Gear Position Signal
The ECM uses this signal to tell when the vehicle A s w itch , lo c a te d in s id e th e a u t o m a t ic
is in the S T A R T I N G mode. transmission, opens when the transmission shifts to
h ig h g e a r . T h is s i g n a l is u sed fo r d e l a y e d
Distributor Reference Signal disengagement o f the transmission converter clutch.
The distributor sends a signal to the E C M to Refer to Section "10 for specific application.
indicate both engine rpm and crankshaft position. See
Section "6 for further information.
DIAGNOSIS
The Computer Command Control system has a SYSTEM CHECK
diagnostic system built into the EC M to indicate a (Figure 3-12)
failed circuit. An amber "Service Engine Soon light Sin c e this is the s t a r t i n g p o i n t f o r the
on the instrument panel will illuminate if a problem diagnostic p rocedu res or finding the cause o f an
has been detected when the engine and vehicle are emissions test failure, a lw a y s begin h ere .
running. This light is also used for a bulb and system
The system check is p e rfo rm ed th r o u g h the
check.
twelve terminal assembly line diagnostic link (A L D L )
The System Check is the starting point for the
d ia g n o s t ic p r o c e d u r e s o r a n e m i s s i o n s test connector (Figure 3-2) under the instrument panel in
failure. The diagnostic charts are related to the ECM the passenger compartment.
and will determine i f the EC M is working properly. The Computer Command Control System Check
This section diagnoses the fuel system controlled by is a procedure that determines the following:
the ECM and has charts to diagnose a circuit when the 1. Bulb Check - to check SES light circuit and
ECM has displayed a code. that the EC M can complete the circuit.
The system requires an A L D L read-out "Sca n 2. D ia gn o stic Mode - this i n d i c a t e s i f the
tool, tach om eter, te s t li g h t , o h m m e t e r , d i g i t a l diagnostic code system is working.
voltmeter with 10 megohms impedance (J-34029A), 3. "Scan Data - this determines if the ECM is
vacuum gage and jumper wires for diagnosis. Refer to
suppling input and output visual data.
Section "13 for additional information about special
4. Engine Start - this step is done after it has
tools. I f a "Scan tool is not available, refer to Section
"15 . been determined that the ECM will display
codes and data.
BULB CHECK 5. Other Codes - Proceed to applicable chart if a
code is displayed. Scanning the d ata for
W ith the ignition " O N and engine not running, typical value may indicate a problem area if
the lamp should illuminate, which indicates that the they are incorrect. If all systems appear to be
ECM has completed the circuit to turn " O N the light. f u n c t i o n i n g , r e v i e w the " D r i v e a b i l i t y
If the "Service Engine Soon light is not " O N , Symptoms in Section "2 .
refer to C H A R T A - l for diagnosis.
The system check starts with a bulb check If
When the engine is started, the light w ill turn
there is no " S ervic e Engine Soon light, refer to
" O F F . I f the light remains " O N refer to system
check C H A R T A -l
Diagnostic Mode Field Service Mode
I f the diagnostic terminal " B , in A L D L connector, is I f the diagnostic terminal " B is grounded with the
grounded with the ignition " O N and the en g in e engine running, the system will enter the field service
stopped, the system will enter the diagnostic mode. mode. In this mode, the "Service Engine Soon light
With the key " O N and the engine " O F F , jumper will show whether the system is in "Open or "Closed
A L D L terminals " B to " A . The "Service Engin e Loop and fuel sytem is operating normally.
Soon light should flash Code 12 to indicate that the Refer to Section "15 for additional information on
diagnostic system is working. Code 12 consists of "one field service mode.
flash followed by a pause and then "two flashes . The
code will repeat for a total of three times and w ill "Scan" Tool
continue to repeat i f there are no other codes stored.
This procedure can also be done with some "S ca n A "Scan tool is designed to interface w ith the
tools. Computer Command Control system. It supplies a
I f Code 12 does not display, refer to C H A R T A-2. visual reading of most inputs to the ECM and some
A flashing Code 12 does not mean an engine problem; outputs. Review the tool in s tru ctio n m anual to
it simply means that the diagnostic mode is working. understand its operation and limitations.
Any other stored codes (F ig u re 3-16) w ill begin to C o n n e c t a " S c a n t o o l to th e A L D L and
flash after Code 12. cigarette/cigar lighter connector or 12 volts and there
Refer to Section "15 for additional information should be a visual instruction displayed. If there is no
about flashing codes. display or tool reads "N o D A T A or No A L D L with
ignition " O N , refer to C H A R T A-2.
With the tool in the code position, the display
IGNITION "O N ", ENGINE STOPPED.
IS THE "SERVICE ENGINE SOON"
window w ill indicate any code stored in the EC M
(SES) LIGHT "O N " STEADY? memory (Figure 3-16). Referring to the applicable
code chart, the tool will Scan an input to determine
if a specific circuit is operating properly. If there are
YES NO no codes, the system check is completed. Additional
zzr rr r information on "Scan tools is in Section "13 .
JUMPER ALDL TERM. "B" TO "A ". SEE CHART A-1
I f there are additional d r iv e a b ility symptoms,
DOES SES LIGHT FLASH CODE 12?
refer to Section "2 .
I f there are additional codes, refer to applicable
code chart.
YES NO
m :
I SEE CHART A-2 J
Engine Does Not Start
DOES "SCAN" DISPLAY ECM DATA?
If the engine cranks but will not start, refe r to

C H A R T A-3 through A-6 to determine if there is a fuel
YES NO
or ignition problem.
I , 3 ----------
DOES ENGINE START? i SEE CHART A-2
l __________________J
Code System
(Figure 3-16)
The ECM is equipped with a self-diagnosis system
YES NO
which detects system failure and aids the technician
, 3 .............. , in locating the circuit at fault via a code.
ARE ANY CODES DISPLAYED? i SEE CHART A-3 '
L __________________J The ECM is really a computer. It uses sensors to
look at many engine operating conditions. It has a
I memory and it knows what a certain sensor reading
YES NO should be under certain conditions. These conditions
are described on the facing page of each code chart. If
a sensor reading is not what the ECM thinks it should
REFER TO APPLICABLE CHECK "SCAN" DATA FOR
CODE CHART. START TYPICAL VALUES. REPAIR AS be, the ECM will turn on the "Service Engine Soon
WITH LOWEST CODE. NECESSARY. IF ALL OK,SEE light on the instrument panel, and will store a code in
DRIVEABILITY SYMPTOMS IN the memory. The code tells which circuit the trouble
SECTION "2 " .
is in. A circuit consists o f a sensor, such as coolant
temperature, the wiring and connectors to it, and the
6-22-87
*7S 3538-6E ECM.
Figure 3-12 System Check
An "intermittent code is one which does not reset Although a rare condition, the rep la c em en t
itself, and is not present while you are working on the ECM may be faulty.
vehicle. This is often caused by a loose connection. In the case of an intermittent problem, refer to
The facing page of a code chart will contain diagnostic Section " 2 and m ake a c a r e f u l p h y s ic a l
aids to help in detecting intermittents. inspection o f the system involved.
A "hard code is one which is present when you are A shorted solenoid, relay coil or harness may
working on the vehicle and the condition still exists cause an ECM to fail and a replacement E C M to
while working on the vehicle. The chart with the fail when it is installed. U se a short tester
stored code number will lead you to the cause o f the J34636, B T 8405, or e q u iv a le n t as a fast,
problem. accurate means of checking for a short circuit.
Refer to ECM quad driver (Q D R) check before
Clearing Codes replacing ECM. (Figure 3-18)
When the ECM sets a code, the "Service Engine ECM Quad Driver (QDR) Check
Soon light will come " O N and a code will be stored in
memory. I f the problem is intermittent, the light will The ECM uses an integrated circuit (IC) called a
go out after 10 seconds when the fault goes away. quad driver (QDR) in place o f separate transistors
However, the code will stay in the ECM memory for 50 toturn " O N or " O F T different circuits controlled by
starts or until the battery vo lta ge to the EC M is the ECM. Each QDR has four separate outputs that
removed. Removing battery voltage for 30 seconds can independently turn " O N or " O F F four different
will clear all stored codes. The ECM B fuse can also be circuits.
used to clear codes on all vehicles except C K which has ECM service part number 1227747, used with V6
a fuse link. & V 8 en gin es, does not h a ve f a u l t p r o t e c t io n ,
Codes should be cleared after repairs have been therefore, a single faulty circuit many times causes all
completed. Also, some diagnostic charts will tell you four QDR outputs to be inoperative or " O N all the
to clear the codes before using the chart. This allows time. A failed QDR usually results in either a shorted
the ECM to set the code while going through the chart, or open ECM output. Because of the increased current
which will help to find the cause o f the problem more flow, two QDR outputs are used to d riv e the T C C
quickly. solenoid.
Refer to the ECM QDR check procedure (F igure 3-
NOTICE: To prevent ECM damage, the key must be 18). This check will not test all E C M functions but it
"O F F w hen d is c o n n e c tin g or will determine if a specific circuit has caused a specific
reconnecting power to ECM (for example QDR to fail in the ECM.
battery cable, E C M pigtail, EC M fuse, A faulty circuit is the largest cause o f a failed QDR,
jumper cables, etc.) therefore, the check procedure should be used if there
is an indication of an ECM replacement, especially if
ELECTRONIC CONTROL MODULE the r em o v ed E C M e x h ib it s c h a r a c t e r is t ic s o f a
damaged QDR such as:
The diagnosis of the electronic control module "S E S light with no codes stored.
(EC M ) starts with the system check. The code system P^ngine will not start and/or E C M will not flash
indicates a failure of a specific circuit and diagnosis Code 12.
may indicate replacement of the ECM. A Code 55 Flickering, intermittent, or dim "S E S light.
indicates that the E C M has fa ile d and must be Output, such as TC C circuit, is inoperative or
replaced. " O N at all times.
I f the ECM has been replaced and the condition Engine misfires, surges or stalls.
was not corrected, the following information may be "Scan tool is erratic or inoperative.
the cause:
A n i n c o r r e c t E C M or P R O M / M e m - C a l The EC M used with an L4 engine has IC circuits
application may cause a malfunction and may that are fault protected, therfore, i f a circuit has
or may not set a code. failed, the IC may not be damaged and will keep the
If the connector at the EC M is the possible circuit open until the fault in the circuit has been
problem, the terminal may have to be removed co rre cted . W h e n the fa u lt has been c o r r e c t e d ,
from the connectors in order to properly check reinstall ECM and check circuit. Replace ECM only if
them. the circuit is still inoperative.
Although the PROM/Mem-Cal rarely fails, it
operates as part of the ECM, therefore, it could
be the cause of the problem.
PROM The IA C valve affects only the idle characteristics

of the engine. I f it is open fully, too much air w ill be
A P R O M th a t has f a i l e d or w as in s t a l l e d allowed in the manifold and idle speed will be high. If
improperly will generally set a Code 51. it is stuck closed, too little air will be allowed in the
manifold, and idle speed will be too low. I f it is stuck
Mem-Cal part way open, the idle may be rough, and w ill not
respond to engine load changes.
A Mem -Cal that has fa iled or was in s ta lled
improperly will set a Code 51. Fuel Pump Circuit
CalPak Code 54 indicates a failu re in the fuel pump
circuit.
A no start and run condition w ill result i f the Two types of fuel pump relays are used on light
CalPak is not installed in the ECM. A CalP ak that is duty trucks. The S,T and M series use one type and C,
removed will set a Code 52. K, R, V, G and P series use the other type. Both relays
have the same function, but terminals arrangement is
FUEL CONTROL different. Both relays have a terminal to test the fuel
pump operation. This is either a separate terminal
Fuel d e liv e ry is co n tr o lle d by the C om p u te r located near the relay or along the ECM harness or at
Command Control system. terminal " G in the A L D L connector. By ap p ly in g
The diagnosis of fuel control starts with "Engine voltage at this terminal, it can be determined if the
Cranks But W ill Not Run C H A R T A-3. This chart fuel pump will operate. This terminal w ill also prime
will test the fuel system and i f there is a problem, will the fuel line to the TB I unit.
lead you to checking the fuel pump relay circuit, Refer to C H A R T A-5 or A-5A for diagnosis o f fuel
diagnosing the injector circuit or diagnosing the fuel pump relay circuit.
system. An inoperative fuel pump would cause a no start
condition. A fuel pump which does not provide enough
Fuel Injector pressure can result in poor performance.
An inoperative fuel pump relay can result in long
Testing the fuel injector circuit is in C H A R T A-3 cranking times, pa rticu la rly if the engine is cold. The
and additional diagnosis in C H A R T A-4. oil pressure switch will turn " O N the fuel pump, as
A fuel injector which does not open may cause a soon as oil pressure reaches about 28 kPa (4 psi).
no-start condition. An injector which is stuck partly
open, could cause loss of pressure after sitting, so long Fuel Module
crank times would be noticed on some engines. Also,
dieseling could ocur because some fuel could be On a 7.4L engine or a G Van with a 5.7L engine
delivered to the engine after the key is turned O F F . and all other 5.7L engines over 8500 G V W , a fuel
module will override the ECM two second tim er and
Pressure Regulator the fuel pump will run for twenty seconds and then
shut O F F i f the vehicle is not started. This circuit
T e s t in g the pressure r e g u la t o r cir c u it is in
corrects a hot restart (vapor lock) d u r in g a high
C H A R T A-3 and A-4.
ambient condition.
If the pressure regu lator in the T B I supplies
pressure which is too low (below 62 kPa or 9 psi), poor
Fuel Module Check
performance could result. I f the pressure is too high,
unpleasant exhaust odor may result. 1. Disconnect the fuel module. (C H A R T A-5 OR A-
5A)
Idle Air Control 2. W it h a test lig h t and ig n it io n " O N , p ro b e
connector terminal " C to ground. Circuit is O K if
The diagnosis of idle air control can be found in light is " O N . There is an open i f the lig h t is
Code 35 chart for 2.5L engine and Section "4 for all "O F F .
other engines. 3. Probe connector terminals " C to " D with test
If the IAC valve is disconnected or connected with light. Circuit is O K if light is " O N . There is an
the engine running, the idle rpm may be wrong. In open in ground circuit if light is "OFF1 .
4. Ignition " O F F . Probe connector terminals " A to
this case, on engines with T B I 220 units, the IA C
" D with test light. Ignition " O N , test ligh t
valve may be reset by turning the ignition switch
should illuminate for two seconds. T h e r e is an
" O N and " O F F one time. On engines using a TBI
open in the circuit if the light is " O F F .
700 unit, the idle rpm is reset at a speed above 30 mph 5. Replace fuel module if there is no twenty second
(48 km/hr). fuel pump operation.
Fuel Pump Circuit

(Two Fuel Tanks)
A quick check can be made by pressing fuel tank
selector switch with the ignition " O N and listening
for movement of the selector valve. N ote that the
selector switch is part of the fuel pump relay circuit,
therefore, the valve will only operate for two seconds
or twenty if equpped with a fuel module.
Refer to C H A R T A -5A for the diagnosis o f the fuel
pump relay circuit.
I f the problem is "Engine Cranks But W ill Not
Run , this diagnosis is used because there is no fuel
pump operation and will determine i f the electrical
system is operating.
The circled numbers on C H A R T A -5 A refer to
information provided below:
1. This procedure applies direct voltage to run
the fuel pump. T oggling the fuel tank selector m FUEL TANK SELECTOR SWITCH
switch will test the operation o f each fuel tank [T 1 FUEL PUM P CONNECTOR
A - TAN WIRE TO LEFT FUEL PUMP
pump. B GRAY WIRE TO RIGHT FUEL PUMP
2. I f neither pump would run, the contacts inside m TAN W H ITE WIRE TO FUEL PUM P RELAY
the relay or fuel tank selector switch may be IT ] BLACK G RO UND WIRE TO FUEL TANK SELECTOR
inoperative. Check single connector (Figure SWITCH
3-13) tan/white wire to the fuel pump relay on m FUSE PANEL
the cowl.Check the two term inal connector I 6 I BUS BAR G RO UND
(Figure 3-13) tan and gray wire to the fuel
8S 4332-6E
pumps.
3. This step checks voltage from the battery and Figure 3 - 1 3 Fuel Tank Selector Switch
the ground circuit to the relay. I f light is " O N in both positions, check fuel
4. This test determines i f there is voltage from gage circuit.
the E C M te r m in a l " A l on the E C M to 5. Disconnect 12 volts, connect fuel pump connector
terminal "D on the relay connector. and check fuel gage.
5. This completes the fuel pump relay circuit but
i f this diagnosis was used because the engine Checking Fuel Gage
would not start, then diagnose the oil pressure (Two Fuel Tanks)
switch. There should be a different quantity of fuel in the
left and right fuel tanks. Refer to C H A R T A -5A for
Fuel Tank Selector Diagnosis electrical circuit.
(Two Fuel Tanks) 1. Disconnect fuel tank selector v a lv e and m eter
A quick check can be made by listening for the switch connector. (Figure 3-14)
selector v a lv e operation when pressing fuel tank 2. Ignition " O N .
selector switch and the ignition " O N . 3. Jumper terminals " A and " B on the selector
Checking selector valve circuit - C H A R T A-5A: v a lv e connector. Fuel g a g e should in d ic a te
1. Disconnect fuel pump connector (Figure 3 - 13). quantity of the right fuel tank.
2. Disconnect fuel tank selector va lve and meter Jumper term inals " C and " B and the g a g e
switch connector (Figure 3 -14). should indicate quantity o f the left fuel tank.
3. Apply 12 volts to the fuel pump test terminal at If there was no indication in either position,
the fuel pump relay. check for an open circuit from terminal " B to
4. Connect a test light between terminals " E and the fuel gage. M a k e sure t h a t the tw o
" D on the selector va lv e connector and move terminal connector, with one pink wire that is
located near the selector valve (Figure 3 - 15),
selector switch from top to bottom positon. Light
is correctly connected.
should be " O N in both positions.
If there was no indication in one position,
If light is " O F F in both positions, check for check for an open circuit in that position or
open in that circuit or faulty switch. faulty sending unit.
If light is " O F F in one position, check for open If there is a change indicated between tanks,
in that circuit or a faulty switch. the circuit is OK.
n~1 GROUND WIRE LEFT UNIT

m CAM
[T 1 LEFT FUEL PUM P AND SENDING
UN IT
[T 1 "O RING SEAL
[ 7 ] REAR LAMP CONNECTOR PINK WIRE FROM FUEL
m LEFT U N IT CONNECTOR GAGE TO FUEL TANK SELECTOR VALVE AND
IT l RIGHT U N IT CONNECTOR METER SWITCH
[T l G ROUND WIRE RIGHT UNIT m LEFT FUEL PUM P AND SENDING U N IT CONNECTOR
HT! RIGHT FUEL PUM P AND [~3~1 LEFT FUEL PUM P AND SENDING U N IT CONNECTOR
SENDING UN IT [Tl LEFT G RO UND WIRE
|~ 9 l RIGHT FUEL TANK [Tl RIGHT FUEL PUM P A ND SENDING UNIT
fio l FUEL TANK SELECTOR VALVE CONNECTOR
AND METER SWITCH
f i n RIGHT GROUND WIRE
fTTl SELECTOR VALVE AND
METER SW ITCH CONNECTOR [Tl RIGHT FUEL PUM P AND SENDING UNIT
n n LEFT FUEL TANK 8S 4334-6E 8S 4333-6E
Figure 3 - 1 4 Selector Valve and M eter Switch Figure 3 - 1 5 Two Fuel Tank Wiring
Connector
run in the "Open Loop mode. The oxygen sensor
4. Ingition " O F F , connect fuel tank selector valve
v o lta g e output can be m ea su red w ith a d i g i t a l
and meter switch connector.
voltm eter h a vin g at least a 10 m eg ohms input
5. Perform fuel system pressure test ( C H A R T A-6) if
impedance. Use o f a standard shop type voltmeter will
engine would not run in one or either selector
result in an inaccurate reading.
switch positions.
Normal "Scan voltage varies between 100 mV to
999 mV (.1 and 1.0 volt) while in "Closed Loop . Code
COOLANTTEMPERATURE SENSOR 13 sets in one minute if voltage remains between .35
and .55 volts, but the system will go "Open Loop in
Code 14 or Code 15 indicates a failure in the
about 15 seconds.
coolant temperature sensor circuit.
Using the "Scan , observe the block learn values
Most "Scan tools display engine temperature in
at different rpm and air flow conditions. The "Scan
degrees centigrade. A ft e r engine is sta rted , the
also displays the block cells, so the block learn values
temperature should rise steadily to about 90C then
can be checked in each o f the cells to determine when
stabilize when thermostat opens.
Code 44 or Code 45 may have been set. If the condition
for Code 44 exists, the block learn values w ill be
MAP SENSOR around 150. I f the condition for Code 45 exists, the
block learn values will be around 115.
Code 33 or Code 34 indicates a failure in the M A P
sensor circuit. Also refe r to M A P output check
THROTTLE POSITION SENSOR
diagnosis on page 3-73 to check the M A P sensor if
there is no code.
Code 21 indicates that there is a shorted T P S
circuit. Code 22 indicates that there is an open in the
OXYGEN SENSOR T P S circuit. When a code is set, the ECM will use an
artificial value for throttle position and some engine
Code 13 indicates an open in the oxygen sensor
performance will return.
circuit. Code 44 indicates a shorted oxygen sensor
A broken T P S can cause interm ittent bursts o f
circuit. Code 45 indicates a high voltage in the oxygen
fuel from the injector(s) and an unstable idle because
sensor circuit. If a code is set, the engine will always
the ECM thinks the throttle is moving.
A "Scan tool reads throttle position in volts. 1. Connect digital voltmeter J34029-A or equivalent,
Should read about .753 volts (2.5L), .45 volts (2.8L), from T P S connector terminal " B (dark blue wire)
.60 volts (4.3L & V8) .75 volts with throttle closed to t e r m in a l " C (b la ck w i r e ) . J u m p e r s fo r
and ignition " O N or at idle. Voltage should increase term inal access can be made using t e r m in a ls
at a steady rate as throttle is moved toward WOT. "1214836 and "12014837 . A "Scan tool can be
"Scan TPS while depressing accelerator pedal used to read the T P S output voltage.
with engine stopped and ignition " O N . D isplay 2. W ith ignition " O N , engine stopped, the T P S
should vary from below 2.5 volts (2500 m V) when voltage should be less than 1.25 volts.If more than
throttle was closed, to over 4.5 volts (4500 mV) when 1.25 volts, replace TPS.
throttle is held at wide open throttle position. 3. Remove the voltm eter and jumpers, reconnect the
T P S connector to the sensor.
TPS Output
VEHICLE SPEED SENSOR
TBI 220 ( 4.3Land V8 Engine)
The vehicle speed sensor circuit diagnosis is in
This check should be performed only when throttle Code 24 chart.
body or TP S has been replaced or, after the minimum " S c a n r e a d i n g sh ou ld c l o s e l y m atch w it h
air flow has been adjusted. speedometer reading, with drive wheels turning.
1. C o n n e c t d i g i t a l v o l t m e t e r J - 3 4 0 2 9 - A , or
equivalent, from T P S connector te r m in a l " B MAT SENSOR
(dark blue w ire) to term in al " A (black wire).
Jumpers for terminal access can be made using Code 23 indicates that there is an open in the M A T
terminals "1214836 and "12014837 . A "Scan circuit. Code 25 indicates that there is a short to
tool can be used to read T P S output voltage. ground in the M A T circuit.
2. W ith ig nition " O N , and engine stopped, T P S A " S c a n tool reads t e m p e r a t u r e o f the a ir
voltage should be less than 1.0 volt. I f more than entering the engine and should read close to ambient
1.0 volt, check m in im u m id le speed b e fo r e air temperature when engine is cold, and rises as
replacing TPS. underhood temperature increases.
3. Remove voltmeter and jumpers and reconnect T P S
connector to sensor. EGR SYSTEM
TBI 220 (2.8L Engine) Code 32 indicates that there is a failu re in the
EGR system circuit.
This check should be performed only when throttle
body parts have been replaced or after the minimum IDLE SPEED
air flow has been adjusted.
1. Connect digital voltm eter J-34029-A or equivalent Code 35 sets when there is a problem with idle air
from T P S connector terminal " B (dark blue wire) control on a 2.5L engine. Refer to diagnosis in Section
to t e r m in a l " A (b la ck w ir e ). J u m p e r s for "4 for idle air control check for other engines.
term inal access can be made using te r m in a ls System too lean. ( High air/fuel ratio)
"1214836 and "12014837 . A "Scan tool can be Idle speed may be too high or too low. En gin e
used to read T P S output voltage. speed may vary up and down, disconnecting IA C
2. With ignition " O N , engine stopped, T P S voltage does not help. May set Code 44.
should be between .42 and .54 volts. "S ca n and/or vo ltm eter w ill read an o x y g e n
3. I f voltage is out o f range, rotate T P S until 0.48 sensor output less than 300 mV (.3 volts). Check
.06 volts are obtained. for low regulated fuel pressure or water in fuel. A
4. If above voltage limitation cannot be obtained, lean exhaust with an oxygen sensor output fixed
replace TPS. above 800 mV (.8 volts) will be a contaminated
5. Remove voltmeter and jumpers, reconnect T P S sensor, usually silicone. This may also set a Code
connector to sensor. 45.
System too rich ( Low air/fuel ratio)
T B I700 Idle speed too low. "Scan counts usually above
80. System obviously rich and may exhibit black
This check should be performed only when throttle smoke exhaust.
body parts have been replaced or after the minimum "Scan tool and/or voltmeter will read an oxygen
air flow has been adjusted. sensor signal fixed above 800 mV (.8 volts).
ELECTRONIC SPARK TIMING PARK/NEUTRAL SWITCH
When the system is ru n ning on the ig n ition Diagnosis of the park/neutral switch is on page 3-
module, that is, no voltage on the bypass line, the 75 of this section.
ignition module grounds the EST signal. The ECM
expects to see no voltage on the EST line during this CRANK SIGNAL
condition. I f it sees a voltage, it sets Code 42 and will
not go into the EST mode. The crank signal diagnosis procedure is on page 3-
When the rpm for EST is reached (about 400 rpm), 77 o f this section. I f there is no crank signal to the
and bypass voltage applied, the EST should no longer ECM, the engine may be hard to start.
be grounded in the ignition module so the EST voltage
should be varying. POWER STEERING PRESSURE SWITCH
If the bypass line is open or grounded, the ignition
module w ill not switch to EST mode so the E S T The diagnosis o f the power s tee rin g pressu re
voltage will be low and Code 42 will be set. switch is covered on page 3-79 o f this section.
If the EST line is grounded, the ignition module
will switch to EST, but because the line is grounded DISTRIBUTOR REFERENCE SIGNAL
there will be no EST signal. A Code 42 will be set.
Code 42 sets i f there is an open or a short to ground The distributor reference signal is covered in
in the EST or bypass circuit. Section "6 of the ignition system and electronic spark
control.
ELECTRONIC SPARK CONTROL
A/C CLUTCH CONTROL
Code 43 sets i f there is an open or short to ground
in the ESC circuit. The diagnosis of the A/C clutch control on a 2.5L
If the conditions for a Code 43 are present, the engine is covered on page 3-81 of this section and on
"Scan will always display "yes . There should not be 2.8L engine on page 3-85.
a knock at idle unless an internal engine problem, or a
system problem exists. A/C "ON" SIGNAL
SYSTEM OVER VOLTAGE The diagnosis o f the A/C " O N sig n a l on all
engines other than 2.5L is covered on page 3-86 o f this
Code 53 sets on a 2.5L engine if there is voltage section.
g rea ter than 17.1 volts for two seconds at E C M
terminal " B l . This indicates that there is a basic EXHAUST SYSTEM
generator problem.
Refer to Figure 3-17 for diagnosis o f a restricted
exhaust system.
CODE IDENTIFICATION
The Service Engine Soon light will only be " O N i f the malfunction exists under the conditions listed
below. I f the malfunction clears, the light will go out and the code w ill be stored in the ECM. A n y codes
stored will be erased i f no problem reoccurs within 50 engine starts.
CODE AND CIRCUIT PROBABLE CAUSE CODE AND CIRCUIT PROBABLE CAUSE
Code 1 3 -0 2 Sensor Indicates that the Code 33 - M A P Sensor M A P 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 3 4 - M A P Sensor Low or no output from
High Temperature signal line becomes High Vacuum sensor with engine
Indication grounded for 3 seconds. running.
Code 15 - Coolant Sensor Sets if the sensor, Code 35 - IAC IAC error
Low Temperature connections, or wires
Indication open for 3 seconds. Code 42 - EST ECM has seen an open
or grounded EST or
Bypass circuit.
Code 2 1 - T P S T P S 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
1200 RPM. long or the system has
failed a functional
Code 22 - TP S A shorted to ground or check.
Signal Voltage Low open signal circuit will
set code in 3 seconds. Code 44 Sets if oxygen sensor
Lean Exhaust Indication voltage remains below
Code 23 - M A T Sets if the sensor, .2 volts for about 20
Low Temperature connections, or wires seconds.
Indication open for 3 seconds. _ ,
Code 45 Sets if oxygen sensor
Code 24 - VSS No vehicle speed present Rich Exhaust Indication voltage remains above
No Vehicle Speed during a road load decel. .7 volts for about 1
Indication minute.
Code 25 - M A T Sets if the sensor or Code 51 Paul tv M E M -C A L ,

High Temperature PROM, or ECM.
signal line becomes
Indication grounded for 3 seconds.
Code 52 Fuel C A L P A K
missing or faulty.
Code 53 System overvoltage.

Indicates a basic
generator problem.
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
than 2 volts when
Switch not closed after
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
6-25-87
period of time. 7S 3337-6E
Figure 3 - 1 6 - ECM Code System

CHART A-1
NO SERVICE ENGINE SOON" LIGHT
ALL ENGINES
Circuit Description:
There should always be a steady "Service Engine Soon light when the ignition is " O N and engine stopped.
Battery ignition voltage is supplied to the light bulb. The ECM will control the light and turn it " O N by
providing a ground path through C K T 419.
Test Description: Numbers below refer to circled Diagnostic Aids:

numbers on the diagnostic chart.
1. If the fuse in holder is blown, refer to facing page If the engine runs O K , check:
of Code 54 for complete circuit. Faulty light bulb.
2. Using a test light connected to 12 volts, probe each C K T 419 open.
o f the system ground circuits to be sure a good Gage fuse blown. This will result in no stop
ground is present. See ECM terminal end view in ligh ts, o il or g e n e r a t o r l i g h t s , s e a t b e lt
front o f this section for E C M pin locations o f 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 C K T 340 to ECM open.
Ignition C K T 439 to ECM open.
Poor connection to ECM.
CHART A-1
NO "SERVICE ENGINE SOON"LIGHT
ALL ENGINES
7S 3687
CLEAR CODES A ND CONFIRM "CLOSED LOOP " OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. ,
CHART A-2
NO ALDL DATA OR WON'T FLASH CODE 12
"SERVICE ENGINE SOON" LIGHT ON STEADY
ALL ENGINES
There should always be a steady "Service Engine Soon light when the ignition is " O N and engine stopped.
Battery ignition voltage is supplied to the light bulb. The ECM will turn the light on by grounding C K T 419.
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 C K T 419, or an open in diagnostic C K T 451.
Test Description: Numbers below refer to circled 4. A t this point the " S ervic e Engine Soon lig h t
numbers on the diagnostic chart. wiring is OK. The problem is a faulty ECM or
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 E C M should be rep la c ed u s in g the o r i g i n a l
should not flash a Code 12. I f Code 12 does flash, PROM/Mem-Cal. Replace the PR OM /M em -C al
be sure that the "Scan tool is working properly on o n ly a f t e r t r y i n g an E C M , as a d e f e c t i v e
another vehicle. I f the "Sca n is fu n c tion in g P R O M / M e m -C a l is an u n li k e ly cause o f the
properly and C K T 461 is OK, the PROM/Mem-Cal problem.
or E C M m ay be at fa u lt for the N O A L D L
symptom.
2. If the light goes " O F F when the ECM connector is
disconnected, then C K T 419 is not shorted to
ground.
3. This step will check for an open diagnostic C K T
451.
3-20 COMPUTER COMMAND CONTROL (WITH "SCAN)
ECM
439 PNK/BLK TO ECM
12V 439 PNK/BLK 439 RED 467 LT BLU

TBI UNIT
AB INJECTOR
lip
A*
7S 3774-6E
6-25-87 7-23-86
CHART A-3
ENGINE CRANKS BUT WILL NOT RUN
2.5L ENGINE
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.
Test Description: Numbers below refer to circled 4. Use an injector test light like J34730, BT8329A or
numbers on the diagnostic chart. equivalent, to test injector circuit. A b lin k in g
1. A "Service Engine Soon light " O N is a basic test light indicates the ECM is controlling the injector.
to determ ine i f there is a 12 volt supply and 5. This test will determine if there is fuel pressure at
ignition 12 volts to ECM. No A L D L may be due to the injector and that the injector is operating.
an ECM problem and C H A R T A-2 will diagnose
the ECM. I f TP S is over 2.5 volts the engine may Diagnostic Aids:
be in the clear flood mode which w ill cause
starting problems. If coolant sensor is below -30C, I f no trouble is found in the fuel pump circuit or
the ECM will provide fuel for this extremely cold ignition system and the cause of a "Engine Cranks
temperature which will severely flood the engine. But W ill Not Run has not been found, 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 C H A R T A-6.
3. W hile cranking engine there should be no fuel W ater or foreign material in the fuel system.
spray with injector disconnected. Replace an A ground C K T 423 (EST) may cause a " N o
injector if it sprays fuel or drips like a leaking Start or a "Start then Stall condition.
water faucet. Basic engine problem.
COMPUTER COMMAND CONTROL (WITH "SCAN) 3-21
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 21. 2.5L ENGINE
COOLANT - IF BELOW -30C. SEE CODE 15.
IGN. "OFF" FOR 10 SECONDS. IGN "O N ". LISTEN FOR
PUMP TO RUN. DOES IT?
YES NO
DISCONNECT ONE SPARK PLUG WIRE. [ SEE FUEL PUMP RELAY j

INSTALL A SPARK TESTER (ST-125 OR CIRCUIT CHART A-5 i
EQUIVALENT). i--------------------------- 1
CRANK ENGINE AND CHECK FOR
SPARK.
IS THERE SPARK?
YES NO
RECONNECT SPARK PLUG WIRE. iT --------------------- 1

DISCONNECT INJECTOR CONNECTOR. I SEE IGNITION SYSTEM j
CRANK ENGINE. i CHECK IN SECTION 6 '

i--------------------------- 1
IS THERE FUEL SPRAY FROM INJECTOR?
NO YES
n =
CONNECT INJECTOR TEST LIGHT
TO HARNESS CONNECTOR.
FAULTY INJECTOR
SEAL OR INJECTOR
CRANK ENGINE.
DOES TEST LIGHT BLINK?
X
YES NO
X it :------------------------ 1
RECONNECT INJECTOR CONNECTOR. | SEE INJECTOR CIRCUIT |
CRANK ENGINE. i DIAGNOSIS CHART A-4 i
IS THERE FUEL SPRAY FROM INJECTOR? i_______________________i
YES NO
nz
NO TROUBLE FOUND. IGN "OFF.
INSTALL FUEL PRESSURE GAGE. REFER TO FUEL SYSTEM
SEE DIAGNOSTIC AIDS
PRESSURE TEST IN SECTION 4.
ON FACING PAGE. IGN "O N ".
FUEL PRESSURE SHOULD BE 62-90 KPa (9-13 psi)
IS IT?
|
I 1
YES NO
- i
FAULTY INJECTOR SEE FUEL SYSTEM i
t DIAGNOSIS CHART A-6 i
i_______________________ i
7S3775
4-27-87
ECM
IGN 10A
ECM
468 LT GRN D14
482 WHT 481 RED 467 LT BLU
TB I220 UNIT
INJECTORS
481 RED
INJ. A 4.3L & V-8 (C. Kf G & M SERIES)

12V 7 S 3777
IGN 10A (7.5 A M -V A N ) 7-07-87
7-30-87
CHART A-3
ENGINE CRANKS BUT WILL NOT RUN
ALL ENGINES EXCEPT 2.5L
This chart assumes that battery condition and engine cranking speed are O K, and there is adequate fuel in
the tank. This chart should be used on engines using the Model 220 throttle body.
Test Description: Numbers below refer to circled 4. Use an in je ctor t e s t l i g h t li k e B T 8 3 2 0 , or

numbers on the diagnostic chart. e q u iv a le n t , to test each in je cto r c ir c u it . A
1. A "Service Engine Soon light " O N is a basic test blinking light indicates the E C M is c o n trollin g
to determ in e i f there is a 12 volt supply and the injectors.
ignition 12 volts to ECM. No A L D L may be due to 5. This test will determine if there is fuel pressure at
an ECM problem and C H A R T A-2 will diagnose the injectors and that the injectors are operating.
the ECM. I f T P S is over 2.5 volts the engine may
be in the clear flood mode which w ill cause Diagnostic Aids:
starting problems. If coolant sensor is below -30C,
the ECM will provide fuel for this extremely cold If no trouble is found in the fuel pump circuit or
temperature which will severely flood the engine. ignition system and the cause of a "E ngine C ranks
2 . Voltage at the spark plug is checked using Spark But W ill Not Run has not been found, check for:
Tester tool ST125 (J26792) or equivalent. No Fouled spark plugs
spark indicates a basic ignition problem. EGR valve stuck open
3. While cranking engine there should be no fuel Low fuel pressure. See C H A R T A-6.
spray with injectors disconnected. Replace an W ater or foreign material in the fuel system.
injector if it sprays fuel or drips like a leakin g A grounded C K T 423 (ES T) may cause a " N o
water faucet. Start or a "Start then Stall condition.
Basic engine problem.
IF CODE 54 IS STORED, USE THAT CHART FIRST
0 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 21. ALL ENGINES EXCEPT 2.5L
COOLANT - IF BELOW -30C, SEE CODE 15.
IGN. "OFF" FOR 10 SECONDS. IGN. "O N ".
ONEFUELTANK:
LISTEN FOR PUMP TO RUN. DOES IT?
TWO FUEL TANKS:
LISTEN FOR PUMP IN EACH TANK USING SELECTOR
SWITCH. BOTH PUMPS MUST RUN.
DO THEY BOTH RUN?
YES NO
rrr
DISCONNECT ONE SPARK PLUG WIRE. { SEE FUEL PUMP RELAY CIRCUIT
INSTALL A SPARK TESTER (ST 125 OR i CHART A-5 OR A-5A
EQUIVALENT)
CRANK ENGINE AND CHECK FOR
SPARK.
IS THERE SPARK?
YES NO
JLZ T
i

RECONNECT SPARK PLUG WIRE.
DISCONNECT INJECTOR CONNECTORS.
| SEE IGNITION SYSTEM |
i CHECK IN SECTION 6 i
CRANK ENGINE. i_____________________ i
IS THERE FUEL SPRAY FROM ONE OR BOTH INJECTORS?
NO YES
xz = c
CO JNECT INJECTOR TEST LIGHT TO ONE HARNESS CONNECTOR.
CRANK ENGINE.
FAULTY INJECTOR
SEAL OR INJECTOR
REPEAT TEST ON OTHER CONNECTOR
DOES TEST LIGHT BLINK ON BOTH TESTS?
1
NO
X
RECONNECT INJECTOR CONNECTORS. I SEE INJECTOR CIRCUIT j
CRANK ENGINE. I DIAGNOSIS CHART A-4 i
IS THERE FUEL SPRAY FROM INJECTORS? i_______________________ i
ONE ONLY NO
NO TROUBLE FOUND. FAULTY INJECTOR IGN "OFF:.

INSTALL FUEL PRESSURE GAGE, REFER TO FUEL SYSTEM
SEE DIAGNOSTIC AIDS
PRESSURE TEST IN SECTION 4.
ON FACING PAGE.
IGN "O N ".
FUEL PRESSURE SHOULD BE 62-90 KPa (9-13 psi)
IS IT?
I k
YES NO
FAULTY INJECTORS | SEE FUEL SYSTEM

i DIAGNOSIS CHART A-6 i
i_______________________ i
7S 3 7 7 8
4-27-87
ECM
467 BLU ~ j P 16
INJECTOR
PICK-UP COIL HALL

[ 0 ) EFFECT
SWITCH
423 W HT D4 EST
TO ECM
430 PPL/WHT B5 REFERENCE
DIST. HEI
10A
MODULE
< [ ECM 1 424 TAN/BLK D5 BYPASS
IGNITION FUSE PRIM. IGN. COIL
SWITCH 23rrmn 453 BLK/RED B3 GROUND

<- EST CONNECTOR
S-T SERIES
439 PNK/BLK
DIST. HEI / -----------

MODULE \ * C __________ G B R E | JL 423 W HT D4 EST

m j IIJ
424 TAN/BLK D5 BYPASS
439 PNK/BLK
453 BLK/RED B3 GROUND
W
TO IGNITION
COIL
M SERIES
5-1-87
7-20-87 *8S 4381-6E
CHART A-4
INJECTOR CIRCUIT DIAGNOSIS
2.5L ENGINE
This chart should only be used if diagnosis in C H A R T A-3 indicated an injector circuit problem.
Test Description: Numbers below refer to circled 2. This step tests for 12 volts to the injector. It will
numbers on the diagnostic chart. also determine i f there is a short to voltage on the
1. This test will determine if the ignition module is ECM side o f the circuit.
generating a reference pulse, if the wiring is at 3. This test checks for continuity to the ECM.
fault or i f the ECM is at fault. By touching and
removing a test light, connected to 12 volts, to
C K T 430, a reference pulse should be generated.
If injector test light blinks, the ECM and wiring
are OK.
CHART A-4
FROM 2.5L ENGINE
CHART A-3
INJECTOR TEST
LIGHT DOES
NOT BLINK
CLEAR CODES AND CONFIRM "CLOSED LOOP " OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 4-28-87
7S 3930-6E
ECM
468 LTGRN D14
482 WHT 481 RED 467 LT BLU D16

n TBI 220 UNIT
AB
INJECTORS
INJ A
OR
ECM 1
12V 439 PNK/BLK TO ECM IF USING
IGN 10A ECM 1 FUSE
PI
O
+c GBRE 423 W HT D4 EST

JU
424 TAN/BLK D5 BYPASS
453 BLK/RED B3 GROUND

W
TO IGNITION 5-1-87
COIL
e8S 4382-6E
CHART A-4
This chart should ony be used if diagnosis in C H A R T A-3 indicated an injector circuit problem, I f both
injector circuits fail to blink when tested, diagnose one injector circuit at a time.
Test Description: Numbers below refer to circled 2. This step tests for 12 volts to the injector. It will
numbers on the diagnostic chart. also determine i f there is a short to voltage on the
1. This test will determine if the ignition module is ECM side o f the circuit.
generting a reference pulse, i f the w irin g is at 3. This test checks for continuity to the ECM.
fault or if the ECM is at fault. By touching and
removing a test light, connected to 12 volts, to
C K T 430, a refernce pulse should be generated. If
injector test light blinks, the ECM and wiring are
OK.
CHART A-4
FROM ALL ENGINES EXCEPT 2.5L
CHART A-3
INJECTOR TEST
LIGHT DOES
NOT BLINK
4-28-87
CLEAR CODES AND CONFIRM "CLOSED LOOP " OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
7S 3931-6E
RELAY
HARNESS
CONNECTOR
ECM B
, 07-07-87
7-30-87 dr 7S3802-6E
CHART A-5
FUEL PUMP RELAY CIRCUIT DIAGNOSIS
S , T &M SERIES
When the ignition switch is turned " O N , the ECM will turn " O N the in-tank fuel pump. It will remain
" O N 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 " O F F the fuel pump within 2 seconds after ignition " O N or
engine stops.
The pump will deliver fuel to the T B I 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.
Test Description: Numbers below refer to circled 3. Determines i f ECM can control the relay.
numbers on the diagnostic chart. 4. The oil pressure switch serves as a backup for the
1. Turns " O N the fuel pump if C K T 120 wiring is fuel pump r e la y to help p r e v e n t a no s t a r t
OK. I f the pump runs, it maybe a fuel pump relay situation. If the fuel pump relay was found to be
circuit problem, which the fo llow in g steps w ill 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.
ECM
GM D
FUEL PUMP
RELAY CONN.
FUSE LINK (CK)

BATT
12V -cm
OR ECM B
440 ORN ------
FUSE (RVGP) FUEL PUMP

RELAY
12 VOLT
< 465 DK GRN/WHT A1 RELAY
DRIVE
450 _
BLK/WHT
OIL
PRESS.
SWITCH
120
N E TAN/WHT B2 FUEL PUMP
SIGNAL
120 TAN/WHT
OR 920 PNK/BLK(CK)
FUEL PUMP 490 RED
TEST TERM. FUEL PUMP
ORALDL (CKG) 20A (CK)
FUEL PUMP
(IN TANK)
A C ^ .
BULKHEAD 150
B 10A
FUEL CONNECTOR
C PNK/BLK 39 IGN 12V x ON A LL7.4L.G V A N WITH
MODULE
_ ECM/IGN 5.7L, AND ALL OTHER 5.7L OVER
D BLK/WHT 450
E 1 8500 GVW ENGINES. 7-9-87
7-20-87 7S3804-6E
CHART A-5
FUEL PUMP RELAY CIRCUIT DIAGNOSIS
(ONE FUEL TANK)
C#K, R, V, G &P SERIES
When the ignition switch is turned "O N , the Electronic Control Module (E C M ) w ill turn " O N the in-tank
fuel pump. It w ill remain "O N as long as the engine is cranking or running, and the ECM is rec eivin g
distributor reference pulses. If there are no reference pulses, the ECM w ill shut "O F F the fuel pump within 2
seconds after ignition " O N or engine stops except when a fuel module is used.
The pump will deliver fuel to the TB I 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, G van with 5.7L, and all other 5.7L over 8500 G V W engines to correct a
hot restart (vapor lock) during a high ambient condition. It is designed to over-ride the ECM two second pump
operation and w ill run the fuel pump for twenty seconds at initial ignition "O N .
1. This procedure applies direct voltage to run the An inoperative fuel module may be the cause o f a
fuel pump. If the pump runs, it may be a fuel hot stall/no start condition. Check for power and
pump relay circuit problem which the fo llo w in g ground circuit to the fuel module and a complete
step w ill locate. circuit to the pump from term inal " A . If O K , and
2. This step checks voltage from the battery and the the pump does not run for the specified 20 seconds
ground circuit to the relay. at in itial ignition "O N , replace the Fuel Module.
3. This test determines if there is voltage from the
ECM, term inal A l , to term inal "D on the relay
connector.
4. This completes the fuel pump relay circuit but if
this diagnosis was used because the engine would
not run then oil pressure switch should also be
diagnosed.
FROM CHART A-3

FUEL PUMP DOES NOT RUN CHART A-5
.......I ..............................

APPLY FUSED 12V TO FUEL PUMP TEST TERMINAL
LISTEN FOR IN TANK FUEL PUMP. DOES IT RUN?
FUEL PUMP RELAY CIRCUIT
DIAGNOSIS (ONE FUEL TANK)
C, K, R, V . G & P SERIES
NO
m
REMOVE 12V FROM TESTTERMINAL
OPEN IN CKT 120/920, RELAY OR
IGNITION "OFF" FOR TEN SECONDS.
CKT 150 TO THE FUEL PUMP OR
DISCONNECT FUEL MODULE*
FAULY PUMP.
IGNITION "O N ". LISTEN FOR IN TANK FUEL
PUMP. PUMP SHOULD RUN FOR 2 SECONDS
AFTER IGNITION ON. DOES IT?
NO YES
zr rr~
DISCONNECT PUMP RELAY. IF NO FUEL MODULE, NO TROUBLE FOUND. IN RELAY
IGNITION "O N" ENGINE STOPPED. CIRCUIT WITH FUEL MODULE:
PROBE RELAY HARNESS-CONNECTOR TERMINAL IGNITION "OFF", CONNECT MODULE & W A IT TEN
CKT 440 WITH A TEST LIGHT TO GROUND. SECONDS..
IGNITION "O N ", FUEL PUMP SHOULD RUN FOR
ABOUT TWENTY SECONDS..
DOES IT?
LIGHT" ON" LIGHT" OFF'
CONNECT A TEST LIGHT BETWEEN REPAIR OPEN

HARNESS CONNECTOR TERMINAL CKT 440. NO YES
CKTS450 AND 440. JlZ
1 REFER TO FUEL NO TROUBLE FOUND
1 MODULE CHECK
PROCEDURE.
1 LIGHT" ON" LIGHT" OFF"
. i 1
CONNECT TEST LIGHT BETWEEN REPAIR OPEN
TERMINAL CKT 465 AND GND. GROUND FUEL M ODULE IS ON
IGNITION "OFF" FOR 10 CKT 450. ALL7.4L, G VAN WITH
SECONDS. 5.7L AND ALL OTHER
IGNITION "O N". TEST LIGHT 5.7L OVER 8500 GVW
SHOULD LIGHT FOR 2 ENGINES.
SECONDS. DOES IT?
YES NO
z c zn
FAULTY CONNECTION AT RELAY TERMINAL "D " OR OPEN OR SHORT TO
FAULTY RELAY. CONNECT FUEL MODULE IF GROUND IN CKT 465
REMOVED. OR FAULTY ECM.
IF ORIGINAL SYMPTOM WAS "ENGINE CRANKS BUT
WILL NOT RUN", CONTINUE.
ENGINE AT NORMAL OPERATING TEMPERATURE.
OIL PRESSURE NORMAL.
DISCONNECT FUEL PUMP RELAY. ENGINE SHOULD
CONTINUE TO RUN. DOES IT?
YES NO
HE X
RECONNECT FUEL PUMP OPEN IN CKT 440 OR 120/920 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
----- 1 zzzr
NO TROUBLE FOUND FAULTY OIL
PRESSURE SWITCH
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S3805
5-28-87
3-32 COMPUTER COMMAND CONTROL (WITH "SCAN)
ECM
r t t
BATT r \1 0 A
QM D FUEL PUMP
RELAY CONN.
12V Y * ----- 440 ORN

ECM B FUSE
FUEL PUMP
RELAY 12 VOLT
465 DK GRN/WHT A1 h-RELAY
DRIVE
OIL
PRESSURE
SWITCH
120 B2
C TAN/WHT
FUEL PUMP
SIGNAL
FUEL PUMP TEST
y 490 RED
TERMINAL
120 TAN/WHT
LEFT
i
Y *[ Right LEFT < - RIGHT
' ----- 921 GRY
7
LEFT
920 TAN ^
i
i
L____________
PM VALVE
LEFT
120 ----- SSI
TAN/W HT //
A ,V RIGHT
RIG HT
FUEL TANK SELECTOR SWITCH
FUEL TANK SELECTOR 150
VALVE & METER SWITCH BLK
BUS
BAR
LEFT FUEL PUMP

A
920 TAN
B
FUEL
C - PNK/BLK 39
MODULE
D - BLK/WHT 450
E 1 SENDING UNIT :r
LEFT TANK
5.7L
(OVER 8500 GVW)
AND ALL 7.4L
ENGINES
FUEL
A (NOT USED) GAGE
30 PNK
20A
IGN
-* X r 39 PNK/BLK
12V
GAGE
FUSE RIGHT FUEL PUMP
921 GRA - C 0 Z } -
931 PNK/BLK
SENDING UNIT 8S 3998-6E

RIGHT TANK 6-19-87
CHART A-5A, Fuel Pump Relay Circuit Diagnosis - (Two Fuel Tanks) - RV Series
TBI
INJECTOR
THROTTLE BODY MODEL 700 TBI
PRESSURE REGULATOR
FUEL RETURN LINE
IN-LINE
FUEL FILTER
f
FLEX HOSE FUEL PRESSURE LINE IN-TANK PUMP
FUEL PRESSURE
GAGE TEST
FUEL ,
TANK | PUMP INLET FILTER
TBI UNIT THROTTLE BODY MODEL 220 TBI

INJECTORS PRESSURE REGULATOR
FUEL RETURN LINE
7 ~
FLEX HOSE FUEL PRESSURE LINE FUEL CAP
IN-LINE FUEL FILTER

FUEL PRESSURE ^ 7S3806-6E
7-20-87 GAGE TEST POINT FUEL TANK I PUMP INLET FILTER ------- ^
7-29-86
CHART A-6
FUEL SYSTEM PRESSURE TEST
ALL ENGINES
W hen 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: Numbers below refer to circled pump test connector, pressure should be from 90 to
numbers on the diagnostic chart. 124 kPa (13 to 18 psi).
1. Pressure but less than 62 kPa (9 psi) falls into two 3. This test determ ines if the high fuel pressure is
areas: due to a restricted fuel return line or a throttle
Regulated pressure but less than 62 kPa (9 psi) - body pressure regulator problem.
Amount o f fuel to injector O K but pressure is too
low. System w ill be lean running and may set Diagnostic Aids:
Code 44. Also, hard starting cold and poor overall
performance. I f the vehicle is equipped with a fuel module, the
Restricted flow causing pressure drop - N orm ally, module must be disconnected before p erform in g
a vehicle with a fuel pressure o f less than 62 kPa the fuel system pressure test. Refer to Section "4 .
(9 psi) at idle w ill not be driveable. However, if Fuel system is under pressure. T o avoid fuel
the pressure drop occurs only w hile driving, the spillage, refer to procedures in Section " 4 for
engine w ill norm ally surge then stop as pressure testing or m aking repairs requiring disassembly
begins to drop rapidly. o f fuel lines or fittings.
2. Restricting the fuel return line a llow s the fuel On V6 or V8 engine, the fuel pressure drops to
pump to develop its maximum pressure (dead head almost zero psi after pump shuts " o f f .
pressure). When battery voltage is applied to the
ECM
- 0 2 SENSOR
D7
SIGNAL
D6 I 0 2 GROUND
~ CIRCUIT
2-20-87
7-30-87 4S 0790-6E
CODE 13
OXYGEN SENSOR OPEN CIRCUIT
ALL ENGINES
The ECM supplies a voltage o f about .45 volt between term inals "D 7 and "D 6 .(If measured with a 10
megohm digital voltm eter, this may read as low as .32 volts.) The O xygen sensor varies the voltage within a
range o f 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 (600F). An open sensor
circuit or cold sensor causes "Open Loop operation.
Test Description: Num bers below refer to circled Diagnostic Aids:

N orm al "Scan voltage varies between 100 mv to
1. Code 13 w ill set if:
999 mv (.1 and 1.0 volt) w hile in closed loop. Code 13
Engine at normal operating temperature
sets in one minute if voltage rem ains between .35 and
A t least 2 minutes engine time after start.
.55 volts, but the system w ill go "Open Loop in about
Oxygen sensor signal voltage steady between
15 seconds. Refer to "E C M In te rm itte n t Codes or
.35 and .55 volts .
Perform ance in Section "2 .
Throttle position sensor signal above 4%.
A ll co n dition s m ust be m et for about 60
seconds.
I f the conditions for a Code 13 e x is t, the
system w ill not go "Closed Loop .
2. This w ill determ ine if the sensor is at fault or the
w irin g or ECM is the cause o f Code 13.
3 In doing this test, use only a high impedence digital
volt ohm meter. This test checks the continuity o f
C K T s 412 and 413 because i f C K T 413 is open the
ECM voltage on C K T 412 w ill be over .6 volts
(600 mv).
CODE 13
OXYGEN SENSOR OPEN CIRCUIT
ALL ENGINES
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
COOLANT TEMPERATURE
SENSOR
ECM
COOLANT SENSOR
SIGNAL
5V
410 YEL --------- 1[ u o j
2 .5 L .4 .3 L M & G VAN 452 BLK I*" I

| SENSOR
ALL EXCEPT ABOVE - 452 BLK Lid

|
GROUND
/S 3690
6-18-87
7-20-87
CODE 14
COOLANT TEMPERATURE SENSOR CIRCUIT
(HIGH TEMPERATURE INDICATED)
ALL ENGINES
The coolant tem perature sensor is a therm istor that controls the signal voltage to the ECM. The ECM
applies a voltage on C K T 410 to the sensor. When the engine is cold, the sensor (therm istor) resistance is high,
therefore the ECM w ill see high signal voltage.
As the engine warms, the sensor resistance becomes less and the voltage drops. A t normal engine operating
tem perature (85C to 95C), the voltage w ill measure about 1.5 to 2.0 volts.

1. Code 14 w ill set if: Check harness rou ting for a potential short to
S ig n a l v o l t a g e i n d i c a t e s a c o o la n t ground in C K T 410.
te m p e ra tu r e a b o v e 130C (2 6 6 F ) fo r 3 "S can tool displays en gin e tem p, in d e g re e s
seconds. centigrade. A fter engine is started, the tem perature
2. This test w ill determ ine if C K T 410 is shorted to should rise steadily to about 90C then stabilize when
ground which w ill cause the conditions for Code thermostat opens.
14. See "E C M Interm ittent Codes or Perform ance in
Section "2 .
The "Tem perature to Resistance V alu e scale at
the right may be used to test the coolant sensor at
various tem perature levels to evaluate the possibility
o f a "slew ed (mis-scaled) sensor. A "slew ed sensor
could result in poor d riveability complaints.
CODE 14
COOLANT TEMPERATURE SENSOR
CIRCUIT
ALL ENGINES
DIAGNOSTIC AID
COOLANT SENSOR
TEMPERATURE TO RESISTANCE VALUES
(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
4-28-87
7S 3055-6E
COOLANT TEMPERATURE
SENSOR
ECM
COOLANT SENSOR
SIGNAL
5V
410 YEL
2 .5 L .4 .3 L M & G VAN 452 BLK SENSOR
ALL EXCEPT ABOVE 452 BLK

GROUND
/S 3690
6-18-87
7-20-87
CODE 15
(LOWTEMPERATURE INDICATED)
ALL ENGINES
The coolant tem perature sensor is a therm istor that controls the signal voltage to the ECM. The ECM
applies a voltage on C K T 410 to the sensor. When the engine is cold, the sensor (therm istor) resistance is high,
therefore the ECM w ill see high signal voltage.
As the engine warms, the sensor resistance becomes less and the voltage drops. A t normal engine operating
temperature (85C to 95C), the voltage w ill measure about 1.5 to 2.0 volts.

1. Code 15 w ill set if: A "Scan tool reads engine tem perature in degrees
S ig n a l v o l t a g e i n d ic a t e s a c o o la n t centigrade. A fter engine is started, the tem perature
tem peratu re less than -44C (-47F) for 3 should rise steadily to about 90C then stabilize when
seconds. thermostat opens.
2. Th is test s im u la tes a Code 14. I f the EC M A faulty connection, or an open in C K T 410 or 452
recognizes the low signal voltage, (high temp.) and w ill results in a Code 15.
the "Scan reads 130C or above, the ECM and See "E C M Interm ittent Codes on Perform ance in
w irin g are OK. Section "2 .
3. This test w ill determ ine if C K T 410 is open. There The "Tem peratu re To Resistance V alu e scale at
should be 5 volts present at sensor connector if the right may be used to test the coolant sensor at
measured with a DVOM. various tem perature levels to evaluate the possibility
o f a "slew ed (m is-scaled) sensor. A "slew ed sensor
CODE 15
COOLANT TEMPERATURE
SENSOR CIRCUIT
(LOW TEMPERATURE INDICATED)
ALL ENGINES
DOES "SCAN" DISPLAY COOLANT -30C OR COLDER?
YES NO

DISCONNECT SENSOR
JUMPER HARNESS TERMINALS TOGETHER
CODE 15 IS INTERMITTENT. IF NO
ADDITIONAL CODES WERE STORED, REFER
TO "DIAGNOSTIC AIDS" ON FACING PAGE.
"SCAN" SHOULD DISPLAY 130C OR MORE.
DOES IT?
NO
YES
FAULTY CONNECTION OR SENSOR.

JUMPER CKT410 TO GROUND.
"SCAN" SHOULD DISPLAY OVER 130C.
DOES IT?
NO
I
DIAGNOSTIC AID
OPEN SENSOR GROUND OPEN CKT410, FAULTY
CIRCUIT, FAULTY CONNECTION AT ECM, OR
COOLANT SENSOR
CONNECTION OR FAULTY ECM.
TEMPERATURE TO RESISTANCE VALUES FAULTY ECM.
(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
2-11-87
7S 3261-6E
CODE 21
THROTTLE POSITION SENSOR (TPS) CIRCUIT
(SIGNAL VOLTAGE HIGH)
ALL ENGINES
The Th rottle Position Sensor (T P S ) provides a voltage signal that changes relative to the throttle blade
angle. Signal voltage w ill vary from about .5 volts at idle to about 5 volts at wide open throttle.
The T P S signal is one o f the most important inputs used by the ECM for fuel control and for most of the
ECM control outputs.

1. Code 21, w ill set if: A "S ca n tool reads th rottle position in volts.
Engine running Should read about .73 volts (2.5L), .45 volts (2.8L), .60
T P S 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
A ll conditions met for 5 seconds. steady rate as throttle is moved toward W OT.
OR Also some "Scan tools w ill read throttle an gle.0%
T P S signal voltage over 4.5 volts with ignition = closed throttle 100% = W O T.
"O N . Refer to Section "2 for "E C M Interm ittent Codes
W ith throttle closed, the T P S should read less or Perform ance .
than .70 volts. I f it doesnt, check adjustment. "Scan T P S while depressing accelera tor pedal
2. W ith the T P S sensor d iscon n ected , the T P S w ith en gin e stopped and ig n ition " O N . D isp la y
voltage should go low i f the ECM and w irin g is should vary from below 2.5 volts (2500 m v) when
OK. throttle was closed, to over 4.5 volts (4500 mv) when
3. Probing C K T 452 with a test light checks the 5 throttle is held at wide open throttle position.
volts return C K T , because a faulty 5 volts return
w ill cause a Code 21.
CODE 21
ALL ENGINES
2-24-87
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. -
CODE 22
(SIGNAL VOLTAGE LOW)
ALL ENGINES
The Th rottle Position Sensor (T P S ) provides a voltage signal that changes rela tive to the throttle blade.
Signal voltage w ill vary from about .5 at idle to about 5 volts at wide open throttle.
The T P S signal is one o f the most important inputs used by the ECM for fuel control and for most o f the
ECM control outputs.

1. Code 22, w ill set if: A "S ca n tool reads th ro ttle position in volts.
Engine running Should read about .73 volts (2.5L), .48 volts (2.8L), .60
T P S 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. V oltage should increase at a
2. Simulates Code 21: (high voltage) I f the ECM steady rate as throttle is moved toward W O T.
recognizes the high signal voltage the ECM and An open or short to ground in C K T s 416 or 417
w irin g are O K. w ill result in a Code 22.
3. T P S - 2.8L: R efer to "A d ju s ta b le T P S Output Refer to Section "2 for "E C M Interm ittent Codes
Check in this section. T P S - except 2.8L: Replace or Perform ance .
TPS. "Scan T P S w hile depressin g a cce lera to r pedal
4. This simulates a high signal voltage to check for w ith en gin e stopped and ig n itio n " O N . D is p la y
an open in C K T 417. should vary from below 2.5 vo lts (2500 m v) when
throttle was closed, to over 4.5 volts (4500 m v) when
throttle is held at wide open throttle position.
CODE 22
(TPS) CIRCUIT
ALL ENGINES
6-25-87
CLEAR COOES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7 S 336 S-6 E
MANIFOLD AIR ECM

TEMPERATURE
SENSOR
M AT SENSOR
SIGNAL
472 TAN
-ED-
452 BLK
SENSOR
GROUND
TO TPS AND
COOLANT
TEMPERATURE
SENSOR 7-20-87
7-30-87 7 S 3692
CODE 23
MANIFOLD AIR TEMPERATURE (MAT) SENSOR CIRCUIT
2.5L ENGINE
The Manifold A ir Tem perature (M A T ) Sensor is a therm istor that controls the signal voltage to the ECM.
The ECM applies a voltage (4-6 volts) on C K T 472 to the sensor. When the air is cold, the sensor (therm istor)
resistance is high, therefore the ECM w ill see a high signal voltage. I f the air is warm, the sensor resistance is
low therefore the ECM w ill see a low voltage.

1. Code 23 w ill set if all conditions are met: A "S c a n tool reads te m p e ra tu re o f the a ir
A signal vo lta g e in d icates a m a n ifo ld a ir entering the engine and should read close to am bient
tem p e ra tu re b e lo w -30C (-2 2 F ) fo r 12 air tem perature when engine is cold, and rises as
seconds. underhood tem perature increases.
Tim e since engine start is 1 minute or longer. C a re fu lly check harness and co n n ectio n s for
No VSS (vehicle not m oving) possible open C K T 472 or 452.
2. A Code 23 w ill set, due to an open sensor, wire, or Refer to Section "2 for "E C M Interm ittent Codes
connection. This test w ill determ ine if the w iring or Perform ance.
and ECM are OK. The "Tem perature to Resistance V alu e scale at
3. This w ill determ ine i f the signal C K T 472 or the the rig h t may be used to test the M A T sensor at
5V return C K T 452 is open. various tem perature levels to evaluate the possibility
CODE 23
2.5L ENGINE
DOES "SCAN" TOOL DISPLAY MAT -30C OR COLDER?
YES NO

DISCONNECT SENSOR.
JUMPER HARNESS TERMINALS TOGETHER.
"SCAN" SHOULD DISPLAY TEMPERATURE OVER 130C .
CODE 23 IS INTERMITTENT. IF NO
ADDITIONAL CODES WERE STORED,
REFER TO "DIAGNOSTIC AIDS" ON
DOES IT? FACING PAGE.
YES NO
FAULTY CONNECTION OR SENSOR.

JUMPER CKT472 TO GROUND.
"SCAN" SHOULD DISPLAY TEMP.
OVER 130C.
DOES IT?
YES NO
OPEN SENSOR OPEN CKT472,

GROUND CIRCUIT, FAULTY CONNECTION
FAULTY CONNECTION OR FAULTY ECM.
DIAGNOSTIC AID
OR FAULTY ECM.
MAT SENSOR
(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
2-25-87
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S 3285
ECM
* * VEHICLE SPEED SIGNAL <~ 437 BRN A10 -AAAr ~ 12V
P/N SWITCH
450 BLK/WHT ----- 434 ORN/BLK B10 A A /V - 12V

E CLOSED IN
PARK OR NEUTRAL
7S3693
7-9-86
CODE 24
VSS CIRCUIT FAULT
ALL ENGINES
The ECM applies and monitors 12 volts on C K T 437. C K T 437 connects to the Vehicle Speed Sensor (V SS)
which alternately grounds C K T 437 when drive wheels are turning. This pulsing action takes place about 2000
times per mile and the ECM w ill calculate vehicle speed based on the tim e between "pulses .
A "Scan tool reading should closely match with speedometer reading with drive wheels turning.
Test Description: Numbers below refer to circled 3. A stea d y 8-12 v o lts at th e E C M c o n n e c to r

numbers on the diagnostic chart. indicates C K T 437 is open or a faulty vehicle speed
Code 24 w ill set if: sensor.
C K T 437 voltage is constant. 4. This is normal voltage which indicates a possible
Engine speed is more than 200 rpm . interm ittent condition.
V eh icle speed signal (v o lta g e on te rm in a l
" A 9 is less than 10 mph (16 k/mh) Diagnostic Aids:
A ll conditions must be met for 10 seconds.
Th ese conditions are m et d u rin g a road load 1. "S c a n r e a d in g sh ou ld c lo s e ly m atch w ith
deceleration. speedometer reading, with drive wheels turning.
1. This test monitors the ECM voltage on C K T 437. 2. Check park/neutral sw itch d ia g n o s is ch a rt i f
W ith the wheels turning, the pulsing action w ill vehicle equipped with automatic transmission.
result in a va ryin g voltage. The variation w ill be 3. I f park/neutral sw itch is O K , r e fe r to "E C M
greater at low wheel speeds to an average o f 4-6 Interm ittent Codes or P e rfo rm a n ce in Section
volts at about 20 mph (32 km/h). " 2 .
2. A voltage o f less than 1 volt at the ECM connector

indicates that the C K T 437 w ire is shorted to
ground. Disconnect C K T 437 at the vehicle speed
sensor. I f voltage now reads above 10 volts, the
vehicle speed sensor is faulty. I f voltage remains
less than 10 volt, then C K T 437 w ire is grounded.
I f 437 is not grounded, check for a fa u lty ECM
connector or ECM.
CODE 24
VSS CIRCUIT FAULT
ALL ENGINES
DISREGARD CODE 24 IF SET WHILE DRIVE WHEELS ARE NOT TURNING.
7S 3694
CLEAR CODES AND CONFIRM "CLOSED LOOP " OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 07-06-87
MANIFOLD AIR ECM

TEMPERATURE
SENSOR
M AT SENSOR
SIGNAL
472 TAN -/W L 5 V
452 BLK
SENSOR
TO TPS AND
GROUND
COOLANT
TEMPERATURE 7S3692
SENSOR 7-20-87
CODE 25
2.5L ENGINE
The Manifold A ir Tem perature (M A T ) Sensor is a therm istor that controls the signal voltage to the ECM.
The ECM applies a voltage (4-6 volts) on C K T 472 to the sensor. W hen the air is cold, the sensor (therm istor)
resistance is high, therefore the ECM w ill see a high signal voltage. As the air warms, the sensor resistance
becomes less, and the voltage drops.

1. Code 25 w ill set if: A "S c a n tool reads te m p e ra tu re o f th e a ir
S ig n a l v o lta g e in d ic a te s a m a n ifo ld a ir entering the engine and should read close to am bient
te m p e ra tu r e b e lo w 150C (3 0 2 F ) fo r 2 air tem perature when en gin e is cold, and rises as
seconds. underhood tem perature increases.
Tim e since engine start is 1 minute or longer. Check harness routing for possible short to ground
A vehicle speed is present. in C K T 472.
Refer to Section "2 for "E C M Interm ittent Codes
or Perform ance.
The "Tem perature to Resistance V a lu e scale at
the rig h t may be used to test the M A T sensor at
various tem perature levels to evaluate the possibility
CODE 25
MANIFOLD AIR TEMPERATURE
(MAT) SENSOR CIRCUIT
ALL ENGINES
DIAGNOSTIC AID
MAT SENSOR
(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
6-17-87
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S 3190-6E
TO EGR VALVE
ECM
-f
2.5L
ONLY
- G D
EXCEPT
2.5L
7-15-87
7-30-87 7S 3737
CODE 32
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
2.5L & 5.0L
4.3L (EXCEPT ST)
5.7L (UNDER 8500 GW)
The ECM operates a solenoid to control the Exhaust Gas Recirculation (E G R ) valve. This solenoid is
norm ally closed. By providing a ground path, the ECM energizes the solenoid which then allows vacuum to pass
to the EGR valve.
The ECM monitors EGR effectiveness by de-energizing the EGR control solenoid thereby sh utting o ff
vacuum to the EGR valve diaphragm. W ith the EGR valve closed, fuel integrator counts w ill be greater than
they were during normal EGR operation. I f the change is not within the calibrated window, a Code 32 w ill be
set.
The ECM w ill check EGR operation when:
Vehicle speed is above 50 mph.
Engine vacuum is between 40 and 51 kPa.
No change in throttle position while test is being run.
Test Description: Num bers below refer to circled 5. When engine is started, exhaust backpressure
numbers on the diagnostic chart. should cause vacuum to bleed o ff and valve should
1. By grounding the diagnostic term inal, the EG R fully close.
solenoid should be energized and allow vacuum to
be applied to the E G R va lv e and the vacuum Diagnostic Aids:
should hold.
2 . When the diagnostic term inal is ungrounded, the Before replacing ECM, use an ohm m eter and
vacuum to the EGR valve should bleed o ff through check the resistance of each ECM controlled
a vent in the solenoid and the valve should close. relay and solenoid coil. Refer to ECM QDR
The gage may or may not bleed o ff but this does Check procedure, F ig u r e 3-18. See E C M
not indicate a problem. w ir in g d ia g r a m fo r c o il te r m . 1.1), o f
3. This test w ill determ ine if the elc tric a l control solenoid(s) and relay(s) to be checked. Replace
part o f the system is at fault or if the connector or any solenoid where resistance measures less
solenoid is at fault. than 20 ohms.
4 . This system uses a negative backpressure valve
which should hold vacuum with engine "O F F .
BEFORE USING THIS CHART, CHECK V A C U U M SOURCE TO EGR

SOLENOID, ALSO CHECK HOSES FOR LEAKS OR RESTRICTIONS. CODE 32
SHOULD BE AT LEAST (7 ") HG VACUUM AT 2000 RPM.
EGR SYSTEM
2.5L & 5.0L
DISCONNECT EGR SOLENOID VACUUM LINE FROM THROTTLE BODY.
IGNITION "O N ", ENGINE STOPPED. 4.3L (EXCEPT ST)
GROUND DIAGNOSTIC TERMINAL. 5.7L (UNDER 8500 GVW)
INSTALL A HAND HELD VACUUM PUMP WITH GAGE TO THROTTLE BODY
SIDE OF EGR SOLENOID.
APPLY VACUUM AND OBSERVE EGR VALVE DIAPHRAGM.
VALVE SHOULD MOVE.
DOES IT?
YES NO
H Z xz
UNGROUND DIAGNOSTIC TERMINAL. CONNECT VACUUM PUMP TO EGR VALVE SIDE OF
VACUUM SHOULD BLEED OFF AND HARNESS.

VALVE SHOULD CLOSE. APPLY VACUUM AND OBSERVE VALVE.
DOES IT? VALVE SHOULD MOVE.
DOES IT?
YES NO
~~1 m

IGNITION "OFF"
CONNECT A VACUUM
DISCONNECT
SOLENOID
YES NO
I
PUMP TO EGR VALVE. ELECTRICAL FAULTY VACUUM HOSE
USING A MIRROR, CONNECTOR. TO EGR VALVE OR FAULTY
OBSERVE EGR DOES VACUUM VALVE
DIAPHRAGM WHILE BLEED OFF?
APPLYING VACUUM.
DIAPHRAGM SHOULD DISCONNECT EGR ELECTRICAL CONNECTOR.
YES NO CONNECT TEST LIGHT BETWEEN HARNESS
MOVE FREELY AND
HOLD VACUUM FOR AT CONNECTOR TERMINALS.
LEAST 20 SECONDS. CKT 435 REPLACE IGNITION "O N " ENGINE "OFF"
DOES IT? SHORTED TO SOLE TEST LIGHT SHOULD LIGHT.
GROUND OR NOID. DOES IT?
FAULTY ECM
**
YES NO
3 = ~r~
YES NO FAULTY CONNECT TEST LIGHT
~1 m SOLENOID BETWEEN HARNESS

APPLY VACUUM TO EGR VALVE.
START ENGINE AND
REPLACE EGR
VALVE.
CONNECTION
OR FAULTY
TERMINAL "A " AND
GROUND
IMMEDIATELY OBSERVE SOLENOID.
VACUUM GAGE ON VACUUM
PUMP. NO LIGHT LIGHT
VALVE IS GOOD IF DIAPHRAGM
HAS M O VED TO SEATED
REPAIR OPEN REPAIR OPEN CKT 435.
POSITION (VALVE CLOSED) AND
CKT439. IF NOT OPEN, IT IS A
VACUUM DROPPED WHILE
FAULTY ECM. * *
STARTING ENGINE.
VAC UUM DROPPED NO VACUUM DROP

T X
BE SURE VACUUM HOSE REMOVE EGR VALVE.
CHECK PASSAGES * * BEFORE REPLACING ECM, REFER TO ECM QDR CHECK
BETWEEN SOLENOID AND EGR
FOR BEING PLUGGED. PROCEDURE.
VALVE IS OK. (NO LEAKS OR
IF NOT PLUGGED, REPLACE ANY RELAY OR SOLENOID IF THE COIL RESISTANCE
RESTRICTIONS) IF NO PROBLEM
REPLACE VALVE. MEASURES LESS THAN 20 OHMS.
IS FOUND. THE EGR CIRCUIT IS
OK.
* 7S3870-6E
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 6-22-87
ECM
CODE 32
EGR SYSTEM
2.8L, 4.3L (ST), 7.4L & 5.7L (OVER 8500 GVW)
The ECM operates a solenoid to control the Exhaust Gas Recirculation (E G R ) valve. This solenoid is
norm ally closed. By providing a ground path, the ECM energizes the solenoid which then allows vacuum to pass
to the EGR valve.
The ECM monitors EGR effectiveness by de-energizing the EGR control solenoid th ereb y sh u ttin g o ff
vacuum to the EGR va lve diaphragm. W ith the EGR valve closed, fuel integrator counts w ill be greater than
they were during normal EG R operation. I f the change is not within the calibrated window, a Code 32 w ill be
set.
The ECM w ill check EGR operation when:
Vehicle speed is above 50 mph.
Engine vacuum is between 40 and 51 kPa.
No change in throttle position while test is being run.

1. W ith the ign ition " O N , en gin e stopped, the B efore rep la c in g EC M , use an oh m m eter and
solenoid should not be en ergized and vacuum check the resistance o f each ECM controlled relay
should not pass to the EGR valve. Grounding the and solenoid coil. R efer To E C M Q D R check
diagnostic term inal w ill energize the solenoid and procedure, Figure 3-18.
allow vacuum to pass to valve. See E C M w ir in g d ia g ra m fo r c o il t e r m in a l
2. Checks for plugged EGR passages. I f passages are id en tifica tio n o f solenoid(s) and re la y (s ) to be
plugged, the engine may have severe detonation checked.
on acceleration. Replace any solenoid where resistance measures
3. The EG R solenoid w ill not be energized in Park or less than 20 ohms.
N e u t r a l. T h is te s t w ill d e t e r m in e i f th e
Park/Neutral switch input is being received by the
ECM.
3-56 COMPUTER COMMAND CONTROL (WITH SCAN")
MAP SENSOR
ECM
( ).
1
\
MANIFOLD
-
416 GRY
432 LTGRN H e n I -
5V REF
MAP SIGNAL
ABSOLUTE
PRESSURE
(VACUUM)
ALL CK -------- 4 55 PPL EE} SENSOR
2.5L ENGINE 469 BLK/ORN Q T } GROUND
4.3L M , ALL GVAN & RV -------- 455 PPL H~E}

7S 3697
7-31-87 5-27-87
CODE 33
MAP SENSOR CIRCUIT
SIGNAL VOLTAGE HIGH
(LOW VACUUM)
ALL ENGINES
The M anifold Absolute Pressure (M A P ) Sensor responds to changes in m anifold pressure (vacuum). The
ECM receives this inform ation as a signal voltage that w ill vary from about 1 to 1.5 volts at idle to 4-4.5 volts at
wide open throttle.

1. Code 33 w ill set when: The "A ltitu d e To V oltage scale at the right may
Signal is too high for a tim e greater than 6 be used to test the M A P sensor at a specific altitude
seconds. level to evaluate the possibility o f a "slew ed (m is-
Engine m isfire or a low unstable idle may set scaled) sensor. A "slew ed sensor could result in poor
Code 33. drivea b ility complaints.
Engine Running: Engine m isfire or a low unstable idle may set Code
M anifold pressure greater than 75.3 kPa (A/C 33. Disconnect M A P sensor and system w ill go into
"O F F ) 81.2 kPa (A/C " O N ) backup mode. I f the m isfire or idle condition remains,
Th rottle angle less than 2% see "D riv ea b ility Sym ptom s in Section "2 .
Conditions met for 2 seconds. R e fe r to " E C M In t e r m itt e n t C od es or
2. W ith the M A P sensor disconnect the ECM; should Perform ance in Section "2 .
see a low voltage if the ECM and w irin g is O K .
CODE 33
MAP SENSOR CIRCUIT
SIGNAL VOLTAGE HIGH
(LOW VACUUM)
ALL ENGINES
IGNITION "ON" ENGINE STOPPED VOLTAGES

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
L O W A L T IT U D E = H IG H PRESSURE = H IG H VO LTA G E
7S 3698
CLEAR CODES AND CONFIRM "CLOSED LOOP OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
07-06-87
MAP SENSOR j
ECM
I n i i ( ( D (D lJ
, \
1u
416 GRY -/VW^5VREF

0 H 1
-ED-
\
432 LTGRN - MAP SIGNAL
MANIFOLD
ABSOLUTE
ALL CK ----- 455 PPL
PRESSURE E E F
(VACUUM ) SENSOR
C El
2.5L ENGINE 469 BLK/ORN GROUND
4 .3 L M , ALL GVAN &RV ------- 455 PPL - H

7 S 3697
7-30-87 5-27-87
CODE 34
MAP SENSOR CIRCUIT
SIGNAL VOLTAGE LOW
(HIGH VACUUM)
ALL ENGINES
The M anifold Absolute Pressure (M A P ) Sensor responds to changes in manifold pressure (vacuum). The
ECM receives this inform ation as a signal voltage that w ill vary from about 1 to 1.5 volts at idle to 4-4.5 volts at
wide open throttle.
I f the M A P sensor fails the ECM w ill substitute a fixed M A P value and use the Th rottle Position Sensor
(T P S ) to control fuel delivery.

1. Code 34 w ill set when: An interm ittent open in C K T s 416 w ill result in a
W hen engine is less than 600 rpm. Code 34.
M anifold pressure reading less than 13 kPa, R e fe r to " E C M I n t e r m i t t e n t C o d e s o r
conditions met for 1 second Perform ance in Section "2 .
or The "A ltitu de to V o lta g e scale at the righ t may
Engine is greater than 600 rpm. be used to test the M A P sensor at a specific altitude
Th rottle angle over 20%. level to evaluate the possibility o f a "slew ed (m is-
m anifold pressure less than 13 kPa conditions scaled) sensor. A "slew ed sensor could result in poor
met for 1 second.. d riveability complaints.
2 . This tests to see if the sensor is at faulty for the
low voltage or if there is a ECM or w irin g problem.
3 . This sim ulates a high signal voltage to check o f an
open in C K T 432. if the test light is bright during
this test, C K T 432 is probable shorted to ground.
If "Scan reads over 4 volts at this lest C K T 416
can be checked by m ea su rin g the v o lta g e at
term inal "C . (should be 5 volts)
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?
1
YES NO
I
IGNITION "OFF". CODE 34 IS INTERMITTENT.
DISCONNECT SENSOR ELECTRICAL CONNECTOR. IF NO ADDITIONAL CODES WERE
JUMPER HARNESS TERMINALS "B" TO "C". STORED, REFER TO DIAGNOSTIC
IGNITION "O N ". AIDS ON FACING PAGE.
MAP VOLTAGE SHOULD READ OVER 4 VOLTS.
DOES IT?
NO YES
IGNITION "OFF". FAULTY CONNECTION

REMOVE JUMPER WIRE. OR SENSOR.
PROBE TERMINAL "B" (CKT 432) WITH A
LIGHT TO 12 VOLTS.
IGNITION "O N ".
"SCAN" SHOULD READ OVER 4 VOLTS.
DOES IT?
YES NO
IE c
CKT416 OPEN OR CKT416 SHORTED CKT 432 OPEN
TO GROUND OR CKT 416 SHORTED TO OR
SENSOR GROUND OR FAULTY ECM CKT 432 SHORTED TO GROUND
OR
IGNITION "ON" ENGINE STOPPED VOLTAGES CKT 432 SHORTED TO SENSOR GROUND
OR
ALTITUDE VOLTAGE RANGE FAULTY ECM
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 -1 21 9 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
2133-24 38 7,000-8,000 2.8 4.3V
2438-2743 8,000-9,000 2.64.2V
2743-30 48 9,000-10,000 2.5 4.0V
L O W A LT IT U D E = H IG H PRESSURE = H IG H VOLTAG E
7S3699
TBI UNIT
AIR
FLOW
ECM
IAC CONNECTOR
IAC COIL "A " HI
LT BLU/WHT 441 C5
IAC COIL "A " LO
LT BLU/BLK 442 C6
C4 IAC COIL "B" HI

LT GRN/WHT 443 -
LT GRN/BLK444 C3 IAC COIL "B" LO

IDLE AIR
N *7S 3852-6E
CONTROL (IAC)
7-30-87 8-18-86
CODE 35
IDLE AIR CONTROL (IAC) SYSTEM
2.5L ENGINE
Code 35 w ill set when the closed throttle engine speed is 100 rpm above or below the correct engine idle
speed for 45 seconds. R eview "G eneral Description in Section "4 .
Test Description: Numbers below refer to circled System too lean. (H igh air/fuel ratio)
numbers on the diagnostic chart. Idle speed may be too high or too low. Engine speed
1. Continue with test even i f engine w ill not idle. If may vary up and down, disconnecting IA C does not
idle is too low, "S ca n w ill display 80 or more help. M ay set Code 44.
counts, or steps. I f idle is high, it w ill display "0 "Scan and/or V oltm eter w ill read an oxygen sensor
counts. output less than 300 mv (.3 volts). Check for low
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. D iscon n ect IA C . I f the c o n d itio n is 800 mv (.8 volts) w ill be a contam inated sensor,
unchanged, the IA C is not faulty, there is a system usually silicone. This may also set a Code 45.
problem. Proceed to paragraph three below. System too rich (Low air/fuel ratio)
2. W hen the en gin e was stopped, the IA C v a lv e Idle speed too low. "Scan counts usually above 80.
retracted (more air) to a fixed "P a rk position for System obviously rich and may exhibit black smoke
increased air flow and idle speed during the next exhaust.
engine start. A "Scan w ill display 100 or more "Scan tool and/or voltm eter w ill read an oxygen
counts. sensor signal fixed above 800 mv (.8 volts).
3. Be sure to disconnect the IA C valve prior to this Check:
test. The test light w ill confirm the ECM signals by High fuel pressure
a steady or flashing light on all circuits. Injector leaking or sticking.
4. There is a remote possibility that one o f the circuits Throttle body.
is sh orted to v o lta g e w hich w ould h a ve been Remove IA C and inspect bore for foreign m aterial
indicated by a steady light. Disconnect ECM and or evidence o f IA C valve draggin g the bore.
turn the ig n ition " O N and probe term in als to A/C Compressor or relay fa ilu re.
check for this condition. See i f A/C diagnosis circuit i f shorted to ground. I f
the relay is faulty, an idle problem may exist.
Diagnostic Aids: R e fe r to "R o u g h , U n sta b le, In c o rr e c t I d le or
S tallin g in "D riv e a b ility S ym ptom s in Section
A slow unstable idle may be caused by a system " 2 .
problem that cannot be overcom e by the IAC . "Scan

counts w ill be above 60 counts if too low and "0 counts
if too high.
If idle is too high, stop engine. Ig n itio n " O N .
Ground diagnostic term inal. W a it a few seconds for
IA C to seat, then disconnect IAC. Start engine. I f idle
speed is above 800 50 rpm, locate and correct
vacuum leak.
"SCAN" TOOL MUST BE tN OPEN

MODE DURING THIS CHECK.
CODE 35
A/C "OFF" DURING ENTIRE CHECK. 2.5L ENGINE
ENGINE AT NORMAL OPERATING
TEMPERATURE AND TRANSMISSION IN DRIVE
(A/T) OR NEUTRAL (M/T).
RECORD ENGINE SPEED. IF IDLE IS ERRATIC OR
UNSTABLE. REFER TO FACING PAGE.
IGNITION "OFF" FOR 10 SECONDS.

START ENGINE AND IMMEDIATELY
OBSERVE RPM IN NEUTRAL.
RPM SAME AS RECORDED RPM HIGHER THAN RECORDED IN FIRST STEP.

IN FIRST STEP. :~-i ....... :
IDLE ENGINE FOR 1 MINUTE IN
DRIVE (A/T) OR NEUTRAL (M/T).
SHIFT TO NEUTRAL (A/T).
NOTE ENGINE SPEED.
WILL NOT RETURN TO RPM RETURNS TO RPM RECORDED IN FIRST STEP.

RECORDED IN FIRST STEP.
.1 .................................... ...........
IDLE AIR CONTROL CIRCUIT OK.
REFER TO "DIAGNOSTIC AIDS"
IGNITION "OFF".
ON FACING PAGE.
DISCONNECT IAC VALVE HARNESS.
IGNITION "O N " , ENGINE STOPPED.
GROUND DIAGNOSTIC TEST TERMINAL.
CONNECT A TEST LIGHT BETWEEN EACH IAC
HARNESS CONNECTOR TERMINAL AND GROUND.
NO LIGHTS, ONE OR
MORE CIRCUITS.
LIGHT STEADY
OR FLASHING ALL
CIRCUITS
I
CHECK FOR OPEN OR SHORT TO 1
GROUND IN CIRCUIT WITH NO FAULTY IAC
LIGHT. ARE ALL CIRCUITS OK? CONNECTION OR IAC
VALVE, OR PLUGGED
PASSAGE. IF LIGHT
NO APPEARS TO BE STEADY,
REFER TO TEST,STEP 4
CHECK RESISTANCE ACROSS IAC COILS. SHOULD BE REPAIR WIRING AND ON FACING PAGE.
MORE THAN 20 OHMS BETWEEN IAC TERMINALS RECHECK.
OPPOSITE HARNESS CONNECTOR TERMINALS "A " TO
"B" AND "C" TO "D ".
Z L
OK
T
FAULTY ECM NOT OK
CONNECTION OR ECM.
REPLACE IAC VALVE AND RETEST.
IDLE NOT OK
REPLACE ECM
CLEAR CODES, CONFIRM "CLOSED LOOP" OPERATION, NO "SERVICE ENGINE SOON' 7-17-87
LIGHT, AND VERIFY CONTROLLED IDLE. 8S 4652-6E
PICK-UP COIL ECM

HALL
O J EFFECT - f
SWITCH
B+
D4 EST

IGNITION A>-
W B5 REFERENCE
MODULE
r - q l 1' 4 z4 TAN/d LK D5 BYPASS
PRIM. IGN. COIL >
1 453 BLK/RED B3 GROUND
EST CONNECTOR
IGN 2.5LS/T TRUCK
PICK-UP
COIL
IGNITION
(M E ECM
MODULE
DISTRIBUTOR
GBRE
DISTRIBUTOR 4 TERM.
nunn CONNECTOR
IGN.
IGN. COIL ' b

GRY. -------------- 423 W HT EST
& r CONN.
-------- 430 PPL/WHT H B5 REFERENCE
' I s* BLK. <<- 424 TAN/BLK - BY-PASS

! / CONN.
CONNECTOR <EXC6PT 2 '5L M VAN> ,------- ,
------------------------------------------ 453 BLK/RED ~ | B3
-
TACH.LEAD
ALL EXCEPT 2.5LS/T TRUCK * 7S 3700-6E
8 - 11-86 7-16-86
CODE 42
ELECTRONIC SPARK TIMING (EST)
ALL ENGINES
Circuit Description
Refer to page 3-9 for EST and Code 42.
Test Description: Numbers below refer to circled S e le c tin g the 10-20,000 ohm s p o s itio n w ill
numbers on the 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 C K T 423 shorted to ground.
code is present. Bypass C K T 424 open.
2. Checks for a normal EST ground path through the Faulty ignition module connection or module.
ignition module. An EST C K T 423 shorted to 5. Confirms that Code 42 is a faulty ECM and not an
ground w ill also rea d less th a n 500 ohm s; interm ittent in C K T s 423 or 424.
however, this w ill be checked later.
Diagnostic Aids:
3. As the test light voltage touches C K T 424, the
module should switch causing the ohm m eter to The "Scan tool does not have any ability to help
"overran ge if the meter is in the 100-200 ohms diagnose a Code 42 problem.
position. Refer to Section "2 for "E C M Interm ittent Code
or Perform ance.
ECM 1
PNK/BLK IGN ECM
10A FUSE
ESC
485 BLK B7 ESC SIGNAL
MODULE YEL/BLK
486 BRN OR BLK/RED YEL/RED
496 DK BLU
,J
J
ENGINE
7S 3 7 1 0
GROUND
7-21-87 5-27-87
CODE 43
ELECTRONIC SPARK CONTROL (ESC) CIRCUIT
ALL ENGINES EXCEPT 2.5L. AND 7.4L
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 drops, and this signals the
ECM to retard tim ing. The ECM w ill retard the tim ing when knock is detected and rpm is above about 900
rpm.
Code 43 means the ECM has been low voltage at C K T 485 term inal "B 7 for longer than 5 seconds w ith 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,
the ECM w ill advance the spark when coolant is above 95C and at a high load condition (near W .O .T.). The
ECM then checks the signal at "B 7 to see if a knock is detected. The functional check is perform ed once per
start-up and if knock is detected when coolant is below 95C (194F), the test has passed and the functional
check w ill not be run. I f the functional check fails, the "Service Engine Soon light w ill rem ain on until ignition
is turned "O F F or until a knock signal is detected.
Test Description: Num bers below refer to circled 5. I f C K T 496 is routed to close to secondary ignition
numbers on the diagnostic chart. wires, the ESC module may see the interference as
1. I f the conditions for a Code 43 are present, the a knock signal.
"Scan w ill always display "y e s . There should 6. This checks the ground circuit to the module. An
not be a knock at idle unless an internal engine open ground w ill cause the voltage on C K T 485 to
problem, or a system problem exists. be about 12 volts which would cause the Code 43
2. T h is te s t w ill d e te r m in e i f th e s y s te m is functional test to fail.
functioning at this time. U sually a knock signal 7. Connecting C K T 496 with a test ligh t to 12 volts
can be generated by tapping on the right exhaust should g e n e ra te a knock s ig n a l. T h is w ill
manifold. I f no knock sign al is generated, try d e te rm in e i f the ESC m o d u le is o p e r a t in g
tapping on block close to the area o f the sensor. correctly.
3. Because Code 43 sets when the signal voltage on
C K T 485 remains low, this test should cause the Diagnostic Aids:
signal on C K T 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 w irin g are OK. the knock sensor at the ESC module or at the ECM.
4. This test w ill determ ine i f the knock signal is Also check C K T 485 for possible open or short to
being detected on C K T 496 or if the ESC module is ground.
at fault. Refer to Section "2 for "E C M Interm ittent Codes
or Perform ance .
CODE 43
ENGINE IDLING. ELECTRONIC SPARK CONTROL
"SCAN SET ON KNOCK SIGNAL. (ESC) CIRCUIT
IS THERE A KNOCK SIGNAL INDICATED?
ALL ENGINES EXCEPT
2.5L AND 7.4L
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? NO YES
zn m
1

DISCONNECT ESC MODULE.
PROBE HARNESS TERMINAL
CODE 43 IS INTERMITTENT. IF
NO ADDITIONAL CODES WERE
NO YES
"D " (CKT 486) WITH A TEST STORED, REFER TO "DIAG NO S
z c
LIGHT TO 12 V. TIC AIDS" ON FACING PAGE.
IGNITION "O N ". CKT485 OPEN,
PROBE TERMINAL SHORTED TO
"B"(C KT 439) GROUND, OR LIGHT "O N ' LIGHT "OFF*
WITH A TEST LIGHT FAULTY ECM.
TO GROUND.

RECONNECT ESC MODULE.
DISCONNECT KNOCK SENSOR.
REPAIR OPEN
GROUND CKT 486.
ENGINE IDLING.
MOMENTARILY TOUCH KNOCK
SENSOR HARNESS (CKT 496) WITH
A TEST LIGHT TO 12V.
EACH TIME THE TEST LIGHT
CONTACTS CKT 496. A KNOCK
SIGNAL SHOULD BE GENERATED.
IS A KNOCK SIGNAL INDICATED
WITH "SCAN"?
YES NO
IE I t
FAULTY CONNECTION AT SENSOR CKT 496 OPEN, SHORTED TO
OR FAULTY KNOCK SENSOR. GROUND. FAULTY CONNEC
TION AT ESC MODULE. OR
FAULTY ESC M ODULE.
LIGHT "O N ' LIGHT "OFF"
1 I

REMOVE CKT 496 FROM CONNECTOR.
RECONNECT ESC MODULE.
OPEN CKT 439
ENGINE IDLING.
IS THERE A KNOCK SIGNAL INDICATED?
YES NO
~I HZ
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.
2-12-87
7S3292-6E
ECM
PPL 412 0 2 SENSOR

D7
SIGNAL
TAN 413 D6 I 0 2 GROUND

OXYGEN ( O 2) SENSOR
CIRCUIT
S\\\
ENGINE
EXHAUST
M
GROUND
2-20-87
7-20-87 4S0790-6E
CODE 44
LEAN EXHAUST INDICATED
ALL ENGINES
The ECM supplies a voltage o f about .45 volts between term inals "D 6 and "D 7 . ( I f measured with a 10
meg ohm digital voltm eter, this may read as low as .32 volts.) The oxygen senior varies the voltage within a
range o f about 1 volt if the exhaust is rich, down through about .10 volts i f exhaust is lean.
The sensor is like an open circuit and produces no voltage when it is below about 315C (600F). An open
sensor circuit or cold sensor causes "Open Loop operation.
Test Description: Numbers below refer to circled F u el C o n ta m in a tio n . W a te r , even in s m a ll

numbers on the diagnostic chart. amounts, near the in-tank fuel pump inlet, can be
1. Code 44 is set when the oxygen sensor signal delivered to the injectors. The w ater causes a lean
voltage on C K T 412: exhaust and can set a Code 44.
Remains below .2 volts for 20 seconds. Fuel Pressure. System w ill be lean if pressure is
And the system is operating in "Closed Loop . too low. It may be necessary to m onitor fuel
pressure while drivin g the vehicle at various road
Diagnostic Aids: speeds an/or loads to confirm. See Fuel System
diagnosis.
Using the "Scan , observe the block learn values A IR 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 . I f the
also displays the block cells, so the block learn values block learn value goes down w hile squeezing air
can be checked in each o f the cells to determ ine when hose to left side o f exhaust ports, refer to Section 8.
the Code 44 may have been set. I f the conditions for I f the above are O K, it is a fau lty oxygen sensor.
Code 44 exists, the block learn values w ill be around C K T 413. I f C K T 413 is open, the vo lta g e at
150. term inal "D 7 w ill be over one volt.
O xygen Sensor W ir e . Sensor p ig t a il m ay be S ensor H a rn e s s . S e n s o r p i g t a i l m a y be
m is p o s itio n e d and c o n ta c t in g the e x h a u s t m is p o s itio n e d and c o n ta c t in g th e e x h a u s t
manifold. manifold.
Check for interm ittent ground in w ire between I f all check O K , the oxygen sensor is faulty.
connector and sensor.
CODE 44
LEAN EXHAUST INDICATED
ALL ENGINES
5-27-87
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S 3191-6E
ECM
PPL412 0 2 SENSOR
D7
SIGNAL
TAN 413 D6 I 0 2 GROUND

O X Y G E N (0 2 )SENSOR
~ CIRCUIT
ENGINE
EXHAUST
GROUND
2-20-87
7-20-87 4S 0790-6E
CODE 45
RICH EXHAUST INDICATED
ALL ENGINES
The ECM supplies a voltage o f about .45 volts between term inals "D 6 and "D 7 . ( I f measured with a 10
meg ohm digital voltm eter, this may read as low as .32 volts.) The oxygen sensor varies the voltage w ithin a
range o f about 1 volt if the exhaust is rich, down through about .10 volts i f exhaust is lean.
The sensor is like an open circuit and produces no voltage when it is below about 315 C (600F). A n open
sensor circuit or cold sensor causes "Open Loop operation.
Test Description: Num bers below refer to circled H E I S h ie ld in g . A n op en g ro u n d C K T 453

numbers on the diagnostic chart. (ignition system reference low) may result in E M I,
1. Code 45 is set when the oxygen sensor signal or induced electrical "noise . The ECM looks at
voltage or C K T 412: this "noise as reference pulses. The additional
Remains above .7 volts for 50 seconds, and in pulses result in a higher than actual engine speed
"Closed Loop . sign a l.T h e EC M then d e liv e rs too much fu e l,
Engine tim e after start is 1 minute or more. causing system to go rich. Engine tachom eter w ill
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.
Canister P u rge. Check for fuel saturation. I f full
Diagnostic Aids: o f fuel, check can ister control and hoses. See
E vaporative Emission Control in Section 5.
Using the "Scan , observe the block learn values M A P Sensor. An output that causes the EC M to
at different rpm and air flow conditions. The "Scan sensor a higher than normal m anifold pressu re
also displays the block cells, so the block learn values (low vacuum) can cause the system to go rich.
can be checked in each o f the cells to determ ine when D isconnecting the M A P sensor w ill a llo w the
the Code 45 may have been set. I f the conditions for ECM to set a fixed valu e for the M A P sensor.
Code 45 exists, the block learn values w ill be around Substitute a d iffe re n t M A P sensor i f the rich
115. condition is gone w hile the sensor is disconnected.
Fuel Pressure. System w ill go rich i f pressure is Pressu re R e g u la to r . C h eck fo r le a k in g fu e l
too high. Th e EC M can com pensate for some pressure regu lator dia p h ra gm by ch eck in g for
increase. H ow ever, if it gets too high, a Code 45 presence o f liquid fuel in the vacuum line to the
may be set. regulator.
See Fuel System diagnosis chart. C h eck fo r le a k in g fu e l p r e s s u re r e g u la t o r
Leaking Injector. diaphragm by checking vacuum line to regu lator
Check for fuel contaminated oil. for fuel.
TPS. An interm ittent T P S output w ill cause the
system to go rich, due to a false indication o f the
engine accelerating.
CODE 45
RICH EXHAUST INDICATED
ALL ENGINES
5-27-87
CLEAR CODES AND CONFIRM CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. >75 3 19 2 - 6 E
CODE 54
FUEL PUMP CIRCUIT
(LOW VOLTAGE)
Circuit Description
The status o f the fuel pump C K T 120 is monitored by the ECM at term inal "B 2 and is used to compensate
fuel delivery based on system voltage. This signal is also used to store a 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 C K T 120 for at least
2 seconds after the ignition is turned, or any tim e reference pulses are being received by the ECM.
Code 54 w ill set if the voltage at term inal "B 2 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 tim e, and the code w ill
help the diagnosis o f an engine that "Cranks But W ill N ot Run.
I f a fault is detected during start-up, the "Service Engine Soon light w ill stay " O N until the ignition is
cycled "O F F .
Diagnostic Aids:
See "E C M Interm ittent Codes or

Perform ance in Section "2 .
CODE 51 CODE 51
CODE 52
FAULTY MEM-CAL
CODE 53
CODE 55 (2.5L ENGINE)
OR
PROM PROBLEM
(EXCEPT 2.5L ENGINE)
CHECK THAT ALL PINS ARE FULLY INSERTED IN THE SOCKET. IF OK, REPLACE
PROM, CLEAR MEMORY, AND RECHECK. IF CODE 51 REAPPEARS. REPLACE ECM.
CODE 52
FUEL CALPAK MISSING
CHECK FOR MISSING CALPAK AND THAT ALL PIN ARE FULLY INSERTED IN THE
SOCKET - IF OK, REPLACE ECM.
CODE 53!
SYSTEM OVER VOLTAGE
(2.5L ENGINE)
THIS CODE INDICATES THERE IS A BASIC GENERATOR PROBLEM.
CODE 53 WILL SET IF VOLTAGE AT ECM TERMINAL B1 IS GREATER THAN 17.1 VOLTS FOR 2 SECONDS .
CHECK AND REPAIR CHARGING SYSTEM.
CODE 55
ALL ENGINES
EXCEPT 2.5L ENGINE
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. c -> o-.
RESTRICTED EXHAUST SYSTEM CHECK

ALL ENGINES
Proper diagnosis for a restricted exhaust system is essential before any components are replaced. E ither o f
the follow ing procedures may be used for diagnosis, depending upon engine or tool used:
CHECK AT A. I. R. PIPE: OR CHECK AT O 2 SENSOR:

1. R em ove the ru b ber hose at the ex h au st 1. Carefully rem ove O 2 sensor.
manifold A.I.R. pipe check valve. R em ove 2. In stall B orroughs Exhaust B a c k p re ss u re
check valve. Tester (B T 8515 or BT 8603) or equ ivalent in
2. Connect a fuel pump pressure gauge to a hose place o f O 2 sensor (see illustration).
and n ip p le from a P rop an e E n ric h m en t 3. A fter com p letin g test described below , be
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 equ iva len t
A.I.R. pipe. prior to re-installation.
1. W ith the engine idling at normal operating tem perature, observe the exhaust system backpressure
reading on the gauge. Reading should not exceed 1 } psi (8.6 kPa).
2. Accelerate engine to 2000 rpm and observe gauge. Reading should not exceed 3 psi (20.7 kPa).
3. I f 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 m uffler failure.
5. I f 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 3 3 4 0 -6 E
Figure 3-17 Exhaust System Check
MAP SENSOR
ECM
-o I
A N \ IV- 5VREF
*
416 GRY | c ih
- 432 LTGRN ----- 1 Cl 1 |~ - M AP SIGNAL

MANIFOLD
ABSOLUTE
PRESSURE ALL CK ------- 455 PPL E E }
(VACUUM ) SENSOR
2.5L ENGINE 469 BLK/ORN 0 0 " GROUND
4 .3 L M , ALL GVAN & RV 455 PPL -CEJ

7S 3697
7-30-87 5-27-87
MAP OUTPUT CHECK

ALL ENGINES
The M anifold Absolute Pressure (M A P ) sensor measures m anifold pressure (vacuum) and sends that signal
to the ECM. The M A P sensor is m ainly used for fuel calculation, when the ECM is running in the throttle body
backup mode. The M A P sensor is also used to determ ine the barom etric pressure and to help calculate fuel
delivery.
Test Description: Num bers below refer to circled 2. A pplyin g 34 kPa (10 hg) vacuum to the M A P
numbers on the diagnostic chart. sensor should cause the voltage to be 1.2 volts less
1. Checks M A P sensor output voltage to the ECM. than the voltage at Step 1. Upon applying vacuum
This voltage, without engine running, represents to the sensor, the change in vo lta g e should be
a barom eter reading to the ECM. instantaneous. A slow voltage change indicates a
faulty sensor.
3. Check vacuum hose to sen sor fo r le a k in g or
restriction. Be sure no other vacuum devices are
connected to the M A P hose.
MAP OUTPUT CHECK

ALL ENGINES

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
L O W A LT IT U D E = H IG H PRESSURE = H IG H V O LTA G E
*7S 3162-6EA
PARK/NEUTRAL SWITCH DIAGNOSIS

ALL ENGINES
EXCEPT "P" SERIES
(AUTO TRANSMISSION ONLY)
The Park/Neutral Switch contacts are closed to ground in park or neutral and open in d rive ranges.
The ECM supplies ignition voltage, through a current lim itin g resistor, to C K T 434 and senses a closed
switch, when the voltage on C K T 434 drops to less than one volt.
The ECM uses the P/N signal as one o f the inputs to control:
Idle A ir Control
VSS Diagnostics
EGR

1. Checks for a closed sw itch to ground in park I f C K T 434 indicates P/N (groun ded), w h ile in
position. D ifferent makes o f "Scan tools w ill read drive range, the EGR would be inoperative, resulting
P/N differently. Refer to operators m anual for in possible detonation.
type o f display used for a specific tool. I f C K T 434 always indicates drive (open), a drop in
2. Checks for an open sw itch in d riv e or reverse the idle may exist when the gear selector is moved into
range. drive range.
3 Be sure "S c a n in d ica te s d r iv e , e v e n w h ile
w ig g lin g sh ifter to test for an in term itten t or
misadjusted switch in drive range.
PARK/NEUTRAL SWITCH DIAGNOSIS

ALL ENGINES
EXCEPT "P" SERIES
(AUTO TRANSMISSION ONLY)
5-27-87
e7S 3161-6E
ECM
N.O.
IGNITION- 806 PPL/WHT CRANK SIGNAL

SWITCH M A N. TRANS.
CRANK FUSE-3A
CLUTCH START
SWITCH OR
FUSE LINK (2.5L)
STARTER
SOLENOID
7-20-87
7-20-87 7S3708-6E
CRANK SIGNAL DIAGNOSIS

ALL ENGINES
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.
Test Description: Numbers below refer to circled 2. Checks to determ ine if source o f open fuse or fuse
numbers on the diagnostic chart. link was a faulty ECM.
1. Checks for normal (cranking) voltage to term inal
"C 9 o f ECM. Test light should be " O N during
cran kin g and then go " O F F w hen en gin e is
running.
COMPUTER COMMAND CONTROL (WITH SCAN") 3-79
CRANK SIGNAL DIAGNOSIS

ALL ENGINES
7S 3709-6E
ECM
POWER STEERING
PRESSURE SWITCH
(CLOSES WITH PRESSURE)
BLK/WHT
rh
450 (GND) 495 (12V) ENGINE
HARNESS CONNECTOR GROUND
7-20-87 (END VIEW) 7S3706-6E
POWER STEERING (P/S) PRESSURE SWITCH CHECK

2.5L ENGINE
The power steering pressure switch is norm ally open to ground, and C K T 495 w ill be near battery voltage.
Turning the steering wheel increases power steering oil pressure and its load on an idlin g engine. The
pressure switch w ill close before the load can cause an idle problem
C losing the switch causes C K T 495 to read less than 1 volt. The ECM w ill increase the idle air rate and
retard the timing.

1. Checks for ECM signal voltage on C K T 495 and A pressure switch that w ill not close, or an open
confirms that ground C K T 450 is OK. C K T 495 or 450, may cause the engine to stop when
2. M axim um resistance, or in fin ity , indicates an
power steering loads are high.
open switch.
A switch that w ill not open, or a C K T 450 or 495,
3. Less than 1 ohm indicates that the switch is closed
shorted to ground, w ill cause tim in g to retard at idle,
when the power steering pressure is high. Switch
is OK. and may affect idle quality.
POWER STEERING (P/S)

PRESSURE SWITCH CHECK
2.5L ENGINE
CLEAR CODES AND CONFIRM "CLOSED LOOP OPERATION AND NO "SERVICE ENGINE SOON LIGHT.
7 S 3707
6-23-87
A/C CLUTCH CONTROL DIAGNOSIS

(Page 1 of 2)
2.5L ENGINE
ECM control o f the A/C clutch improves idle quality and performance by;
D elaying clutch apply until the idle air rate is increased.
Releasing clutch when idle speed is too low.
Releasing clutch at wide open throttle.
Smooths cycling o f the compressor by providing additional fuel at the instant clutch is applied.
Turning on air conditioning supplies C K T 459 battery voltage to the clutch control relay and term inal B8.
A fter a tim e delay o f about 1/2 second the ECM w ill ground term inal "A 4 , C K T 458, and close the control relay.
A/C compressor clutch w ill engage.
Test Description: Num bers below refer to circled 2. Th is and fo llo w in g tests check for fa u lty A/C
numbers on the diagnostic chart. control relay.
1. Checks for low refrigeran t as cause for no A/C.

(Page 2 of 2)
2.5L ENGINE
ECM control o f the A/C clutch improves idle quality and perform ance by;
Turning on a ir conditioning supplies C K T 459 battery voltage to the clutch control relay and term inal "B 8 .
A fter a tim e delay o f about 1/2 second, the ECM w ill ground term inal "A 4 , C K T 458, and close the control
relay. A/C compressor clutch w ill engage.

3. Checks for faulty cycling switch. Before replacing ECM , use ohm m eter and check
Solenoids and relays are turned "O N or "O F F by resistance o f each ECM controlled relay or solenoid
the ECM , using internal electronic switches called coil. See EC M w irin g d ia gram for coil te r m in a l
"d rivers . Each driver is part o f a group o f four, id en tifica tio n for so len o id s(s ) and r e la y (s ) to be
called Quad-Drivers. Failure o f one d riv e r 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 w ill cause
e a rly fa ilu re o f the EC M " d r iv e r . U s in g an
ohm m eter, check the coil resistance o f the A/C
relay before replacing the ECM.
A/C CLUTCH CONTROL

DIAGNOSIS
(Page 2 of 2)
FROM A/C CLUTCH
CONTROL DIAGNOSIS
2.5L ENGINE
CHART (1 OF 2)
7S3850-6E

(Page 1 of 2)
2.8L ENGINE
ECM control o f the A/C clutch improves idle quality and performance by:
Turning on air conditioning supplies C K T 59 battery voltage to the clutch control relay and term inal "B 8 o f
the ECM connector. A fter a tim e delay o f about 1/2 second the ECM w ill ground term inal " A 2 of the ECM
connector, C K T 459, and close the control relay. A/C compressor clutch w ill engage.
Test Description: Num bers below refer to circled 2. Th is and fo llo w in g tests check for fa u lty A/C
numbers on the diagnostic chart. control relay.
1. Checks for low refrigeran t as cause for no A/C.
A/C CONTROL
HTR A/C A/C PRESSURE
FUSE PANEL SWITCH
25A ECM
IGNITION -*---- 9T ---- i-
i l
I_____________1
A/C CLUTCH
59D K G R N B8
SIGNAL
A. C.
CLUTCH
CONTROL CLUTCH
- 39 PNK/BLK
RELAY CONTROL
HID- 459
DK GRN/WHT
A2
959
GRN/WHT GAGES
FUSE
FT 20A
hi IGNITION 1
RELAY
HARNESS
CONNECTOR
7-20-87
7-30-87 A/C COMPRESSOR CLUTCH 7S3848-6E

(Page 2 of 2)
2.8L ENGINE
ECM control of the A/C clutch improves idle quality and performance by;
Delaying clutch apply until the idle air rate is increased.
Turning on air conditioning supplies C K T 59 battery voltage to the clutch control relay and terminal "B 8 of
the ECM connector. A fter a time delay of about 1/2 second the ECM will ground terminal " A 2 of the ECM
connector, C K T 459, and close the control relay. A/C compressor clutch will engage.

3. Checks for faulty cycling switch. Before replacing ECM, use ohmmeter and check
Solenoids and relays are turned " O N or " O F F by resistance of each ECM controlled relay or solenoid
the ECM, using internal electronic switches called coil. Refer to ECM QDR Check (Figure 3-18). See
"drivers . Each driver is part o f a group of four, ECM wiring diagram for coil terminal identification
called Quad-Drivers. Failure o f one driv er can for solenoid(s) and relay(s) to be 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 w ill cause
ea rly failure of the EC M " d r i v e r . U s in g an
ohmmeter, check the coil resistance o f the A/C
relay before replacing the ECM.
A/C CLUTCH CONTROL

DIAGNOSIS
(Page 2 of 2)
FROM A/C CLUTCH
2.8L ENGINE
CONTROL DIAGNOSIS
CHART (1 of 2)
7S3851-6E
5-27-87
3-90 COMPUTER COMMAND CONTROL (WITH SCAN*)
4.3L AND V8 ENGINE

Circuit And Test Description:
Turning on the air conditioning supplies C K T 59 battery voltage to the A/C compressor clutch and to
terminal "B 8 of the ECM connector to increase idle air rate and maintain idle speed.
The ECM does not control the A/C compressor clutch, therefore, i f A/C does not function, refer to the A/C
section of the service manual for diagnosis of the system.
If A/C is operating properly and idle speed dips too low when the A/C compressor turns " O N or flares too
high when the A/C compressor turns "O F F , check for an open C K T 59 to the ECM. If circuits are O K, it is a
faulty ECM connector terminal "B 8 or ECM.
ECM QDRCHECK PROCEDURE

V6 OR V8 ENGINE
USE THIS CHECK PROCEDURE ONLY AFTER OTHER
DIAGNOSTIC CHARTS IN THE SERVICE M ANUAL HAVE
DETERMINED THAT THERE WAS AN ECM FAILURE.
REMOVE THE ECM FROM THE VEHICLE.
IDENTIFY THE SERVICE NUMBER OF THE ECM IN THE
VEHICLE.
IS THE ECM SERVICE PART NUMBER 1227747?
YES NO
m
REFER TO LIST BELOW OF THE ECM TERMINALS WHICH L4 ENGINE ECM IS FAULT PROTECTED.
ARE QDR OUTPUTS. CORRECT FAULTY CIRCUIT, REINSTALL ECM
USING THE 200K O H M SCALE ON D V M *, MEASURE AND CHECK CIRCUIT. REPLACE ECM ONLY
RESISTANCE BETWEEN THE ECM CASE AND EACH ECM IF CIRCUIT IS STILL INOPERATIVE.
TERMINAL LISTED, BLACK (NEG.) LEAD TO CASE AND
RED (POS.) LEAD TO ECM TERMINAL.
ALL TERMINALS LISTED SHOULD HAVE RESISTANCE OF
50K OHMS OR MORE.
DO THEY?
NO YES
= r m
THE PRIOR TEST HAS DETERMINED THAT A QDR IN THE KEY "O N ", ENGINE NOT RUNNING.
ECM HAS BEEN DAMAGED. IT IS MOST IMPORTANT TO USE A FUSED AMMETER CAPABLE OF MEASURING
LOCATE AND REPAIR THE CIRCUIT OR COMPONENT THAT AT LEAST 2 AMPS (J-34029-A OR EQUIVALENT).
CAUSED THE DAMAGE. FAILURE TO DO SO WILL RESULT CONNECT ONE LEAD OF THE AMMETER TO
IN ANOTHER FAILURE OF THE NEWLY REPLACED ECM. CHASSIS GROUND.
ANY TERMINAL WITH LESS THAN 50K OHMS RESISTANCE CONNECT THE REMAINING LEAD TO EACH VEHICLE
IS CONNECTED TO A DEFECTIVE QDR. THE ECM CIRCUIT WHICH WAS LISTED ABOVE.
TERMINAL WITH THE LOWEST RESISTANCE WAS MEASURE SUSTAINED CURRENT FLOW THROUGH
CONNECTED TO THE VEHICLE CIRCUIT MOST LIKELY TO EACH CIRCUIT FOR 2 MINUTES EACH (IN MOST
HAVE CAUSED THE QDR FAILURE. CASES, THE TCC SOLENOID CANNOT BE EASILY
TESTED FOR CURRENT DRAW).
NOTE AMPERAGE.
DISCONNECT THE COMPONENT IN THAT VEHICLE
CIRCUIT AND CHECK FOR A SHORT TO VOLTAGE. IF
THE CIRCUIT IS NOT SHORTED TO VOLTAGE, REPLACE
THE COMPONENT IN THAT CIRCUIT AND THE ECM.
IF A CIRCUIT(S) HAS MORE IF NO CIRCUIT HAS

THAN 0.75 AMPS CURRENT MORE THAN 0.75
ECM # 1227747
DRAW. AMPS CURRENT
ECM DRAW.
QDR OUTPUT CIRCUIT I ......... ~
NUMBER TERMINAL CHECK FOR A SHORT TO REPLACE ECM
VOLTAGE IN EXCESSIVE
A2 A/C RELAY (2.8L)
CURRENT DRAW CIRCUIT.
A3 NOT USED IF NO SHORT TO
1 VOLTAGE, REPLACE
C1 NOT USED RELATED SOLENOID OR
RELAY.
C2 EAC SOLENOID
A4 EGR OR EVRV SOLENOID
A5 SES LIGHT
USE DVM J-34029-A OR EQUIVALENT
2
A7 TCC SOLENOID, DOWNSHIFT
A7 RELAY OR SHIFT LIGHT

6-10-87
8S-4335-6E
Figure 3-18 ECM QDR Check Procedure (V6 or V8)

ON-VEHICLE SERVICE
WIRE HARNESS
The ECM harness electrically connects the ECM term in a l pair, it is possible to da m age c e r t a i n
to the various solenoids, switches, and sensors in components. A lw a y s use ju m p e r w ire s b e tw e e n
vehicle engine and passenger compartment. connectors, for circ u it ch ecking. N E V E R probe
W ire harnesses should be replaced with proper through the W eather-Pack seals. Use tachometer
part number harnesses. W h e n sign a l w ire s are adapter J35812, or equivalent, which provides an easy
s p lic e d , into a h a r n e s s , use w i r e w i t h h ig h hook up of the tach. lead. The connector test adapter
temperature insulation only. kit J35616, or equivalent, contains an assortment of
W ith the low current and voltage levels found in flexible connectors, used to probe term inals du ring
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 3-19. fuse holder, with a meter, for diagnosis.
M o l d e d on c o n n e c t o r s r e q u i r e c o m p l e t e 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. a lign m ent are hidden by the connectors. M e r e ly
Refer to Figures 3-22 through 3-33, for w irin g wiggling a connector on a sensor, or in the w irin g
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,
also, be caused by oxidized or loose connections.
CONNECTORS AND TERMINALS Before making a connector repair, be certain of the
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
opposite terminals. I f this happens, to the wrong
TWISTED/SHIELDED CABLE TWISTED LEADS

D R A IN W IRE
Z O UTER JACKET
MYLAR
1. REM O VE O UTER JACKET. 1. LOCATE DAM A G ED W IRE.

2. UNWRAP A L U M IN U M /M Y L A R TAPE. DO NOT 2. REM O VE IN S U L A T IO N AS R E Q U IR E D .
REM O VE M Y L A R .
SPLICE & SOLDER

3. UN TW IST CONDUCTORS. STRIP IN S U L A T IO N AS 3. SPLICE TWO W IRES TO G E TH E R USING SPLICE

NECESSARY. CLIPS AND ROSIN CORE SOLDER.
, uDnRnAi IN
iK W
IRE
in t
K g a 2
4 . SPLICE W IRES USING SPLICE CLIPS A N D ROSIN CORE 4. COVER SPLICE W ITH TAPE TO INSU LA TE
SO LDER . WRAP EACH SPLICE TO IN SU LA TE. FROM O THER WIRES.
5. WRAP W ITH M Y L A R A N D D R A IN (U N IN S U L A T E D ) W IRE. 5. RETW IST AS BEFORE A ND TAPE W ITH
E L EC TR IC A L TAPE A ND HO LD IN PLACE.
l m
6. TAPE O VE R WHOLE BUNDLE TO SECURE AS BEFORE. 4S 0570-6E
Figure 3-19 - W ire Harness Repair

Micro-Pack To remove a terminal:

1. Slide the seal back on the wire.
Refer to F ig u re 3-20 and repair procedure for 2. I n s e r t tool (3 ) B T -8 5 1 8 , or J 3 5 6 8 9 , or
replacement o f 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 I f reusing the terminal, reshape the locking tang (2).
Series 150. (Figure 3-21). These may used at the
coolant sensor, as well as TB I units. Weather-Pack
They are also called "P u ll-T o -S e a t 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 re a r o f the connector. T h is
The terminal is then crimped on the w ire and the connector, which is used in the engine compartment,
terminal pulled back into the connector to seat it in protects against moisture and dirt, which could create
place. oxid a tion and deposits on the te r m in a ls . T h is
protection is important, because o f the v e r y low
voltage and current levels found in the electronic
system.
Repair of a Weather-Pack terminal is shown in
Figure 3-22. Use tool J28742, or BT8234-A to remove
the pin and sleeve terminals.
I f removal is attempted with an ordin ary pick,
there is a good chance that the terminal will be bent,
or deformed. Unlike standard blade type terminals,
these terminals cannot be straightened once they are
bent.
Make certain that the connectors are properly
seated and all o f the sealin g rings in place, when
connecting leads. The hinge type flap provides a
backup, or s e c o n d a r y lo c k in g f e a t u r e fo r the
l~ n CABLE IT! LOCKING TANG
connector. They are used to improve the connector
l~2~l TERMINAL l ~ 4 l TOOL J33095/BT8234-A
reliability by retaining the term inals, i f the small
7S3548-6E terminal lock tangs are not positioned properly.
Figure 3-20 - Micro-Pack Connector W eather-P ack connections cannot be rep laced
with standard connections. Instructions are provided
with Weather-Pack connector and terminal packages.
1. METRI-PACK SERIES TOOL J35689 OR BT-8446

150 FEMALE TERMINAL CONNECTOR BODY
2. LOCKING TANG SEAL
4-18-86
*7S 3 213-6E
Figure 3-21 M etri-Pack Series 150 Term inal Removal

1. OPEN SECONDARY LOCK HINGE ON CONNECTOR Important

FEMALE T \ ________ ^M ALE
CO NNECTO R^^^^ CONNECTOR
When replacing a production ECM with a service
c o n tr o lle r , t ra n s fer the b r o a d c a s t code and
production ECM part number to the controller
label. Do not record information on the access
.SECO NDARY/ cover.
LOCK HINGE
2. REMOVE TERMINAL USING TOOL
PUSH TO
NOTICE: T h e i g n it io n must be " O F F , w h e n
RELEASE disconnecting or reconnecting the ECM
connector, to prevent internal damage to
TERMINAL TOOL J-28742/BT8234-A the ECM.
3. CUT WIRE IM MEDIATELY BEHIND CABLE SEAL
ECM Connector Terminal Voltages
WIRE
Refer to Figure 3-33 through 3-35, for voltage
4. REPLACE TERMINAL charts to aid in diagnosis.
A. SLIP NEW SEAL ONTO WIRE.
B. STRIP 5 mm (.2") OF INSULATION FROM WIRE.
C. CRIMP TERMINAL OVER WIRE AND SEAL ECM Replacement - with Mem-Cal (2.5L)
Figures 3-36,3-37 and 3-44
SEAL
Remove or Disconnect
5. PUSH TERMINAL AND CONNECTOR AND

1. N egative battery cable.
ENGAGE LOCKING TANGS.
6. CLOSE SECONDARY LOCK HINGE 2. Connectors from ECM.
3. ECM mounting hardware.
7S 3542-6E 4. ECM from passenger compartment.
Figure 3-22 - Weather-Pack Terminal Repair 5. ECM access cover (Figure 3-3).
6. Mem-Cal removal (Figure 3-38).
Compact Three
Important
The Compact Three connector, which looks similar Replacement ECM is supplied without a Mem-Cal,
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 o f connector, most likely, is used at the air new ECM.
control solenoid. Use the standard method, when
repairing a terminal. Do not use the Weather-Pack Using two fingers, push both retaining clips back
term inal tool J28742, or BT8234-A, as these w ill away from the Mem-Cal. A t the same time, grasp it at
damage the terminals. both ends and lift it up out o f the socket. Do not
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 o f the Electronic Control Module
(E C M ) consists o f a service controller, w ithou t a Inspect (Figure 3-39)
PROM/Calpak, or Mem-Cal.
For a lig n m e n t notches o f the M e m - C a l 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 PR O M and Calpak, or Mem-Cal, and
install them in the service controller. The service
controller will not contain a PROM/Calpak, or Mem-
Cal.
Figure 3-23 - ECM W irin g D iagram - 2.5L(1 o f 3)

ECM
n LT BLU/WHT 441 -
C5 IAC COIL "A " HI
IAC .....1 C LT BLU/BLK 442 - C6 IAC COIL "A " LO
VALVE _ B LT GRN/WHT 443 C4 IAC COIL "B" HI

JU U U u LT GRN/BLK 444 - C3 IAC COIL "B" LO
\ A
HALL EFFECT SWITCH
D X . D BLK/RED 453 B3 REFERENCE LOW

C r f i C TAN/BLK 424 D5 BY-PASS
B b PPL/WHT 430 B5 REFERENCE HIGH
L lJ
A A ----- WHT 423 D4 EST
DISTRIBUTOR
(2.5L ST TRUCK)
PICK-UP COIL
24 PIN A-B
CONNECTOR
DISTRIBUTOR
(2 .5 L M VAN)
W H T 4 23 D4 EST
PPL/WHT 430 B5 REFERENCE HIGH
BY-PASS
TAN/BLK 424 I 0 5
PRIMARY COIL
BLK/RED 453 - J 83 REFERENCE LOW
ECM B
12 V 10A zinciF^
- ORN 440 B1 12V
--a c t-'
ORN 440 C16 12V -3 3 U ---
FUEL PUMP RELAY ::Q Q r-
DK GRN/WHT 465 A1
DRIVE (12V)
- BLK/WHT -|
32 PIN C-D
CONNECTOR
FUEL M u. 3 3
B ENGINE GROUND
PUMP
RELAY
n TAN/W HT 120 B2 FUEL PUMP SIGNAL
FUEL PUMP
_ j TEST CONNECTOR
TO
FUEL
PUMP
SWITCH 7 S 3266
07-06-87
Figure 3-24 - ECM W irin g Diagram - 2 .5L (2 o f 3)

Figure 3-25 - ECM W irin g D iagram 2.5L (3 o f 3)

ECM
ED ORN 461 - A8
WHT/BLK 451 - A9
SERIAL DATA
DIAGNOSTIC TEST
ALDL CONNECTOR [ 1 }
BLK/WHT 450 A12 SYSTEM GND

o
_551 D1 SYSTEM GND
TAN/WHT
= ENGINE GND'S
N.O. / A1 .
CRANK
IGN SW.
PPL/WHT 806 C9 CRANK SIGNAL BACK VIEW
START
MAN. TRANS. \ OF A
CLUTCH START CONNECTOR
SWITCH
START SOLENOID - :
PPL412 - D7 OXYGEN SENSOR

SIGNAL
OXYGEN SENSOR
TAN 413 - D6 OXYGEN SENSOR
ENGINE GND GROUND
A
PPL 455 - A11 SENSOR GROUND 24 PIN A-B
MAP SENSOR CONNECTOR
B C11 MAP SIGNAL
LTGRN432
c
/m \
GRY 416 C14 + 5VREF
c
DK BLU 417 C13 TPS SIGNAL
TPS B
A
BLK452 D2 SENSOR GROUND
COOLANT
TEMPERATURE -----
SENSOR YEL 410 C10 COOLANT TEMP
SIGNAL
IGN. 3
; i e
25A
PRESSURE CYCLING B DKGRN 59 B8 A/C SIGNAL
SWITCH
F 39 GAGE20A 32 PIN C-D
- PNK/BLK -IGN CONNECTOR
A
T DK GRN/WHT 459 A2 A/C RELAY
-n m m I
L> CONTROL
A/C RELAY
A/C COMPRESSOR
------- 59GRN
6S 2678-6E
5-27-87
Figure 3-26 - ECM W irin g Diagram - 2.8L (1 of 3)

_________ ECM
A ------- LT BLU/WHT 441 IAC COIL "A " HI

n r r m _ C5
IAC
VALVE a JUUUU
B
D
LT BLU/BLK 442
LT GRN/WHT 443
LT GRN/BLK 444
- C6
C4
C3
IAC COIL "A " LO
IAC COIL "B" HI
IAC COIL "B" LO
E-CELL
B | C | A | D
+ 1 2 V ---------- ORN 440 ----- DK BLU/WHT 421 C12 E-CELL

IGN + 1 2 V ---------- PNK/BLK 439
ECM 1
IGN A6
PNK/BLK ----- 439 IGN.
12v 10A
T\RED
W IN J. 1
- > 'T T r L - LTBLU 467 D16 | _ INJECTOR
d r iv e r
482 |Nj 2
PICK-UP COIL D14 INJECTOR
W HT -------- _ n r T t T _ < 3 --------- LT GRN ------------------ 468 DRIVER
24 PIN A-B
CONNECTOR
A A
B^CK VIE
OF
CO^NEtfTOR
W HT ------ 423 - D4 EST
PPL/WHT ----- 430 B5 REFERENCE
SET TIMING C O N N E C TO R ^_____ TAN/BLK 424 D5

BY-PASS
PRIMARY COIL
B3 REF. LOW
------------------------------------------------------ BLK/RED *5 3
ECM B
12v 10A
------------ ORN 440 B1 12V
------------ ORN 440 C16 12V -- C X -

DK GRN/WHT 465 A1 FUEL PUMP RELAY
DRIVE (12V)
BLK/WHT
r 32 PIN C-D
CONNECTOR
| E D A C B |
FUEL ENG.GND
PUMP 1
RELAY
l _ * - * --------------
TO
FUEL TAN/W HT 120 B2 FUEL PUMP SIGNAL
PUMP
OIL
- FUEL PUMP
pre s s . (
------- L - J TEST
SWITCH 6S 2679
connector
7-24-86
Figure 3-27 - ECM W irin g D iagram - 2.8L (2 of 3)

ECM
/ci\ ZmX
Figure 3-28 - ECM W irin g Diagram - 2.8L (3 of 3)

ECM
ORN/GRN 461 A8 SERIAL DATA

> r C D - ORN ~ D
ALDL ^ | B |---------------------------- WHT/BLK 451 A9 DIAGNOSTIC TEST
BLK/WHT 450 A12 SYSTEM GND
450
D1 SYSTEM GND
| BLK/WHT
ENGINE GROUNDS J l
N.O. )
CRANK FUSE
IGN SW.
START ---------------------------------- PPL/WHT 806 C9 CRANK SIGNAL
MAN. TRANS. 5A PPL 906 (P)
CLUTCH START
SWITCH
START SOLENOID - =
PPL 412 - D7 OXYGEN SENSOR

SIGNAL
OXYGEN SENSOR 24 PIN A-B

CONNECTOR
TAN 413 - D6 OXYGEN SENSOR
ENGINE GND. GROUND
PPL 455 MAP GROUND
D2
(4.3L 8. V8 RVMGP)
A PPL 455 A11 MAP GROUND
(V 8 & 4 .3 L C K )
H
MAP SENSOR
B
LTGRN432 C11 MAP SIGNAL
C
c GRY 416 - C14 + 5V REFERENCE
TPS DKBLU 417 C13 TPS SIGNAL

^ _ v V y- B
A
BLK 452 A11 SENSORGROUND
(4.3L & V8 RVMGP)
COOLANT rs ^ y A BLK 452 - D2 SENSOR GROUND

TEMPERATURE ----- (4.3L CK & V8))
SENSOR
YEL410 C10 COOLANT TEMP.
SIGNAL
A/C
IGN 3 LTGRN 66 DK GRN/WHT 59 - B8 A/C SIGNAL
- 32 PIN C-D
PRESSURE CYCLING
SWITCH CONNECTOR
A/C COMPRESSOR 7S 3 1 9 8
5-27-87
Figure 3-29 - ECM W irin g Diagram - 4.3L & V8 (1 o f 4)

ECM
LT BLU/WHT 441 -
n rrm _ C5 IAC COIL "A " HI
IAC
VALVE a '
ju u u u ~ \
LT BLU/BLK 442
LT GRN/WHT 443 C4
LT GRN/BLK 444
- C6
H C3
IAC COIL "A " LO
IAC COIL "B" HI
IAC COIL "B" LO
ECM B
ORN 440 B1 12V
ORN 440 C16 12V

A1 FUEL PUMP RELAY
DK GRN/WHT 465
DRIVE (12V)
ENG.GND
TAN/W HT 120 i B2 FUEL PUMP SIGNAL
FUEL PUMP

TEST CONNECTOR
SWITCH 24 PIN A-B

CONNECTOR
FUEL PUMP RELAY CIRCUIT (M )
FUSE LINK (CK)

ECM
BATT | ) RED 2C B1
ORN 440 12V
12 v JUNCTION BLOCK OR ECM B
FUSE (RV G P)
OIL PRESS. SWITCH ( gjO '
ORN 440 C16 12V
CLOSES AT 4 PSI
- DK GRN/WHT 465 A1 FUEL PUMP RELAY
Eh BLK/WHT DRIVE (12V)

RED 490
ALDL (CK) C I A D | F [ E
TERM. (RV G P) ENGGND
FUEL
PUMP
FUEL PUMP
20A (CK)
RELAY i
1
|
PNK/BLK 920 (CK) OR TAN/W HT 120
TAN/WHT 120 - B2 FUEL PUMP SIGNAL
REFER TO CHART A-5A FOR 32 PINC-D

TWO FUEL TANK SYSTEM CONNECTOR
FUEL A
PUMP
B
FUEL 20A
L PNK/BLK 39 IGN 12 V
MODULE
BLK/WHT D
E
ALL7.4L AND
r h SOME 5.7L
FUEL PUMP RELAY CIRCUIT (CK RV G P) 7S 3 1 9 9

7-7-87
Figure 30 - ECM W irin g Diagram - 4.3L & V8 (2 of 4)

Figure 3-31 - ECM W irin g Diagram - 4.3L & V 8 (3 o f 4)

ECM
INJ A 10A 481 INJ. 1
IGN (<K G M )_ RED INJECTOR
BLU 467 D16
DRIVER
12 V E C M 110A
(RVP) BLU 467 D15 INJECTOR
DRIVER (5.7LP)
482 INJ. 2,
INJECTOR
WHT - rrn V < GRN 468 D14 DRIVER
GRN 468 C15 INJECTOR

DRIVER (5.7LP)
ECM/IGN
IGN. -V \ ^ - 439 _ A /\/Y W \B _ GRY 435 A4 EGR SOLENOID
12V 4 .3 L & 5 .0 L
EGR SOLENOID
10 A
A GRY 435
A4 EVRV SOLENOID
5.7L& 7.4L
EVRV SOLENOID
BLK/WHT
ALDL
_ A _ A ^ V W \J L BRN 436 C2 EAC SOLENOID

EAC SOLENOID
PNK/BLK 439 A6 12V IGN
ESC SENSOR INPUT

ELECTRONIC
ESC GROUND 486 BRN OR BLK/RED ------- TO ENGINE GRD.
SPARK KNOCK
CONTROL SPARK RETARD 457 YEL/BLK OR YEL/RED OR BLK --------------- B7 RETARD 24 PIN A-B
SIGNAL (ESC) CONNECTOR
MODULE 12 V IGN.
(EXCEPT P)
496 DK BLU
/Q\ / Q l\
KNOCK
PICK-UP COIL
SENSOR
d
m
----- WHT 423 D4 -EST

32 PIN C-D
PPL/WHT 430 B5 -REFERENCE CONNECTOR
SET TIMING CONNECTOR
I TACH ~ TAN/BLK 424 D5 -BY-PASS
\AAAJ LEAD
BLK/RED 453 B3 REF. LOW
PRIMARY COIL
7S 3 2 0 0
5-27-87
Figure 32 - ECM W irin g Diagram - 4.3L & V8 (4 o f 4)

TBI FUEL INJECTION ECM CONNECTOR IDENTIFICATION

This ECM voltage chart is for use w ith 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 tem perature Engine idling in closed loop (for "Engine Run" column)
VO LTAGE VOLTAGE
KEY ENG. WIRE WIRE KEY ENG.

"ON ' m m . CIRCUIT ;,!N COLOR Z aj\ /&l\ .COLOR PIN CIRCUIT ON" RUN
3KGRN/ ORN B1 BATT.12.VOLTS 12 14
) 0 14 FUEL PUMP RELAY A1 WHT
SHIFT LIGHT (M T) TAN/ TAN/
12 .. ! 4 . ICC CONTROL (AT) A2 RLK WHT 82 FUEL PUMP SIGNAL 0 14
BLK/
12 14.... EGR SOI FNOID A3 RRY RED 63 ESTREFLOW 0 0 .
B4 NOTUSED
12 14 A/C RELAY A4 BLU
"SERVICE ENGINE BRN/ PPL/ EST 4.5ST
0 14 SOON"CONTROL AS W HT W HT B5 REFERENCE HI 0 1.6M
pnk/
12 . 14 _ IGN K M r USE BLK Bt) ,.... MOT USED
B7 NOTUSED
NOT USED A7
DK GRN/
2 5 . ^ ... SERIAL DATA 48 ORN WHT 88 A/C SIGNAL 0 0
WHT/
5 . . i ........ ..DJAfc . w * . .. A9 BLK B9 NOTUSED
SPEED 24 PIN A-B ORN/ PARK/NEUTRAL
12 () SENSOR SIGNAL A10 BRN CONNECTOR BLK B10 SW.SIGNAL 0 0
M AT 8.
0 0 TPS GROUND A11 BLK B11 NOTUSED
BLK/
0 0 SYSTEM GROUND A12 WHT B12 NOTUSED
BLK//
NOTUSED Cl WHT 01 SYSTEM GROUND Q____ 0
BLK/
NOTUSED C2 RED D2 5V RETURN 0 0
LTGRN/
NOT I SEABLE IAC "B" LO C3 BLK D3 NOTUSED
LT GRN/ BACK VIEW
NOT I ISEABLE iAC "B " HI C4 WHT WHT D4 EST CONTROL ...0 .._i.LQ.. ..
LT BLU/ c o n n e cto r TAN/
NOT I SEABLE IAC "A " HI C5 WHT BLK Db ESTBYPASS o 4.75
LT BLU/
NOT I SEABLE IAC "A " LO C6 BLK TAN D$ GRN D. (0 /) 0 0 ....._
NOTUSED Q7 PPL D7 & SENSOR SIGNAL 0 CO

BLU/
12.3 ..U J. P/S SWITCH C8 YEL DK . ... NjQXllSLLL..................
.0 .. .. 0 .. CRANK SIGNAL C9 PPL/WHT Rl K oq fiR OSIND n 0

COOLANT
I 12 ... \J TEMP SIGN At CIO YEL RLK n :n n R m iN n n n
4.7 2-0 MAP SIGNAL cn LTGRN D 1 1 .. 'uOi l i i l l i ...................
13 . 1J .... M AT SIGNAL C12 TAN D12 . NOTUSED

73 V ,73V TPS SIGNAL C13 DK BLU m i N OT IISFD
5 VOLT
... ...... 5 REFERENCE C 14 GRY 32 PIN C-D rm NOTUSED
CONNECTOR
NOTUSED C1 b D 15 NOTUSED
12 14 BATTERY 12 VOLTS C16 ORN ... . 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 A11( ,05V). 7S3264
5-28-87
Figure 3-33 - ECM Connector Term inal End V i e w - 2 .5L


This ECM voltage chart is for use w ith a digital voltmeter to further aid in diagnosis. The voltages
Engine at operating temperature Engine idling in closed loop (for "Engine Run" column)
VOl.TAGE VOLTAGE

"ON ' RUN C IR C U IT PIN COLOR . COLOR PIN CIRCUIT ON" RUN
3KGRN/ ORN B1 BATT.12.VOLTS 12 14
0 14 FUEL PUMP RELAY A1 WHT
A/C CLUTCH TAN/
1? 14 fOiVTROI A? DK BRN WHT R? R i f t PUMP SIGNAL n 14
b lk ;
N D T IiS FD A3 RED B3 ESTREFLOW 0 0
B4 NOTUSED
12 14 EGRCONTROL A4 GRY
"SERVICE ENGINE BRN/ PPL/ EST
0 14 SOON"CONTROL A5 WHT WHT B5 REFERENCE HI 0 1.6
PN K
12 14 IGN ECM FUSE A6 BLK B6 NOTUSED
SHIFT LIGHT OR TAN/ BLK B7 ESC SIGNAL 9 9
12 14 TCC CONTROL A7 BLK
ORN/ B8 A/C SIGNAL 0 0 /1 2
2-5 2.5 SERIAL DATA A8 GRN DK GRN
WHT /
5 S DSAG. TERM AS BLK B9 NOTUSED
SENSOR SIGNAL A10 BRN CONNECTOR BLK B10 SW.SIGNAL 0 0
0 0 MAP GROUND A11 PPL B11 NOTUSED
BLK/
0 0 SYSTEM GROUND A12 WHT B12
TAN/
NOTUSED C1 W HT D1 SYSTEM GROUND 0 0
12
NOTL SEABLE
14 EACSOL.
IAC "B" LO
C2
C3
BRN
LT GRN/
BLK
A A BLK D2
D3
5V RETURN
NOTUSED
0 0
LT GRN/ B^CKVI&W
NOTL SEABLE IAC "B" HI C4 WHT W HT D4 ESTCONTROL 0 1.0
LT BLU/ CONNECTOR TAN/
NOTL SEABLE IAC "A " HI G5 WHT BLK D5 ESTBYPASS 0 4.75
LT BLU/
NOTL SEABLE IAC "A " LO C6 BLK TAN D6 GRN'D. (0?) 0 0
NOTUSED C? PPL D7 02 SENSOR SIGNAL 0
NOTUSED C8 D8 NOTUSED
0 0 CRANK SIGNAL C9 PPL/WHT D9 NOTUSED
1.9 1.7
COOLANT
TEMP. SIGNAL C 10 YEL D10 NOTUSED
4.9 2.0 MAP SIGNAL C11 LT GRN D11 NOTUSED

ELAPSED DK BLU/
.4 .4 TIMER MODULE C12 WHT D12 NOTUSED
,45 V ,45V . TPS SIGN A

5 VOLT
C1.J DK BLU D13 NOTUSED
5 5 REFERENCE C14 GRY 32 PINC-D LT GRN D14 INJECTOR B 12 14

CONNECTOR
NOTUSED C15 D15 NOTUSED
12 14 BATTERY 12 VOLTS C16 ORN BLU D16 INJECTOR A 12 14
ENGINE 2.8L LL2

1 Varies from 60 to battery voltage 5 Measured between terminals C13 and D2 ( 05V).
depending on position of drive wheels. 6 12 V in gear VEHICLE S/T TRUCK
2 Varies with temperature 7 0 V with A/C "on"
3 Varies (toggles) 8 12 V with A/C "on '
4 12V First two seconds 9 12 V when cold
7-7-87
* 6S2819-6E
Figure 3-34 - ECM Connector Term inal End V ie w - 2.8L


This ECM voltage chart is for use with a digital voltmeter to further aid in diagnosis. The voltages
Engine at operating temperature Engine idling (for "Engine Run" column)
Diagnostic terminal not grounded ALDL tool not installed
VO LTAGE VOL1 AGE

"ON 'RUN C IR C U IT PIN COLOR A COLOR PIN CIRCUIT ON" RUN
)K GRN/ ORN B1 BATT.12.VOLTS 12 14

o 14 F U E L P U MP R E L A Y A1 W HT BACK VI E
IN
OF TAN/
NOTIISFD a; CO MNECTOR WHT B2 .....FUEL PUMP SIGNAL ...0. ... 14
BLK/
N O T llS F n A3 RED B3 EST REF LOW 0 0
C B4 NOTUSED
12 14 EGRCONTROL GRY & I
A4 c
1 PPL/ EST
"SERVICE ENGINE BRN/ c
0 14 SOON"CONTROL A5 WHT c W HT B5 REFERENCE HI 0 1.6
FRr c
12 14 IG N -E C M FUSE A6 BLK c NOr USED_________
SHIFT LIGHT OR TAN/ t=
0
BLK B7 ESC SIGNAL 9 9

12 14 TCCCONTROL A7 BLK c
I
DK GRN B8 A/C SIGNAL 0 0

2-S 2.5 SERIAL DATA A8 ORN 3E
W HT/
5 5 DIAG. TERM. A9 BLK B2 NOTUSED
0 <) SENSOR SIGNAL A1Q BRN CONNECTOR JsUJL . _ B in . S W. S I G NA L 0 0 ...
PPL OR
0 0 SENSOR GROUND A11 BLK B11 NOTUSED

BTK7 '
0 0 SYSTEM GROUND A12 WHT B12
BLK/
NOTUSED C1 WHT D1 SYSTEM GROUND 0 0
BLK/RED
12 14 EACSOL. C2 BRN PPL/BLK D2 SENSOR GROUND 0 0
/C l\ / d\
LT GRN/
NOT I SEABLE IAC "B" LO C3 BLK D3 NOTUSED
LTGRN/ BA CK VIEW
NOT I SEABLE IAC "B" HI C4 WHT OF 7 W HT D4 EST CONTROL 0 1.0
LTBLU/ COf<NEOTQR TAN/
NOT I SEABLE IAC "A " HI C5 WHT BLK D5 ESTBYPASS 0 4.75
LT BLU/
NOTt SEABLE IAC "A " LO C6 BLK n fi TAN D6 GND (O?) 0 0
-
12 14 HI GEAR SWITCH C7 LTBLU
PPL D7 O2 SENSOR SIGNAL 0
NOTUSED
NOTUSED CR D8

NOTUSED
0 0 CRANK SIGNAL C9 PPL/WHT D9

COOLANT
saa
1.7 TEMP. SIGNAL YEL D10 NOTUSED
0
1.9 no ___ l_J

4.9 2.0
~ - n n .- z D11 NOTUSED
MAP SIGNAL C11 LTGRN
n~~-~
NOTUSED Cl 2 D12 NOTUSED
6V 6V TPS SIGNAL rn DK BLU D13 NOTUSED

5 VOLT
5 5 REFERENCE C14 GRY 32 PIN C-D LTGRN D14 INJECTOR B 12 14
CONNECTOR
NOTUSED CIS D15 NOTUSED
12 14 BATTERY 12 VOLTS Cl 6 ORN BLU D16 INJECTOR A 12 14
1 Varies from .60 to battery voltage dependmq on position of drive wheels.

2 V a rie s w ith te m D e ra tu re ENGINE 4.3L, 5.0L, 5.7L, 7.4L
3 Varies.
4 12v First two seconds on 4.3L & 5 0L (12v first 20 seconds on 5.7L & 7 4L). VEHICLE CKRVGPM
5 Measured between terminals C1 3and A11 ( 05V)
6 Used on 4 3L, 5.0L or 5.7L engine Wire color may also be yel/black or yeilow/red
7 Also downshift control on THM 400 7 6 87
8 Refer to wiring diagram for terminals A11 or D2 sensor ground 7 S 3582
Figure 3-35 - ECM Connector Term inal End V ie w - 4.3L & V8

PUSH
4-3-85 *6S 2544-6E
Figure 3-38 - Mem/Cal Unit Socket
IF ECM IS BEING REPLACED:
rn ELAPSED TIMER MODULE 1. N e w E C M from its p a c k a g in g and check the
m RETAINER service number to make sure it is the same as the
fT l IN STR U M EN T PANEL defective ECM.
m ELECTRONIC CONTROL MODULE 2. Access cover.
6S2886-6E
Figure 3-36 - Electronic Control Module (ST) Install or Connect
1. Mem-Cal in Mem-Cal socket.
Important
3ress only on the ends o f the Mem-Cal.
Small notches in the Mem-Cal must be align ed
with the small notches in the Mem -Cal socket.
Press on the ends o f the M e m -C a l, u ntil the
retaining clips snap into the ends o f the Mem-Cal.
Do not press on the middle of the Mem-Cal, only
the ends.
PUSH
FT! RIGHT HAND PLENUM SIDE PANEL

m HO USING ASSEM BLY
|" T ] SEAL
[~ 4 l ELECTRONIC CONTROL MODULE
H I RETAINER
7S3761-6E 3-20-85 *6S 2 5 4 5-6 E
Figure 3-37 - Electronic Control M od u le (M )
Figure 3-39 - Mem /Cal U nit Installation
2. Access cover on ECM.

3. ECM in passenger compartment.
4. Connectors to ECM.
Functional Check
1. Turn ignition " O N .

2. Enter diagnostics.
A. Code 12 should flash four times (i f no other
codes are present). This indicates the Mem-
Cal is installed properly, and the E C M is
functioning.
B. I f 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
defective.
I f not fully seated, press firmly on the ends
of the Mem-Cal.
I f it is necessary to remove the Mem-Cal,
follow the previous removal instructions.
ECM Replacement - With PROM & CALPAK H I ECM HO USING

(V6 & V8) m RETAINER
Figures 3-36 and 3-37; 3-40 through 3-43 [T l ELECTRONIC CONTROL M ODULE
IT] BRACKET
Remove or Disconnect m SEAT RISER
7S 3765-6E
1. N ega tive battery cable or ECM B fuse
Figure 3-41 - Electronic Control Module (G)
2. Connectors from the ECM.
3. ECM. Refer to Figure 3-39 for servicing the ECM. PROM
Install or Connect Refer to Figure 3-43, for removal and installation

1. ECM into vehicle. of a PROM.
2. Connector to the ECM.
3. N ega tive battery cable or EC M B fuse. CALPAK
4. Perform System Check.
Refer to Figure 3-43, for removal and installation
of a C A L P A K .
m ELECTRONIC CONTROL M ODULE

m FUEL MODULE
m ELECTRONIC CONNECTOR
8S4613-6E
Figure 3-40 - Electronic Control M od u le (CK)

Figure 3-42 - Electronic Control M o d u le (RV)
1. Remove ECM access cover.
CALPAK CARRIER
CALPAK
CALPAK CARRIER
2. Remove PROM using the rocker-type PROM removal If a service controller is being installed, check the
tool shown. Engage one end of the PROM carrier with eervice 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
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
the PROM socket easily.
7. Install PROM and CALPAK (if used). If a service PROM

or CALPAK is being installed, make sure they have the
same part number as the removed PROM or CALPAK.
3. Inspect reference end of the PROM carrier and care CD Important (Before installing PROM)
fully set aside. Do not remove PROM from the carrier
ANY TIME THE PROM IS INSTALLED BACKWARDS
to confirm PROM correctness. Notch in J^ROM re
AND THE IGNITION SWITCH TURNED ON, THE PROM
ferenced to smaller notch in carrier and the Q l} .
IS DESTROYED.
m Important
| DO NOT press on PROM or CALPAK - ONLY CARRIER.
Small notch of carrier must be aligned with small notch

4 . Remove CALPAK (if used) using removal tool shown. in socket. Press on PROM or CALPAK carrier until it
Grasp the CALPAK carrier of the narrow ends only. is dirmly seated in the socket Do not press on PROM
Gently rock the carrier from and to and while applying or CALPAK, only the carrier.
a firm upward force.
5. Inspect reference and of the CALPAK carrier and Install ECM access cover.
carefully aet aside. Do not remove CALPAK from Install ECM in passenger compartment and perform a
the carrier to confirm CALPAK correctness. Notch in "DIAGNOSTIC CIRCUIT CHECK" to confirm proper
CALAK reference to smaller notch in carrier and installation.
the .
11 1984
6S2511-6E
Figure 3-43 - Servicing ECM - Except 2 .5L
f~| Remove or Disconnect (Figures 1 and 2)

j y j Inspect
1. ECM access cover
Type of clips used on the MEM-CAL sockets
| 9j Important
DO NOT remove any of the other screws. There are two types of clips used on the MEM-CAL
sockets. A solid* type is used on the early produc
tion models and a 'hollow* type is used on later
production models. See Figure 3.
Hoikm ryp* Solid Typo
Figure 4
j \ | important
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.
Figure 1
L
Figure S
MEM-CAL removal
Important e
Replacement Electronic Control Module (ECM) is Figure S
supplied without a Memory-Calibration unit (MEM-
CAL) so care should be taken when removing the Installing MEM-CAL with 'solid* clips
MEM-CAL Irom the defective ECM as it will be
reused in the new ECM. Press on the ends of the MEM-CAL until the
retaining clips snap into the ends of the MEM-CAL
Press the clips into the side of the MEM-CAL until
Using two fingers, push both retaining clips back they snap into place. Listen for the click. Do not
away from the MEM-CAL at the same time Grasp press on the middle of the MEM-CAL; only on the
the MEM-CAL at both ends and lift up out of the ends.
MEM-CAL socket. Do not remove the cover of the
MEM-CAL Use of unapproved MEM-CAL removal
methods will cause damage to the MEM-CAL or
MEM-CAL socket.
inspect Figure 7
Retaining clips have snapped into place

Installing MEM-CAL with 'hollow' clips.
Press down on the ends of the MEM-CAL until the
clips are against the side of the MEM-CAL Press
Figure 2 inward on the clips until they snap into place
Listen for the click.
Inspect (Figure 3)
Do not press on the ends of the MEM-CAL until the
For alignment notches of the MEM-CAL and clips snap into place because the clips may be
carefully set aside Do not open the MEM-CAL damaged.
u dh
-I'-:--'..-:
Figure 3
Figure
|-| Remove or Disconnect (Figure 1)
Inspect
1. New Electronic Control Module (ECM) from its
packaging and check the service number to make Retaining clips have snapped into place
sure it is the same as the defective ECM.
2. Access cover Install or Connect (Figure 1)
1. Access cover on ECM
{-<-{ Install or Connect (Figures 4, 5, 6, 7 and 8)
2. ECM in passenger compartment and perform
1. MEM-CAL in MEM-CAL socket "System Check to confirm proper installation
8S 4697-6E
Figure 3-44 - Servicing E C M -2 .5 L
TTH
|-+| Install or Connect
1. Bolts or snap sensor on bracket
p a l
'l ij 2. Electrical connector
II ll
i! ll
I 1 t i p i
3. Vacuum harness
11 aSf*>
1111
4. Negative battery cable
I f
l l 1
' 11L-
n~ l DASH A N D TOE PANEL

|~2~1 BRACKET
m RETAINER
[T ] ELECTRONIC CONTROL M ODULE
7S3760-6E
Figure 3-45 - Electronic Control Module (P)
COOLANT TEMPERATURE SENSOR

Figure 3-46
NOTICE: C a re must be tak en , w h en h a n d lin g m CO O LANT TEM PERATURE SENSOR

coolant sensor. Damage to coolant sensor IT! INLET M A N IFO LD 7S 3815-6E
w ill affect proper operation o f the fuel
control system. Figure 3-46 - Coolant Sensor
2. Drain cooling system below level of sensor.
3. Electrical connector releasing locking tab.
4. Coolant sensor.
-- Install or Connect
1. Sensor in engine.
2. Electrical connector.
3. Refill coolant system.
MAP SENSOR
Figures 3-47 through 3-53
Other than checking for loose hoses and electrical
c o n n ec tio n s, the o n ly s e r v i c e p o s s ib le is u nit
replacement, if diagnosis shows sensor to be faulty.

2. Vacuum harness assembly.
m PORT "J"
[T l HARNESS ASSEM BLY
m RETAINER
4. Bolts or release lock tabs and remove sensor.
m MAP SENSOR
m BRACKET
7S3754-6E
Figure 3-47 - M AP Sensor - 2 .5L (ST)
m PORT "J"
m HARNESS ASSEM BLY
m BRACKET
m M AP SENSOR
I 5 I RETAINER
7S3753-6E
Figure 3-49 - MAP Sensor - 2.5L (M )
OXYGEN SENSOR
Figure 3-54 through 3-61
NOTICE: The oxygen sensor uses a permanently

attached p ig t a il and connector. T h is
pigtail should not he rem oved from the
oxygen sensor. Damage or removal of the
pigtail or connector could affect proper
operation of the oxygen sensor.
Figure 3-51 - M AP Sensor - 5.0L/5.7L (CKRVP)
The oxygen sensor may be difficu lt to rem ove,
when engine tem perature is be low 48C (1 2 0 F ).
Excessive force may da m age threads in ex h a u st
manifold or exhaust pipe.
1. Negative battery cable.
3. Carefully back out oxygen sensor.
Install or Connect
Important
A special anti-seize compound is used on the
oxygen sensor threads. The compound consists of
a liquid graphite and glass bead. The grap hite
will tend to burn away, but the glass beads will
remain, making the sensor easier to remove.
[~H PORT "F"

FT! HARNESS ASSEMBLY
m MAP SENSOR
fT ] BRACKET
_________________________________________________7S 3749-6E
Figure 3-52 - MAP Sensor - 7.4L (CKRVG)
m EXHAUST M ANIFOLD
m ELECTRICAL CONNECTOR
f~3~1 OXYG EN SENSOR
|~4~| GASKET 7S 3743-6E |
Figure 3-54 - Oxygen Sensor - 2.5L (ST)
New, or service sensors w ill alread y have the

compound applied to the threads. I f a sensor is
removed from an engine, and i f for any reason it is to
1 PORT " F "
be reinstalled, the threads must have a n ti-s e iz e
~T~ HARNESS ASSEMBLY
compound applied before reinstallation.
~~3~ MAP SENSOR
1 Coat threads o f oxygen sensor with anti-seize
BRACKET
7S3752-6E co m p ou n d P/N 3613695, or e q u i v a l e n t , i f
Figure 3-53 - MAP Sensor 5.0L/5.7L(G) necessary.
2. Sensor, and torque to 41 Nm (30 ft. lbs.).
Take care when handling the oxygen sensor. The 3. Electrical connector.
in-line electrical connector and louvered end must be 4. N egative battery cable.
kept free o f grease, dirt, or other contaminants. Also,
avoid using cleaning solvents o f any type. Do not drop
or roughly handle the oxygen sensor.
m EXHAUST MANIFOLD
UU ELECTRICAL CONNECTOR
LU OXYGEN SENSOR
LsJ GASKET 7S 3744-6E
Figure 3-55 - Oxygen Sensor - 2.5L (M) Figure 3-58 - Oxygen Sensor- 5.0L/5.7L (CK)
Figure 3-59 - Oxygen Sensor - 5.0L/5.7L (RVPG)
Figure 3-57 - Oxygen Sensor - 4.3L (STCKRVMG) Figure 3-60 - Oxygen Sensor - 7.4L (CK)
Screw assemblies to 2.0 N*m (18.0 in. lbs.).

4. A ir cleaner and new gasket.
Replacement - TBI 220

Figure 3-63
Important
On 2.8L (V-6) engines, the T P S is adjustable and is
supplied with attaching screw retainers. On all
oth er en gin es, it is n o n - a d ju s ta b le w it h o u t
retainers. In addition, on 2.8L (V-6) and 7.4L (V-
H I EXH AU S T M AN IFO LD 8) engines, the TP S has a horizontal electrical
[~Fl OXYGEN SENSOR 7S 3748-6E connector; on all other engines, the connector is
Figure 3-61 - Oxygen Sensor - 7.4L (RVG) vertical.
THROTTLE POSITION SENSOR Remove or Disconnect

Replacement - TBI 700
Figure 3-62 1. A i r c le a n er, adapter, and gaskets. D isc ard
gaskets.
NOTICE: The T P S is an electrical component and 2. Electrical connector releasing locking tab.
must not be soaked in any liquid cleaner 3. T w o T P S a t t a c h in g s c r e w a s s e m b l i e s a nd
or solvent, as damage may result. retainers (if applicable).
4. T P S from throttle body assembly.
NOTICE: The T P S is an electrical component and
1. A ir cleaner and gasket. Discard gasket.
must not be soaked in any liquid cleaner,
or solvent, as damage may result.
3. Two T P S attaching screw assemblies.
4. T P S from throttle body assembly.
m THROTTLE BODY ASSEM BLY

fT l THROTTLE POSITION SENSOR - NO N-ADJUSTABLE
|~3~| THROTTLE POSITION SENSOR - NON-ADJUSTABLE
fT l THROTTLE POSITION SENSOR - ADJUSTABLE
H~1 THROTTLE BODY ASSEMBLY IT! SCREW ASSEM BLY
m THROTTLE POSITION SENSOR fTl RETAINER 7S 3652-6E
[~T1 SCREW ASSEMBLY Figure 3-63 - TPS Configurations - TBI 220
7S3415-6E
Figure 3-62 - Throttle Position Sensor-TBI 700

Install or Connect
-4- Install or Connect 1. TP S on throttle body assembly, while lining up

T P S lever with T P S drive lever on throttle body.
1. W ith throttle valve closed, install T P S on throttle 2. T w o T P S a t t a c h i n g s c r e w a s s e m b l i e s a nd
shaft. Rotate counter-clockwise, to align mounting retainers (i f applicable).
holes.
2. Tw o T P S attaching screw assemblies.
Adjust - (2.8L V-6 engines only)

F o llo w " A d j u s t a b l e T P S O u tp u t C h e c k
procedure below.
^ Tighten
Screw assemblies to 2.0 N*m (18.0 in. lbs.).
4. A ir cleaner, adapter, and new gaskets.
ADJUSTABLE TPS OUTPUT CHECK - TBI 220

2.8L Engines Only
This check should be p e rfo rm ed , only, when (APPLY SEALER TO THREADS ONLY)
throttle body parts have been replaced, or after the FT! ENGINE INTAKE MANIFOLD
minimum idle speed has been adjusted.
1. C o n n e c t d i g i t a l v o l t m e t e r J 3 4 0 2 9 - A , or 7S3544-6E
equivalent, from T P S connector, center terminal Figure 3-64 - MAT Sensor - 2.5L
" B to outside terminal " A , (jumpers for terminal
access can be made using terminals 1214836 and
12014837). A L D L Scanner can be used to read
T P S output voltage.
2. With ignition " O N , engine stopped, T P S voltage
should be less than 1.25 volts.
3. If voltage is more than 1.25 volts, rotate T P S until
0.48 .06 volts are obtained.
4. If above voltage limitation cannot be obtained,
replace TPS.
5. Remove voltmeter and jumpers, reconnect T P S
connector to sensor.
MAT SENSOR
Figure 3-64 P n IN STR U M EN T PANEL CLUSTER
m VEHICLE SPEED SENSOR
Remove or Disconnect H I VSS BUFFER
[ ~ 4 l ELECTRICAL CONNECTOR 6S2893-6E
2. Electrical connector releasing locking tab. Figure 3-65 - Vehicle Speed Sensor, Typical
3. M A T sensor. Except CK & P
E Install or Connect PARK/NEUTRAL SWITCH

1. M A T sensor.
The Park/Neutral switch is located on the steering
column.
Adjustment
E-CELL
1. Move the switch housing all the way toward "low
Refer to Figure 3-36 for replacement o f the E-Cell
gear position.
(elapsed timer module).
2. Move gear selector to "park position. The main
KNOCK SENSOR h o u s in g and h o u s in g back s h o u ld r a t c h e t ,
pi'oviding proper switch adjustment.
Refer to Section "7, "Electronic Spark Control.
for replacement of the knock sensor. <-- Remove or Disconnect
1. Mace gear selector in "neutral .
VEHICLE SPEED SENSOR 2. Electrical connectors.
Figure 3-65 3. Spread tangs on housing and pull switch.
Refer to Section 8C, in Service Manual, for
vehicle speeci sensor service, which is part o f the
speedometer and instrument cluster.
+- Install and Connect

1. A lign 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 " p a r k and sw itch is
adjusted.
5. Electrical connectors.
P H ELECTRICAL CONNECTOR
POWER STEERING PRESSURE SWITCH
|~ n OIL PRESSURE RELAY
Figure 3-66
1T1 A C RELAY
The switch is located in the inlet pipe of the power
steering gear.
[7 ] RELAY BRACKET
I 5 1 BULKHEAD CONNECTOR
f i l FUEL PUM P RELAY
Remove or Disconnect 6S 2885-6E
1. Electrical connector releasing locking tab. Figure 3-67 - A/C Clutch Control Relay - (S/T)
2. Power Steering Pressure switch.
A/C CONTROL
Install and Connect
Refer to Figure 3-67 and 3-68, for replacement of
1. Power Steering Pressure switch. the A/C clutch control relav on S/T Truck and M Van.
f T j A/C CLUTCH CONTROL RELAY 6S 2857-6E
Figure 3-68 - A/C Clutch Control R e la y -(M )
PARTS INFORMATION
PART NAME GROUP
PH OUTLET PIPE
HH POWER STEERING GEAR Controller, ECM .............................................3.670
l~3~1 INLET PIPE Calibrator. P R O M ...........................................3.670
CHI POWER STEERING PRESSURE SWITCH Sensor, Coolant T e m p .................................... .3.670
HE] ELECTRICAL CONNECTOR 6S2708-6E Sensor, Exhaust Oxygen ............................. .3.670
Sensor, M A P ....... .......................................... .3.670
Figure 3-66 - Pow er Steering Pressure Switch
Sensor, Throttle Position: Part of
Sensor Kit, Throttle Position......................... 3.440
Switch. Neu. St. & Backing L P .................... ..2.698
FUEL CONTROL 4-1
SECTION 4
FUEL CONTROL SYSTEM
TBI MODEL 220 - V6 OR V8 ENGINE
TBI MODEL 700-L4 ENGINE
CONTENTS
GENERAL DESCRIPTION .................................. ..4-2
Fuel Pressure Relief P ro c e d u re ............... 4-12
PURPOSE.......................................................... ..4-2
Fuel System Pressure T e s t......................... 4-12
MODES OF OPERATION ..................................4-2
Thread Locking C o m p o u n d ...................... 4-12
S tarting M o d e ..............................................4-2
M O D EL220AN D 700 TBI UNITS ....................4-15
Clear Flood M o d e .........................................4-2
C ontrolled Idle Speed C h e c k .................... 4-17
Run M o d e .....................................................4-2
M inim um Idle A ir Rate C heck....................4-17
Open L o o p .....................................................4-2
TBI 220 COMPONENT SERVICE FUEL
Closed L o o p ................................................ ..4-2
METER COVER ASSEMBLY-TBI 220 ____4-18
A cceleration M o d e .................................... ..4-3
FUEL INJECTOR ASSEMBLY-TBI 220 ____4-19
D eceleration M ode .................................. ..4-3
FUEL METER BODY ASSEMBLY -
Battery Correction M o d e ...........................4-3
TBI 2 20................................................................ 4-21
Fuel C u to ff M o d e .........................................4-3
FUEL CONTROL OPERATION ........................ ..4-3
(TPS)-TBI 220 ................................................. 4-21
MODEL 220 TBI U N I T .................................... ..4-3
IDLE AIR CONTROL (IAC) VALVE -
MODEL 700 TBI U N I T .................................... ..4-3
TBI 220 ............................................................... 4-22
Vacuum P orts........................... .................. ..4-4
THROTTLE BODY ASSEMBLY - TBI 220 ____4-23
Fuel In je c to r(s )..............................................4-4
TBI 700 COMPONENT SERVICE ................. 4-24
Pressure R e g u la to r.................................... ..4-4
FUEL INJECTOR ASSEMBLY-TBI 700 ____4-24
Idle A ir Control S yste m ............................. ..4-4
PRESSURE REGULATOR ASSEMBLY .......... 4-25
TPS (T h ro ttle Position Sensor) ...............4-6
FUEL METER ASSEM BLY................................ 4-26
FUEL PUMP CIRCUIT....................................... ..4-7
THROTTLE POSITION SENSOR...................... 4-26
FUEL FILTER..................................................... ..4-7
IDLE AIR CONTROL (IAC) V A L V E ................. 4-27
In-Line F ilte r......................................... ........4-7
TUBE MODULE ASSEM BLY........................... 4-28
In-Tank F ilt e r .............................................. ..4-7
THROTTLE BODY ASSEMBLY ...................... 4-28
FUEL AND VAPOR PIPES..................................4-7
FUEL PUMP........................................................ 4-29
FUEL T A N K ..........................................................4-7
FUEL PUMP R E LA Y .......................................... 4-29
Filler N e c k ................................................... ..4-7
FUEL M O D U L E ................................................. 4-31
Fuel Filler Cap ..............................................4-7
OIL PRESSURE S W IT C H .................................. 4-31
ACCELERATOR CO NTRO L............................. ..4-8
FUEL FILTER...................................................... 4-32
EVAPORATIVE EMISSION C O N T R O L.......... 4-8
In -Line Filter R e p la ce m e n t...................... 4-32
DIAGNOSIS ..........................................................4-8
In-Tank filte r R e p la ce m e n t...................... 4-32
FUEL CONTROL .............................................. ..4-8
AUXILIARY FUEL TANK C O N T R O L ............ 4-34
Fuel In je c to rs .............................................. ..4-8
Selector Valve and M e te r Switch .......... 4-34
Pressure R egulator .................................. ..4-8
FUEL HOSE AND PIPE ASSEMBLIES............... 4-34
Idle A ir C ontrol ......................................... ..4-8
M a te r ia l........................................................ 4-34
T h ro ttle Position Sensor (TPS) ...............4-9
Fuel Line R e p a ir.......................................... 4-34
D riv e a b iltiy S y m p to m s ............................. ..4-9
FUEL T A N K ........................................................ 4-35
FUEL PUMP CIRCUIT.........................................4-9
D raining ...................................................... 4-35
Fuel Pump R ela y......................................... .. 4-9
R e p la c e m e n t............................................... 4-35
Oil Pressure S w itc h .................................... .. 4-9
P u r g in g ........................................................ 4-35
Fuel M od u le .............................................. .. 4-9
FUEL SYSTEM CLEANING................................ 4-37
Fuel F ilte r ..................................................... .. 4-9
In-Line Fuel F ilt e r ............... s2 ..................... 4-40
Fuel Pipes and Hoses .................................. 4-9
Leak T e s t...................................................... 4-40
Fuel T a n k ..................................................... .. 4-9
ACCELERATOR CO NTRO L.............................. 4-40
ACCELERATOR CONTROL ............................. 4-9
A ccelerator Control C a b le .........................4-40
EVAPORATIVE EMISSION CONTROL ____4-9
A ccelerator Pedal ..................................... 4-41
ON-VEHICLE SERVICE .................................... .. 4-12
PARTS INFORMATION ..................................... 4-43
GENERALSERVICE M A N U A L ........................ .. 4-12
SPECIFICATIONS .............................................. 4-44
4-2 FUEL CONTROL
GENERAL DESCRIPTION
(M A P ) sensor, and crank signal, then determines the
proper air/fuel ratio for starting. This ranges from
PURPOSE
1:5:1 at -36C (-33F) to 14.7:1, at 94C (2 0 1 F )
running temperature.
T h e fuel control system is co n trolle d by an The ECM controls the amount o f fuel delivered in
ele c tr o n ic control m odule (E C M ) located in the the starting mode by changing how long the injector is
passenger compartment. The ECM is the control turned " O N and "OFF1 . This is done by "pulsing the
center o f the Computer Command Control system injector for very short times.
found in Section " 3 which p rovides a d d it io n a l
information about fuel control and deliver.
Clear Flood Mode
The basic function of the fuel control system is to
control fuel delivery to the engine. Fuel is delivered to
I f the engin e floods, c le a r it by pushing the
the engine by a throttle body injection (TB I) unit.
The main control sensor is the oxygen (O2) sensor, accelerator pedal down all the way. The ECM then
which is located in the exhaust manifold. The O 2 pulses the injector at a 20:1 air/fuel ratio, and holds
sensor tells the ECM the amount o f oxygen in the this injector rate as long as the throttle stays wide
exhaust gas, and the ECM changes the air/fuel ratio to open, and the engine is below 600 rpm. If the throttle
the engine by controlling the fuel injector. A 14.7:1 position becomes less than 80%, the ECM returns to
air/fuel ratio is re q u ir e d for e f fic ie n t c a t a l y t i c the Starting mode.
converter operation. Because the constant measuring
and adjusting of the air/fuel ratio, the fuel injection Run Mode
system is called a "Closed Loop system (Figure 4-1).
The Run mode has two conditions called 'Open
MODES OF OPERATION Loop and "Closed Loop .
The ECM monitors voltages from several sensors Open Loop

to determine how much fuel to give the engine. The
fuel is delivered under one o f several conditions called When the engine is first stared, and it is above 400
"modes . A ll the modes are controlled by the ECM. rpm, the system goes into "Open Loop operation. In
"Open Loop , the ECM ignores the signal from the O2
Starting Mode sensor, and calculates the air/fuel ratio based on
inputs from the coolant t e m p e r a t u r e and M A P
sensors.
When the key is first turned " O N , the ECM turns
The system stays in "O p en L o o p u n til the
on the fuel pump relay for two seconds, and the fuel
following conditions are met:
pump builds up pressure to the TB I unit. The ECM
1. Th e 0> sensor has v a r y i n g v o l t a g e o u tp u t,
checks the coolan t te m p e r a t u r e sensor, th r o ttle
showing that it is hot enough to operate properly.
position sensor (TPS), manifold absolute pressure
(This depends on temperature. )
2. Th e coolan t t e m p e ra tu r e s e n s o r is a b o v e a
INJECTORS specified temperature.
3. A specific am ount o f tim e has elapsed a ft e r
FU EL 81 AIR ' starting the engine.
%- The 7.4L engine is designed to operate "Open
ENGINE Loop at idle. The system will go to "Closed Loop
%-
COMBUSTION when the rpm is increased and all conditions above are
FU EL M IXTU RE
% COMMAND met.
EX H A U ST GAS.
Closed Loop
OXYGEN SENSOR
O X Y G E N SENSOR The specific values for the above conditions vary
V O L T A G E IN FO RM ATIO N
w ith d i f f e r e n t e n g in e s , and a re s t o r e d in the
OTHER programmable read only memory (P R O M ). When
SENSOR ELECTRONIC 14.7-1 COMMAND
INPUT these conditions are met, the sy s te m s goes into
CONTROL "CLOSED LOOP"
INFORMATION MODULE "Closed Loop operation. In "Closed Loop , the ECM
8P0361-SYE calculates the air/fuel ratio (injector on-time) based on
the signal from the Oo sensor. This allows the air/fuel
Figure 4-1 - "Closed Loop" TBI System
ratio to stay very close to 14.7:1.
FUEL CONTROL 4-3
Acceleration Mode
The EC M looks at rapid changes in th r o ttle

position and manifold pressure, and provides extra
fuel.
Deceleration Mode
When deceleration occurs, the fuel remaining in

the intake manifold can cause excessive emissions and
backfiring. A ga in , the ECM looks at changes in r n -FUEL PUMP AND
throttle position and manifold pressure and reduces ----SENDING UNIT
the amount of fuel. When deceleration is very fast, the I 2 | FUEL SUPPLY LINE
ECM can cut off fuel completely for short periods. I T ] FUEL FILTER
m TBI UNIT
Battery Voltage Correction Mode dH FUEL RETURN LINE
4S0055-6E
W hen b a t te ry v o lta g e is low, the E C M can Figure 4-2 - Fuel Control System
com pensate for a w eak spark d e l i v e r e d by the
A pressure r e g u la t o r in the T B I keeps fu e l
distributor by:
ava ilab le to the injectors at a co nstan t pressu re
Increasing injector on time o f fuel delivered
between 62 and 90 kpa (9 and 13 psi). Fuel in excess o f
Increasing the idle rpm
injector needs is returned to the fuel tank by a
Increasing ignition dwell time
separate line.
The ECM controls the injectors that are located in
Fuel Cutoff Mode
the fuel meter body assembly o f the TBI. The injectors
deliver fuel in one of several modes, described above.
No fuel is delivered by the injectors when the
In order to properly control the fuel supply, the
ignition is " O F F . This prevents dieseling. Also, fuel
fuel pump is operated by the ECM through the fuel
is not delivered i f no reference pulses are seen from
pump relay and oil pressure switch (see "Fuel Pump
the d is trib u to r, which means the e n gin e is not
Electrical Circuit ).
running. Fuel cutoff also occurs at high engine rpm,
to protect internal engine components from damage.
MODEL 220 TBI UNIT
FUEL CONTROL Model 220, used on V6 and V8 engines (Figure 4-

OPERATION 3), consists of three major casting assemblies:
Fuel meter cover with:
Pressure regulator
The fuel control system (Figure 4-2) consists of the Fuel injectors
following components: Throttle body with:
Throttle body injection (TB I) unit Idle air control ( IAC ) valve
Fuel pump Throttle position sensor (TP S)
Fuel pump relay
Fuel tank MODEL 700 TBI UNIT
Accelerator control
Fuel lines Model 700, used on the L4 engine (Figure 4-4), is
Fuel filters made up of two major casting assemblies:
Evaporative emission control system Fuel meter assembly with:
The fuel control system has an electric fuel pump, Pressure regulator
located in the fuel tank with the gage sending unit, Fuel injector
which pumps fuel to the TB I through the fuel supply Throttle body with:
line, then through and in-line fuel filter the pump is Idle air control (IA C )
designed to provide pressurized fuel at about 125 kPa Throttle position sensor (TP S)
(18 psi). On vehicles with two fuel tanks, there is
anelectric fuel pump and gage sending unit in each
fuel tank.
4-4 FUEL CONTROL
The fuel which is not used by the injectors passes

through the pressure regulator before being returned
to the fuel tank.
Pressure Regulator
The pressure regulator (see Figure 4-5 and 4-6) is

13 h S a d ia ph ra g m -opera ted r e l i e f v a lv e w ith in je c to r
pressure on one side and air cleaner pressure on the
[T~| FUEL INJECTORS other. The function of the regulator is to maintain a
constant pressure at the injectors at all times, by
|~~2~] THROTTLE BODY ASSEMBLY
controlling the flow in the return line (by means o f a
[~3~| THROTTLE POSITION SENSOR (TPS) calibrated bypass).
f T l IDLE AIR CONTROL (IAC) VALVE ASSEMBLY The pressure regu lator on a T B I 220 unit is
[~5~| FUEL METER BODY ASSEMBLY serviced as part o f the fuel meter cover and should not
be disassembled.
[~6~1 FUEL METER COVER ASSEMBLY 8P Q922-AS
The pressure regu lator on a T B I 700 u nit is
Figure 4-3 - Model 220 TBI Unit serviced as part of the fuel meter assembly and can be
disassembled.
Vacuum Ports
Idle Air Control System
The throttle body portion of both TBI units may
All engine idle speeds are controlled by the EC M
contain ports located above, or below the throttle
through the idle air control (IA C ) valve mounted on
valve. These ports generate the vacuum signals for
the throttle body (Figures 4-7 or 4-8). The ECM sends
the exhaust gas recirculation (E G R ) v a lve , M A P
voltage pulses to the IAC motor windings causing the
sensor, and the canister purger purge system.
IAC motor shaft and pintle to move " I N or " O U T a
given distance (number of steps) for each pulse, (called
Fuel Injector(s)
counts).
Th e fuel injectors ( f i g u r e 4-5 and 4-6) a re

solenoid-operated device, controlled by the ECM. The
ECM turns on the solenoid, which lifts a norm ally
closed ball valve off a seat. Fuel, under pressure, is
injected in a conical spray pattern at the walls of the
throttle bodv bore above the throttle valve.
| PRESSURE REGULATOR
|FUEL INJECTOR
| FUEL INJECTOR INLET FILTER
m FUEL METER ASSEM BLY

| THROTTLE BODY ASSEMBLY
j FUEL FROM PUMP
[T 1 PRESSURE REGULATOR COVER ASSEMBLY
j INJECTOR ELECTRICAL TERMINALS
|~3~| FUEL INJECTOR ASSEM BLY
j CONSTANT BLEED - (SOME MODELS)
|~4~| THROTTLE POSITION SENSOR (TPS)
j PRESSURE REGULATOR DIAPHRAGM ASSEMBLY
[in THROTTLE BODY ASSEM BLY
] PRESSURE REGULATOR SPRING
[T | TUBE MODULE ASSEM BLY
j FUEL RETURN TO TANK
I 7 [ IDLE AIR CONTROL (IAC) VALVE 8S 4698-6E THROTTLE VALVE
Figure 4-4 - M odel 700 TBI Unit
8P 0320-SY
Figure 4-5 - TBI 220 U n it O peration

FUEL CONTROL 4-5
[ 7 ] FUEL METER COVER & BODY ASSEM BLIES

[T~lFUEL INJECTOR [ a ] FUEL INLET
[~2~1 FUEL METER ASSEMBLY [ T ] FUEL OUTLET I T l THROTTLE BODY ASSEMBLY
[~3~1 PURGE FILTER [ T 1 IDLE AIR CONTROL VALVE ASSEMBLY

[~4~1 INLET FILTER [~A~| FILTERED AIR INLET
[~5~1 THROTTLE BODY ASSEMBLY |~j~| PINTLE
f i l PRESSURE REGULATOR COVER ASSEMBLY f c l THROTTLE VALVE
|T1PRESSURE REGULATOR SPRING [~D~| VACUUM PORTS - FOR ENGINE OR EMISSION
[~8~] PRESSURE REGULATOR DIAPHRAGM CONTROLS
ASSEMBLY 8P0330-SY 8P 0319-SY
Figure 4-6 - TBI 700 Unit Operation Figure 4-7 - Idle Air Control System (TBI 220 Unit)
This movement controls airflow around the throttle

plate, which in turn, controls engine idle speed, either
cold or hot. IAC valve pintle position counts can be
seen using a "Scan tool. 0 counts corresponds to fully
closed passage, while 140 counts or more (depending
on the application) corresponds to full flow.
Actual or "controlled idle speed is obtained by the L CD
ECM positioning the IA C valve pintle. Resulting
idle speed is generated from the total idle air How
(IAC/passage + P C V + throttle valve + vacuum
leaks).
Controlled idle speed is a lw a y s specified for
normal operating conditions. Normal operating
condition is coolant tem perature in o p e r a tin g
range, the A/C is " O F F , manual transmission is
in neutral or automatic transmission in drive with
proper Park/Neutral switch adjustment. A high or
|~T| FUEL METER ASSEMBLY
low coolant temperature, or A/C clutch engaged
[ T ] THROTTLE BODY ASSEMBLY |~E~1 ELECTRICAL
may signal the ECM to change the IAC counts.
INPUT SIGNAL
The minimum idle air rate is set at the factory [~3~| IDLE AIR CONTROL VALVE
with a stop screw to permit enough air flow by the 1~~A~~1 FILTERED AIR INLET
throttle valves to cause the IAC valve pintle to be f i l PINTLE
positioned a calibrated number of steps (counts) [ C l VACUUM PORTS FOR ENGINE
from the seat d u r in g norm a l c o n trolle d idle OR EMISSION CONTROLS
operation at sea level or low altitude on an engine [ d ] THROTTLE VALVE
with more than 500 miles. The IAC counts will be 8P 0318-SY
higher on an engine with less than 500 miles,
an engine operating at high altitude or an engine Figure 4-8 - Idle A ir Control SYstem (TBI 700 U nit)
with an accessory load such as the alternator. A/C,
power steering or hvdra-boost brakes activated.
4-6 FUEL CONTROL
Throttle Position Sensor (TPS)

As the throttle valve rotates in response to
The throttle position sensor (TPS), is mounted on movement o f the accelerator pedal, the throttle shaft
the side of the throttle body opposite the throttle lever transfers this rotation m ovem ent to the T P S . A
assembly. Its Function is to sense the current throttle potentiometer (variab le res istor) w ith in the T P S
valve position and relay that information to the ECM assembly changes its resistance (and voltage drop) in
(see F ig u r e 4-11 and 4-12). T h r o t t l e p o s itio n proportion to throttle movement.
information allows the ECM to generate the required By applying a reference voltage (5.0 volts) to the
injector control signals (base pulse). T P S input, a va ry in g voltage (r e f le c t in g t h r o tt le
If the T P S senses a wide open throttle, a voltage position) is available at the T P S output. For example,
signal indicating this condition is sent to the ECM. approximately 2.5 volts results from a 50% throttle
The ECM then increases the injector base pulse width, valve opening (depending on T P S calibration). The
permitting increased fuel flow. voltage output from the T P S assembly is routed to the
ECM for use in determining throttle position.
[ 7 ] TERMINAL PINS
IT]BALL BEARING ASSEMBLJT [T]THROTTLE VALVE
l~2~l ENGINE CONTROL MODULE (ECM)
m STATOR ASSEMBLY
[ T ] THROTTLE POSITION
[ T ] ROTOR ASSEMBLY SENSOR (TPS)
[ 5] SPRING
f6~ l PINTLE
[ T ] lead sc r ew
8P 0933-AS
8P0321 -SY
Figure 4-9 - Idle Air Control (IAC) Valve (TBI 220)
Figure 4-11 - Throttle Position Sensor (TBI 220)
[T]TERMINAL PINS
[ T 1 BALL BEARING ASSEMBLY
m STATOR ASSEMBLY
[TJROTOR ASSEMBLY
| T ] SPRING
f~6~l PINTLE
ECM
[ T ] GRIME SHIELD
[~5~1 LEAD SCREW
m THROTTLE BODY
|~2~1 THROTTLE POSITION SENSOR (TPS)

8P 0907-AS | T | THROTTLE VALVE 8p031
Figure 4-10 - Idle Air Control (IAC) Valve (TBI 700)
Figure 4-12 - Throttle Position Sensor (TBI 700)
FUEL CONTROL 4-7
FUEL PUMP CIRCUIT before servicing fuel system

c omponents . (See " F u e l S y s t e m
Pre ss ure Relief P r o c e d u r e . )
The fuel pump is a turbine type, low pressure
electric pump, mounted in the fuel tank. Fuel is
pumped at a positive pressure (above 62 kPa or 9 psi) The inline filter is located in the fuel feed line. It
from the fuel pump through the in-line filter to the prevents dirt from entering the TB I unit.
pressure regulator in the TB I unit (see Figure 4-13).
Excess fuel is returned to the fuel tank through the In-Tank Filter
fuel return line.
The fuel pump is attached to the fuel gage sender A woven plastic filter is located on the lower end of
assembly. A fuel strainer is attached to the fuel pump the fuel pickup tube in the fuel tank. Th e filt e r
inlet line and prevents dirt particles from entering the prevents dirt from entering the fuel line and, also,
fuel line and tends to separate water from the fuel. stops water, unless the filt e r becomes c o m p letely
On vehicles with two fuel tanks, there is an submerged in water. This filter is self-cleaning and
electric fuel pump and gage sending unit in each tank. normally requires no maintenance. Fuel stoppage, at
Vapor lock problems are reduced when using an this point, indicates that the fuel tank contains an
electric pump because the fuel is pushed from the tank abnormal amount o f sediment or water; the tank
under pressure rath e r than b e in g pulled under should, therefore, be thoroughly cleaned.
vacuum, a condition that produces vapor.
When the key is first turned " O N without the
FUEL AND VAPOR PIPES
engine running, the ECM turns a fuel pump relay
" O N for two seconds. This builds up the fuel pressure
The Fuel feed and return pipes and hoses extended
quickly. I f the engine is not started w ith in two
from the fuel pump and sender to the TB I unit. They
seconds, the ECM shuts the fuel pump " O F F and
are secured with clamps and are routed a long the
waits until the engine starts. As soon as the engine is
frame side member.
cranked, the ECM turns the relay " O N and runs the
The vapor pipe and hoses extend from fuel pump
fuel pump.
and sender unit to the evaporative emission control
On the 5.7L engine in the G van and all other 5.7L
vapor canister.
or 7.4L engines in vehicles over 8500 G V W , a fuel
module will override the ECM and the fuel pump will
run for approxim ately tw en ty seconds. T h e fuel FUEL TANK
module corrects a hot restart (vapor lock) during a
high ambient condition. The fuel tank, at the rear of the underbody, is held
When the engine is cra nkin g or running, the in place by two metal straps. Anti-squeak pieces are
ECM receives distributor reference pulses which in used on top of the tank to reduce rattles.
turn energize the fuel injectors.
As a backup system to the fuel pump relay, the Filler Neck
fuel pump can also be turned on bv an oil pressure
switch. When the engine oil pressure reaches about To help prevent refueling with leaded gasoline,
28 kPa (4psi), through cranking and the fuel pump the fuel filler neck on a gasoline engine vehicle has a
relay does not complete the circuit, the oil pressure built-in restrictor and deflector. The opening in the
switch w ill close to complete the circuit to run the fuel restrictor will only admit the smaller unleaded gas
pump. nozzle spout, which must be fully inserted to bypass
An inoperative fuel pump relay can result in long the deflector. Attempted refueling with a leaded gas
cranking times, particularly i f the engine is cold. The nozzle, or fa ilu re to fu lly insert the unleaded gas
oil pressure switch will turn on the fuel pump as soon nozzle, will result in gasoline splashing back out o f the
as oil pressure reaches about 28 kPa (4 psi). filler neck.
FUEL FILTER Fuel Filler Cap
The fuel tank filler neck is equipeed with a screw-

In-line Filter
tvpe cap. The threaded part o f the cap r e q u ir e s
several turns counterclockwise to remove. The long
CAUTION: T o r e d u c e the ris k o f f i re a n d
threaded area was designed to allow any rem aining
personal injury, it is necessary to
fuel tank pressure to escap, while the cap was being
a ll ow fuel pressure to bleed off
4-8 FUEL CONTROL
Figure 4-13 TBI Fuel Supply System (Typical)
removed. A built-in torque-limiting device prevents Fuel Injectors

overtightening. To install, turn the cap clockwise
until a clicking noise is hear. This signals that the Testing the fuel injector circuit is in C H A R T A-3
correct torque has been reached and the cap is fully and additional diagnosis in C H A R T A-4 in Section
seated. "3 .
A fuel injector which does not open may cause a
ACCELERATOR CONTROL no-start condition. An injector which is stuck partly
open, could cause loss of pressure after sitting, so long
The accelerator control system is a control cable crank times would be noticed on some engines. Also,
type, attached to a accelerator pedal assembly. dieseling could occur because some fuel could be
delivered to the engine after the key is turned " O F F .
EVAPORATIVE EMISSION CONTROL
Pressure Regulator
The system transfers fuel vapors from the fuel
tank into a vapor canister and then vapors are purged T e s t i n g the pressure r e g u la t o r c ir c u it is in
into the intake manifold air flow and consumed in C H A R T A-3 and A-4, in Section "3 .
combustion. Refer to Section " 5 , for a d d itio n a l I f the pressure regu lator in the T B I su pplies
information, diagnosis, and on-vehicle service. pressure which is too low (below 62 kPa or 9 psi), poor
performance could result. I f the pressure is too high,
DIAGNOSIS excess emissions and unpleasant exhaust odor may
result.
FUEL CONTROL
Idle Air Control
The diagnosis of fuel control and the TB I unit is in
Section "3 , because the Computer Command Control The diagnosis o f idle air control can be found in
system controls fuel delivery. This system has a built Code 35, Section "3 , for the 2.5L engine and in this
in diagnostic system in the ECM to indicate a failed section for all other engines.
circuit. This section will explain the system check and If the IA C valve is disconnected or connected with
the codes related to fuel control. the engine running, the idle rpm may be wrong. In
The fuel control can be the reason that the engine this case, on engines with T B I 220 units, the IA C
cranks, but will not run and the diagnosis is, also, in valve may be reset by turning the ig n ition switch
Section "3 . I f diagnosis indicates that the engine will " O N for ten seconds and then " O F F . On engines
not run because there is a fuel delivery problem, the using a T B I 700 unit, the idle rpm is reset at a speed
diagnosis o f the fuel system is, also, included in above 30 mph (48 km/hr).
Section "3 . The IAC valve affects only the idle characteristics
of the engine. If it is open fully, too much air will be
allowed to the manifold and idle speed will be high.
FUEL CONTROL 4-9
I f it is stuck closed, too little air will ?e allowed in Oil Pressure Switch
the manifold, and idle speed will be too low. I f it is
stuck part way open, the idle may be rough, and will Refer to fuel pump relay circuit check in Section
not respond to engine load changes. "3 , for oil pressure switch diagnosis.
The minimum air rate is set at the factory with a
stop screw. The stop screw should not be adjusted Fuel Module
unless a replacement throttle body assembly (that has
not been preset at the factory) is installed or the Refer to the diagnosis section in Section "3 fo r
minimum air rate does not meet specifications. fuel module check.
An incorrect readjustment with a high minimum
air rate will cause the IAC valve pintle to constantly Fuel Filter
bottom on its seat and may result in early IAC valve
failure. A minimum air rate that is too low may result The diagnosis o f the fuel f i l t e r is c o v e r e d in
in a no-start condition in cold weather, a stall after Section "3 , as part of the fuel system diagnosis.
start or a stall during deceleration, because o f poor A plugged fuel filter may cause a restricted fuel
air/fuel d is tr ib u tio n through the t h r o t t l e bore. delivery, or a no start condition.
Throttle valve sticking may also occur.
Vacuum leaks will cause the IA C valve pintle to Fuel Pipes and Hoses
be "stopped closer to the seat or to be closed against
its seat in an attempt to maintain controlled idle The diagnosis o f gasoline odor may be a condition
speed. of a leaking fuel feed, or return pipe or hose. Fuel
pipes that are pinched, plugged, or mis-routed m ay
Throttle Position Sensor (TPS) cause restricted fuel delivery.
Refer to Section "3 for diagnosis o f the throttle Fuel Tank

position sensor.
The diagnosis of gasoline odor may be a condition
Driveability Symptoms of leaking fuel tank, filler neck, or filler cap.
A defective filler cap, a plugged or pinched vapor
Refer to Section "2 , for additional fuel control pipe can cause a collapsed fuel tank.
diagnosis. Loose mounting straps, or fo re ig n m ateria l in
tank, may be the cause o f a rattle at the fuel tank.
FUEL PUMP CIRCUIT
ACCELERATOR CONTROL
Refer to system diagnosis in Section "3 , for fuel
pump diagnosis. Check for correct cable routing, or binding, and
An inoperative fuel pump would cause a no start correct as necessary.
condition. A fuel pump which does not provide enough
pressure can result in poor performance. (See "Fuel EVAPORATIVE EMISSION CONTROL
System Pressure Test procedure).
R e f e r to S e c t io n " 5 , fo r d i a g n o s i s o f t h e
Fuel Pump Relay Evaporative Emission Control System.
Refer to fuel pump relay circuit check in Section

"3 , for fuel pump relay diagnosis.
An inoperative fuel pump relay can result in long
cranking times, particularly if the engine is cold. The
oil pressure switch will turn on the fuel pump as soon
as oil pressure reaches about 28 kPa (4psi)
4-10 FUEL CONTROL
IDLE AIR CONTROL CHECK

The ECM sends voltage pulses to the IAC motor winding causing the motor shaft and valve to 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: I f IAC valve pintle position counts are high, look
Numbers below refer to circled numbers on the for carbon build-up in the IA C va lve air inlet
diagnostic chart. passage or evidence of tampering with stop screw.
"Scan" tool must be in open mode during test. Also check for low engine power or ex ces siv e
Keep A/C "O F F " during entire check. accessory loads.
1. Test with engine in drive and continue with test, System too lean (high tailpipe air/fuel ratio) -
even if idle is erratic. If idle is too low, "Scan will E n g in e speed m ay v a r y up and d o w n a nd
display 80, or more, counts or steps. Engine speed disconnecting the IA C may not stabilize en gin e
may va r y 200 rpm, or more, up and down. speed. If "Scan" and/or Voltmeter reads an oxygen
Disconnect IAC. If the condition is unchanged, the sensor output less than 300 mv (.3v), check for low
IAC is not at fault. There is a system problem. regulated fuel pressure or water in fuel. A code 44
Proceed to step "3 below. (lean O2 sensor) may be set. A lean t a ilp ip e
2. W h en the e n gin e was stopped w ith ig n itio n exhaust with an oxygen sensor output fixed above
"O F F ", the IAC valve retracted (more air) to a 800 mv (,8v) could be a contaminated sensor,
fixed " P a r k position, for increased air flow and usually Silicon. This may set a Code 45 (rich O2
idle speed during the next engine start. A "Scan sensor) even with lean tailpipe exhaust.
will display 100 or more counts. System too rich (low tailpipe air/fuel r a t io ) -
3. Be sure to disconnect the IA C valve prior to this System obviously rich and may e x h ib it black
test. The test light will confirm the ECM signals smoke exhaust. "Scan tool and/or Voltm eter will
by a steady or flashing light, on all circuits. read an oxygen sensor signal fixed above 800mv
4. Th ere is a remote possibility that one o f the (.8v).
circuits is shorted to voltage, which would have Check for:
been indicated by a steady light. Disconnect ECM Injector leaking or sticking
and turn the ignition " O N and probe terminals to High fuel pressure
check for this condition. A ir leak in M A P transducer line
If O2 is normal or low, inspect for air being
Diagnostic Aids: pumped into exhaust manifold in front of O2
sensor (or exhaust leak)
An unstable idle may be a system problem that Throttle body - Remove IAC and inspect bore for
cannot be overcome by the IAC. "Scan counts will be fo re ig n m a t e r i a l or e v i d e n c e o f I A C v a l v e
above 80 counts, if too low, and 0 counts, if too high. dragging the bore. (Repair as required)
A/C C om pressor or r e la y f a i l u r e - See A/C
If IAC valve pintle position counts are low or zero, diagnosis if circuit is shorted to ground. I f the
check with vacuum leaks at vacuum fitting, tees relay is faulty, idle problem may exist.
and hoses, the t h r o tt le body and the in take R e fe r to Rough, U n stab le, In c o rr e c t Id le or
manifold. A bottomed (zero count) IAC valve Stalling, in Section 2.
p in t le m ay r e s u lt in an id le sp ee d a b o v e
specification. Refer to minimum air rate check
FUEL CONTROL 4-11
"SCAN" TOOL MUST BE IN OPEN

MODE DURING THIS CHECK.
IDLE AIR CONTROL (IAC)
SYSTEM CHECK
o A/C "OFF" DURING ENTIRE CHECK. ALL ENGINES EXCEPT 2.5L
ENGINE AT NORMAL OPERATING
TEMPERATURE AND TRANSMISSION IN DRIVE
(A/T) OR NEUTRAL (M/T).
RECORD ENGINE SPEED. IF IDLE IS ERRATIC OR
UNSTABLE, REFER TO FACING PAGE.


IN FIRST STEP.
IDLE ENGINE FOR 1 MINUTE IN
DRIVE (A/T) OR NEUTRAL (M/T).
NOTE ENGINE SPEED.

RECORDED IN FIRST STEP. 1
REFER TO "DIAGNOSTIC AIDS"
IGNITION "OFF".
ON FACING PAGE.
IGNITION " O N " , ENGINE STOPPED.
GROUND DIAGNOSTIC TEST TERM INAL
I
NO LIGHTS, ONE OR
MORE CIRCUITS.
LIGHT STEADY
OR FLASHING ALL
I CIRCUITS
CHECK FOR OPEN OR SHORT TO

VALVE, OR PLUGGED
PASSAGE. IF LIGHT
REFER TO TEST, STEP 4
CHECK RESISTANCE ACROSS IAC COILS. SHOULD BE REPAIR WIRING AND ON FACING PAGE.
MORE THAN 20 OHMS BETWEEN IAC TERMINALS RECHECK.
OPPOSITE HARNESS CONNECTOR TERMINALS "A " TO
"B" AND "C" TO "D ".
Z L
OK
NOT OK
FAULTY ECM
CONNECTION OR ECM.
IDLE NOT OK
REPLACE ECM
CLEAR CODES, CONFIRM "CLOSED LOOP" OPERATION, NO "SERVICE ENGINE SOON' 7-23-87
LIGHT, AND VERIFY CONTROLLED IDLE SPEED IS CORRECT. 8S4652-6E
4-12 FUEL CONTROL
ON-VEHICLE SERVICE Refer to the disassembled views (Figure 4-14 and

4-15) for i d e n t ific a t io n o f p a r ts d u r in g r e p a i r
GENERAL SERVICE MANUAL procedures. Service repair of individual components is
performed without removing the TB I unit from the
CAUTION: engine. If removed, it is essential that care is taken to
prevent dam age to the t h r o ttle v a lv e or s e a lin g
To prevent personal injury or da ma ge to the surface while performing any service.
vehicle as the result o f an accidental start, Whenever service is performed on a TB I or any of
d i s c o n n e c t a n d r e c o n n e c t the n e g a t i v e its components, first remove the air cleaner, adapter
battery c a b l e b e f o r e a n d a ft e r se rv ic e is (if applicable), and air cleaner gaskets. Discard the
p e r f o r m e d ( e x c e p t f o r those tests w h e r e gaskets and replace them w ith new ones be fore
battery voltage is required). replacing the air cleaner after service is complete.
To minimize the risk o f fire, a nd per sona l When disconnecting the fuel lines, be sure to use a
in ju ry , r e lie v e the f u el s y s t e m ( w h e r e backup w re n c h (J - 2 9 6 9 8 - A , o r B T 8 2 5 1 - A , or
applicable) before servicing the fuel system. equivalent) to keep the TB I nuts from turning.
( S e e " F u e l P r e s s u r e R e l i e f P r o c e d u r e , '
below.) Fuel Pressure Relief Procedure
Also, catch a ny f uel that l e a k s out w h e n
disconnecting the fuel lines by covering the The TB I Model 200 for V6 and V8 engines contains a
fittings with a shop cloth. Place the cloth in constant bleed feature in the pressure regulator that
a n a p p r o v e d c o n t a i n e r w h e n w o r k is relieves pressure. Therefore, no special pressure relie f
complete. procedure is required.
However, on L4 engines, the TBI Model 700 does
The following is general information required when not con ta in a constant bleed fe a tu re to r e l i e v e
working on the fuel system: pressure. Therefore, the procedures listed below for
A l w a y s keep a dry ch em ica l (C la s s B) fir e relieving fuel pressure are required.
extinguisher near the work area. 1. Place transmission selector in Park (Neutral on
Fuel pipe f it t in g s req u ir e new o-rin g s when manual transmissions), set parking brake, and
assembling. block drive wheels.
A ll fuel pipe must meet the GM Specification 124- 2. Disconnect three terminal electrical connector at
M, or its equivalent. fuel tank.
A ll fuel hose must meet GM Specification 6163-M 3. Start engine and allow to run a few seconds until
or its equivalent. it stops from lack of fuel.
Do not replace fuel pipe with fuel hose. 4. Engage starter for three seconds to dissipate fuel
A lways a llow fuel pressure to bleed o ff before pressure in lines. Fuel connections are now safe
servicing any fuel system components. for servicing.
Do not do any repairs on the fuel system until you 5. After service, reconnect connector at fuel tank.
ha ve read the instru ctions and checked the
pictures relating to that repair. Fuel System Pressure test
Observe all Notices and Cautions.
A fuel system pressure test is part of several o f the
A ll gasoline engines are designed to use only Diagnostic Charts and Symptom checks. To perform
unleaded gasoline to maintain proper emission control this test, follow this procedure:
system operation. Its use will also minimize spark
plug fouling and extend engine oil life. Using leaded 1. Turn engine " O F F to relieve fuel pressure.
gasoline can damage the emission control system and 2. Plug T H E R M AC vacuum port if required on TBI.
could result in loss o f emission warranty coverage. 3. Uncouple fuel supply fle x ib le hose in e n gin e
All vehicles covered in the manual are equipped com partm ent. Insta ll fuel pressu re g a g e J-
with and evaporative emission system. The purpose of 29658A/BT8205 and adapter J-2968A-85 between
the system is to minimize the escape of fuel vapors to steel line and flexible hose.
the atmosphere. Information on this system will be 4. Tighten gage in line to ensure no leaks occur
found in Section "5 . during testing.
The TB I unit repair procedures cover component 5. Start engine and observe fuel pressure reading. It
replacement with the unit on the vehicle. However, should be 62-90 kPa (9-13 psi). If not, refer to
throttle body replacement requires that the complete C H A R T A-6 in Section "3 diagnosis.
unit be removed from the engine. 6. Relieve fuel pressure.
FUEL CONTROL 4-13
M o d e l 700 TBI
1 Gasket Air Cleaner

2 O-Ring Fuel Line Inlet Nut
3 O-Ring Fuel Line Outlet Nut
4 Gasket Flange
5 Fuel Meter Assembly
6 Screw & Washer Assembly
Fuel Meter Body Attaching
7 Gasket Fuel Meter Body to
Throttle Body
8 Screw Injector Retainer
9 Retainer Injector
10 Fuel Injector
11 O-Ring Fuel Injector
Upper
12 O-Ring Fuel Injector
Lower
13 Pressure Regulator Cover
Assembly
14 Screw Pressure Regulator
Attaching
15 Seat Spring
16 Spring Pressure Regulator
17 Pressure Regulator Diaphragm
Assembly
18 Nut Fuel Inlet
19 Seal Fuel Nut
20 Nut Fuel Outlet
21 Throttle Body Assembly
22 Plug Idle Stop Screw
Idle Stop
24 Spring Idle Stop Screw
25 Sensor Throttle Position
(TPS)
TPS Attaching
27 Idle Air Control Valve (IACV)
28 Screw IACV Attaching
29 O-Ring IACV
30 Tube Module Assembly
31 Screw Assembly
Tube Module Assy.
32 Gasket Tube M odule Assy.
7S 3656-6E
Figure 4 -1 4 - M odel 700 TBI Parts Id entification (L-4 Engine)

4-14 FUEL CONTROL
Model 220 TBI
1 Screw Assembly Fuel Meter

Cover Attaching Long
Cover Attaching Short
3 Fuel Meter Cover Assembly
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
10 O-ring Fuel Injector
Lower
11 O-ring Fuel Injector
Upper
12 Washer Fuel Injector
Body Throttle Body
Attaching
14 Fuel Meter Body Assembly
15 Gasket Throttle Body to
Fuel Meter Body
16 Gasket Air Cleaner
17 O-Ring Fuel Return Line
18 Nut Fuel Outlet
19 O-Ring Fuel Inlet Line
20 Nut Fuel Inlet
21 Gasket Fuel Outlet Nut
22 Gasket Fuel Inlet Nut
23 Screw Assemcly TPS
Attaching
24 Retainer TPS Attaching
Screw
25 Sensor Throttle Position
(TPS)
26 Plug Idle Stop Screw
27 Screw Assembly Idle Stop
28 Spring Idle Stop Screw
29 Throttle Body Assembly
30 Gasket Flange
31 Valve Assembly Idle Air
Control (IAC)
32 Gasket Idle Air Control
Valve Assembly
33 O-Ring IACV
34 Screw Assembly
IACV Attaching
7S 3658-6E
Figure 4-15 - M odel 220 TBI Parts Identificatio n (V-6 and V-8 Engine)
FUEL CONTROL 4-15
7. Remove fuel pressure gage. Electrical connectors - idle air co n tro l v a lv e ,

8. Reinstall fuel line. throttle position sensor, and fuel injectors. (On
9. Start engine and check for fuel leaks. TB I 220 units, squeeze plastic tabs on injectors
10. Remove plug from vacuum port if installed, and and pull straight up.)
install air cleaner with new gasket. 4. Grommet with wires from throttle body.
5. Throttle linkage, return springs(s), transmission
Cleaning and Inspection control cable, and cru ise co n tro l ( w h e r e v e r
applicable).
A ll TB I component parts, with the exception o f
those noted below , should be clean ed in a cold
6. Vacuum hoses, noting positions o f hoses.
7. Inlet and outlet fuel line nuts, using back-up
im m ersio n c le a n e r such as Carbon X (X -5 5 ) or
wrench J-29698-A or BT-8251-A.
equivalent.
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
NOTICE: The throttle position sensor (TPS), idle air
Procedu re (a b o v e ), b e fo re
control (I A C ) va lve, pressure regulator
d is c o n n e c t in g fu el lines.
diaphragm assembly, fuel injectors or
o th er com ponents c o n ta in in g ru b b e r,
8. Fuel line o-rings from nuts and discard.
should N O T be placed in a so lv e n t or
9. TBI mounting hardware.
cleaner bath. A chemical reaction w ill
10. TB I unit from intake manifold.
cause these parts to sw ell, harden or
distort. Do not soak the throttle body with
NOTICE: To prevent damage to the throttle valve, it
the above parts attached. If the throttle
is essential that the unit be placed on a
body assembly requires cleaning, soak
holding fixture, before performing service.
time in the cleaner should be kept to a
minimum. Some models have hidden
11. TBI flange (Manifold mounting) gasket.
throttle shaft dust seals that could lose
their effectiveness by extended soaking.
NOTICE: Stuff the manifold opening with a rag, to
p r e v e n t m a t e r i a l fr o m e n t e r i n g th e
1. Clean all metal parts thoroughly and blow dry
e n g in e , and r e m o v e the o ld g a s k e t
with shop air. Be sure that all fuel and a ir
material from surface o f intake manifold.
passages are free of dirt or burrs.
2. Inspect mating casting surfaces for damage that
Inspect
could affect gasket sealing.
> Manifold bore for loose parts and foreign material.
Thread Locking Compound Intake manifold sealing surface for cleanliness.
Service repair kits are supplied with a small vial p+| Install or Connect
of thread locking compound with directions for use. If N ew TB I flange (Manifold mounting) gasket.
material is not available, use Loctite 262, or GM part 2 . TBI with mounting hardware.
number 10522624, or equivalent.
NOTICE: In precoating screws, do not use a higher Hardware on 2.5L engine, 17.0 N *m
stre n g th lo c k in g com p ou n d than (12.5 lb. ft.).
recommended, since to do so could make Hardware on 2.8L engine, 25.0 N *m
removing the screw extremely difficult, or (18.01b.ft.).
result in damaging the screw head. Hardware on 41.;3L, 5.0L, 5.7L, and 7.4L
engines, 16.0 N * m (12.0 lb. ft ).
MODEL 220 AND 700 TBI UNITS New o-rings on fuel line nuts.
Replacement (Figures 4-16 through 4-20) Fuel line inlet and outlet nuts bv hand.
1. T H E R M A C hose from engine fitting (ST Series).

2. A ir cleaner, adapter, and gaskets. Discard gasket.
4-16 FUEL CONTROL
fTI BOLT - TIGHTEN TO 16 N m (12 FT. LBS.)

m TBI U N IT
fT I TBI UNIT
m GASKET (M U S T BE INSTALLED W ITH
STRIPE FACING UP)
fT I GASKET |~ 4 l ENGINE INTAKE M ANIFO LD
m ENGINE INTAKE M ANIFOLD
7S 3546-6E 6S 2799-6E
Figure 4-16 - Replacing TBI 700 Unit - 2.5L Engine Figure 4-18 - Replacing TBI 220 Unit - 4.3L Engine
m - TIGHTEN TO 16 N m (12 FT. LBS.)

fTI TBI UN IT
bo lt
|~2~| TBI UNIT

FTI NUT-TIG HTEN TO 25 N m (18 FT. LBS.)
[~3~| GASKET
f~3~l GASKET
[ T ] ENGINE INLET M ANIFOLD 7S 3547
[T] ENGINE INTAKE M ANIFO LD 6S2797-6E
Figure 4-17 - Replacing TBI 220 U n it - 2.8L Engine Figure 4-19 - Replacing TBI 220 Unit - Ij.OL/SJL
Engine
FUEL CONTROL 4-17
4. Check for correct state o f Park/Neutral switch on

"Scan tool.
5. Check specifications ch art at the end o f this
section for controlled idle speed and IA C va lve
pintle position (counts).
6. If within specifications, the idle speed is being
correctly controlled by the ECM.
7. If not within specificatio ns, r e fe r to " R o u g h ,
Unstable or Incorrect Idle, Stallin g in Section "2
and review information at the beginning of this
check.
Minimum Idle Air Rate Check
1. Check controlled idle speed and perform idle air

control system check first.
2. Set parking brake and block drive wheels.
3. Start engine and bring it to normal op erating
temperature (85-100C) . Turn engine " O F F .
4. Remove air cleaner, adapter and gaskets. On ST
Series vehicle, leave T I I E R M A C hose connected.
Check that the throttle lever is not being bound by
the throttle, T V or cruise control cables..
5. W ith IAC valve connected, ground the diagnostic
terminal ( A L D L connector).
6. Turn " O N ignition, do not start engine. Wrait at
least 10 seconds (this allows IAC valve pintle to
extend and seat in throttle body).
7. With ignition " O N , engine stopped, test terminal
I^ J Tighten still grounded, disconnect IA C va lve electrical
connector. (Th is disables IA C va lve in seated
Fuel line nut to 26.0 N m (20.0 lb. ft). (Use
position). R e m o v e g r o u n d fr o m d i a g n o s t i c
back-up wrench to preven t T B I nuts from
terminal.
turning,)
8. Connect a "Scan tool to the A L D L connector and
5. Vacuum hoses and bracket. place in open mode. I f a tool is not a v a ila b le
6. Throttle linkage, return springs(s), transmission connect a tachometer to the engine.
co ntrol cable, and cru ise c o n tro l ( w h e r e v e r 9. Start engine. With transmission in neutral, allow
applicable). engine rpm to stabilize.
7. Grommet, with wire harness, to throttle body. 10. Check rpm against specifications at the end o f this
8. Electrical connectors, making sure connectors are section. Disregard IAC counts on "Scan tool with
fully seated and latched. the IAC disconnected. If the engine has less than
9. Check to see i f a c c e le r a to r pedal is free, by 500 miles or is checked at altitudes above 1500
depressing pedal to the floor and releasing, while feet, the idle rpm with a seated IA C valve should
engine is " O F F . be lower than valves above.
10. W ith engine " O F F , and ignition " O N , check for 11. I f th e m i n i m u m id le a i r r a t e is w i t h i n
leaks around fuel line nuts. specifications, no further check is required.
11. A i r cleaner, adapter, and new gaskets. 12. I f the m in im u m idle a ir rate is not w i t h i n
12. Start engine and check again for fuel leaks. specifications, perform the following procedures:
13. If present, remove stop screw plug by piercing it
Controlled Idle Speed Check with an awl, then applying leverage (see Figure 4-
21). T h e s c r e w is c o v e r e d to d i s c o u r a g e
Before performing this check, there should be no
unauthorized adjustments.
codes displayed, idle air control system has been
14. With engine at normal op eratin g tem perature
checked and ignition timing correct.
(85-l00C), adjust stop screw to obtain nominal
1. Set parking brake and block drive wheels.
rpm per specifications with seated IAC valve.
2. Connect a " S C A N tool to the A L D L connector
15. Turn ignition " O F F and reconnect IA C va lv e
with tool in Open Mode.
electrical connector.
3. Start engine and bring it to normal operating
16. Disconnect "Scan tool or tachometer.
temperature.
4-18 FUEL CONTROL
TBI 220 COMPONENT SERVICE

FUEL METER COVER ASSEMBLY-TBI 220
(Figure 4-22)
The fuel meter cover assembly contains the fuel
pressure regulator assembly. The regulator has been
adjusted at the factory and should only be serviced as
a complete present assembly.
CAUTION: D O N O T remove the f o ur s c r e w s

securing the pressure regulator to
the fuel me ter cover. T h e fuel
pressure regulator includes a large
spri ng u n d e r heavy c omp r e ss i on
wh i ch , if a c c i d e n t a l l y r e l e a s e d ,
could cause person al injury.
Disassembly might also result in a
8P 0920-AS
fuel leak between the d i a p h r a g m
Figure 4-21 - Removing Stop Screw Plug and the regulator container.
17. Use silicon sealant or equ ivalent to cover stop

screw hole.
18. Install air cleaner, adapter and gasket. 1. Electrical connectors to fuel injectors. (Squeeze
plastic tabs and pull straight up.)
2. Long and short fuel meter cover screw assemblies.
3. Fuel meter cover assembly.
NOTICE: DO N O T im m erse the fuel m eter

cover (w ith pressure r e g u la t o r ) in
cleaner, as damage to the regu lator
diaphragm and gasket could occur.
4. Fuel meter outlet gasket and pressure regulator

seal. Discard gaskets and seal.
Inspect
For dirt, foreign material and casting warpage.
1. New pressure regulator seal, fuel m eter outlet
passage gasket, and cover gasket.
2. Fuel meter cover assembly.
3. A t t a c h in g screw a sse m b lies , precoated w ith
m A TTA C H IN G s c r e w - l o n g
appropriate locking compound to threads. (Short
r~2~| A TTA C H IN G SCREW-SHORT
screws are next to injectors.)
l~3 I FUEL M ETER COVER ASSEMBLY
[ ] COVER GASKET
^ Tighten
I 5 1 O U T LE T GASKET
\~ 6 ~ \ DUST SEAL Screw assemblies to 3.0 N-m (28.0 lb. in.).
F T ] FUEL M ETER BODY ASSEMBLY
4. Electrical connectors to fuel injectors.
Figure 4-22 - Replacing M odel 220 Fuel M e te r Cover 5. With engine " O F F , and ignition " O N , check for
leaks around gasket and fuel line couplings.
FUEL CONTROL 4-19
nozzle. The fuel injector is s e rvice d as a

complete a ssem bly only. A ls o , sin ce the
injectors are e le c t r ic a l com p onents, they
should not be immersed in any type of liquid
solvent or cleaner as damage may occur.
l. Electrical connectors to fuel injectors. (Squeeze
2. Fuel m eter c o ver a ssem b ly , f o l l o w i n g ab ov e
procedure.
3. With fuel meter cover gasket in place to prevent
damage to casting, use a screwdriver and fulcrum
to carefully lift out each injector (Figure 4-24).
4. Lower (small) o-rings from nozzle of injectors and
discard.
5. Fuel meter cover gasket and discard.
6 . Upper (large) o-rings and steel backup washers
H~l FUEL INJECTOR from top of fuel injector cavity and discard.
m IN LET F IL TE R
f~3~| LOWER "O " RING
RH UPPER "O " RING
^1 Inspect
I 5 | WASHER
Fuel injector fi l t e r for e v id e n c e o f d ir t and
I 6 I FUEL METER BODY ASSEMBLY
contamination. If present, check for presence of
5S 1698-6E
dirt in fuel lines and fuel tank.
Figure4-23 - Model TBI 220 Fuel Injector Parts
FUEL INJECTOR ASSEMBLY - TBI 220 Important

(Figures 4-23 to 4-27)
The TB I unit installed on a 4.3L V6 engine has
two D I F F E R E N T fu el i n j e c t o r s ( w i t h t w o
Each fuel injector (see Figure 4-23) is serviced as
D IF F E R E N T flow rates). Injectors having part
a complete assembly only.
number 5235134 (color coded Orange and Green)
NOTICE: Use care in removing the fuel injectors to should be installed on the throttle lev er side.
Those w ith part num ber 5235342 ( P in k and
prevent damage to the electrical connector
Brown) go on the T P S side ( Figure 4-25).
terminals, the injector filter, and the fuel
m TBI MODEL NUMBER

|~n THROTTLE POSITION SENSOR
m THROTTLE LEVER
DU FUEL M ETER COVER GASKET |~4~1 INJECTOR P/N 5235134 (ORANGE/GREEN)
[j ~ \ R EM O VING FUEL INJECTOR m INJECTOR P/N 5235342 (PINK/BROWN) 8S 3999-6E
5S-1G97-6E
Figure 4-25 - Fuel Injector Color Code Locations
Figure 4-24 - Removing TBI 220 Fuel Injector
TBI 220 (4.3L Engine)
4-20 FUEL CONTROL
3. Lubricate new upper (large) o-ring with automatic

transmission fluid and install directly ov er the
backup washer. Be sure o-ring is seated properly
and is flush with top of fuel meter body surface.
NOTICE: Backup washers and o-rings must be

installed before injectors, or improper
seating of large o-ring could cause fuel
to leak.
4. Injector, aligning raised lug on each injector base
n~l TOP VIEW OF INJECTOR QO BUILD DATE with notch in fuel meter body cavity. Push down
on injector until it is fully seated in fuel m eter
Ha ] PART IDENTIFICATION NUMBER D - YEAR
body (F igu re 4-27). (E le c t r i c a l te r m in a ls o f
m VENDOR INDENTIFICATION p ' MONTH
injector should be parallel with throttle shaft).
7S 3653-6E
Figure 4-26 - Fuel Injector Port Number Lacation
TBI 220
Be sure to replace the injector with one having an

identical part number. Injectors from other models
can also fit in T B I model 220, but are calibrated for
different flow rates. (See Figure 4-26 for part number
location).
|-<-[nstall or Connect
1. L u b r i c a t e new lo w e r ( s m a l l ) o - r i n g s w i t h
automatic transmission fluid and push on nozzle
end o f injector until it presses against injector fuel
filter.
2. Steel injector backup washer in counterbore of fuel
meter body.
|~ n FUEL METER BODY ASSEM BLY

[Tl GASKET
m OUTLET N U T GASKET
m OUTLET N U T
[Tl OUTLET " O RING
m INLET " 0 RING
m INLET N U T
m FU EL INJECTOR
m INLET N U T GASKET 7S 3654-6E
GD FU EL METER BODY 4S0099-6E
Figure 4-27 - Installing Fuel Injector - TBI 220 Figure 4-28 - Fuel M eter Body Assembly - TBI 220
FUEL CONTROL 4-21
4. Fuel inlet and outlet nuts with new gaskets to fuel

2J Important meter body assembly.
Be sure to install the injectors in their proper
location. The Orange and Green color coded ^ Tighten
in je ctor (p a rt n u m b er 5235134) sh ou ld be Inlet nut to 40.ON.m (30.0 lb. ft).
installed on the throttle lever side. The Pink and Outlet nut to 29.0 N.m (21.0 lb. ft).
Brown color coded one (part number 5235342) goes
on the T P S side (Figure 4-25). 5. Fuel inlet and return lines and new o-rings. (Use
back-up wrench J-29698-A or BT-8251-A to keep
5. Fuel meter cover gasket. TBI nuts from turning.)
6. Fuel Meter cover, following above procedure.
7. Electrical connectors to fuel injectors.
8. W ith engine " O F F and ignition " O N , check for Fuel lines to 23N.m (17 lb. ft.).
fuel leaks.
6. Injectors, with new upper and lower o-rings in fuel
FUEL METER BODY ASSEMBLY - TBI 220 meter body assembly.
(Figure 4-28) 7. Fuel meter cover gasket, fuel meter outlet gasket,
and pressure regulator seal.
|4~>| Remove or Disconnect 8. Fuel meter cover assembly.
9. Long and short fuel meter cover attaching screw
1. Electrical connections to fuel injectors. (Squeeze
a ssem blies, coated w ith a p p r o p r ia t e t h r e a d
locking compound.
2. F u e l m e t e r c o v e r a s s e m b ly , (S e e p r e v io u s
procedure).
3. Fuel m eter c o v e r a ssem bly, f o l lo w in g above
Q Tighten
procedure. Screw assemblies to 3.0 N.m (27.0 lb. in.)
4. Fuel injectors, following above procedure.
5. Fuel inlet and return lines. Discard o-rings. 10. Electrical connectors to fuel injectors.
6. Fuel inlet and outlet nuts and gaskets from the 11. With engine " O F F , and ignition " O N , check for
fuel meter body assembly. Discard gaskets. leaks around fuel meter body, gasket and around
fuel line nuts.
Important
Note locations of nuts, for proper reassembly later.
THROTTLE POSITION SENSOR (TPS)-TBI 220
Inlet nut has a larger passage than outlet nut.
(Figure 4-29)
7. Fuel meter body to throttle body attaching screw

Important
assemblies. On 2.8L 9V-6) engines, the T P S is adjustable, and
8. Fuel m eter body assembly from throttle body is supplied with attaching screw retainers. On all
assembly. other en gin es, it is non-adjustable, w it h o u t
9. T h ro ttle body to fuel m eter body g a s k e t and retainers. In addition, on 2.8L (V-6) and 7.4 (V8)
discard. en gin es, the TPS has a h o riz o n ta l
electricalconnector; whereas, on all other engines,
+- Install or Connect the connector is a vertical one. Since these T P S
configurations can be mounted interchangeable,
1. N e w throttle body to fuel meter body gasket.
be sure to order the correct one for your engine
Match cut-out portions in gasket with openings in
with the identical part number o f the one being
throttle body.
replaced.
2. Fuel m eter body a s se m b ly on t h r o t t l e body
assembly.
3. Fuel meter body-to-throttle body attaching screw
assemblies, precoated with appropriate locking 1. Electricalconnector.
compound. 2. Tw o T P S a tta c h in g screw a s s e m b lie s a nd
retainers, (if applicable).
Tighten 3. T P S from throttle body assembly.
Screw assemblies to 4.0 N.m (30.0 lb. in.
4-22 FUEL CONTROL
NOTICE: The T P S is an electrical component and

must not be soaked in any liquid cleaner
or solvent, as damage may result.
+ 4- Install or Connect
l. TP S on throttle body assembly, while lin in g up
T P S lever with T P S drive lever on throttle body.
2. Two T P S attaching screw assemblies.
m THROTTLE BODY ASSEM BLY

IT l THROTTLE POSITION SENSOR - NON-ADJUSTABLE
r~3~l THROTTLE POSITION SENSOR - NON-ADJUSTABLE Screw assemblies to 2.0 N.m (18.0 lb. in).
l~T1 THROTTLE POSITION SENSOR ADJUSTABLE 3. Electrical connector.
m SCREW A SSEM BLY 4. Check for T P S output as follows:
Connect A L D L scanner to read T P S output
E RETA'NER 7S 3652-6E
voltage.
Figure 4-29 - TBI Model 220 TPS Configuration With ignition " O N and engine stopped, T P S
voltage should be less than 1.25 volts. If more
than 1.25 volts, replace TPS.
IDLE AIR CONTROL (IAC) VALVE-TBI 220

(Figures 4-30 and 4-31)
NOTICE: The IAC valve is an electrical component

and must not be soaked in any liquid
cleaner or solvent. O therw ise dam age
could result.
Important
H H IDLE AIR CONTROL (IAC) VALVE All IAC valves on TBI Model 220 units (except
[ T | IAC VALVE GASKET those on the 7.4L engine) are thread-mounted and
have a dual taper, 10 mm diameter, pintle. On the
[5] THROTTLE BODY ASSEMBLY 7.4L engine, the IAC valve is flange-mounted and
8P 0952-AS
has a 12mm diameter, dual taper pintle. Any
Figure 4-30 - Thread Mounted Type IAC Valve replacement o f an IAC valve must have the correct
part number, with the appropriate pintle taper
and diameter for proper seating of the valve in the
throttle body.
-+| Remove or Disconnect

2. IAC valve.
On thread mounted units, use a 32 mm ( I V )
wrench ( Figure 4-30).
m IACV ATTACHING SCREW ASSEMBLY On fla n g e-m ou n ted units, r e m o v e s c r e w
assemblies (Figure 4-31)
|T1 EXTERNAL IACV O-RING
3. IAC valve gasket or o-ring and discard.
[~3~1 GRIME SHIELD
IJ I Clean
Thread mounted valve - Old gasket material from
surface of throttle body assembly to insure proper
8P 0917-AS
seal of new gasket.
Figure 4-31 - Flange M ou n ted Type IAC Valve Flange-mounted valve - IA C va lve surfaces on
throttle body to assure proper seal of new o-ring
and contact of I AC valve flange.
FUEL CONTROL 4-23
Important
Mo physical adjustment of the IAC valve assembly
is required after installation. The IA C va lv e
pintle is reset by turning the ignition " O N for ten
seconds and then " O F F . The ECM then resets the
pin tle to the corre ct p o s itio n . P r o p e r id le
regulation should result.
|+4-| Install or Connect

1. IAC valve into throttle body as follows:
Thread-mounted v a lv e - In s ta ll w ith new
gasket.
Flange-m ounted v a lv e - In s ta ll w ith new
lu brica ted o-ring, using a tt a c h in g s c r e w
assemblies.
NOTICE: N ew IAC valves have been reset at the

factory and should be in s ta lled in the
throttle body in an "as is con dition ,
without any adjustment.
$ Tighten
Thread-mounted IAC valve assembly to 18.0 N m
(13.0 lb. ft.) with 32 mm (1 - | ) wrench.
Flange-mounted attaching screw assemblies to 3.2
N m (28.0 lbs. in.)
2. Electrical connector to IA C valve.
3. Start engine and allow engine to reach operating
temperature.
THROTTLE BODY ASSEMBLY-TBI 220
|4H>| Remove or Disconnect

1. TB I unit, as described above.
assemblies.
NOTICE: I f the IA C va lv e was rem ov ed d u r in g
3. Fuel meter body assembly.
s e r v i c e , it o p e r a t io n m ay be t e s t e d
4. Th rottle body-to-fuel m eter body g a s k e t and
electrically with the IAC/ISC Motor Tester
discard.
(J-37027 or BT-8256K). However, if the
valve pintle is extended electrica lly, it
Disassemble
must also be retracted electrically. Before
in s t a llin g a I A C v a lv e , m e a s u r e the T P S from old throttle body, according to previous
distance betw een the tip o f the v a lv e instructions, for reuse on new throttle body. (The
pintle and the mounting su rfa ce.If the IAC valve does not have to be removed, since a
dimension is g rea te r than 28 mm (1.10 new one comes with replacement throttle body.)
inches), it must be reduced to prevent
damage to the valve. This may be done * Assemble
electrically using an IAC/ISC motor tester T P S onto replacement throttle body assembly,
(J-37027 or B T-8256K) or m anually by according to previous instructions.
exerting firm pressure, as shown in Figure
4-32 or 4-33, with a slight side-to-side |+4-| Install or Connect
movement on valve pintle to retract it. 1. New throttle body-to-fuel meter body gasket.
2. Fuel m eter body a sse m b ly on t h r o t t le body
assembly.
4-24 FUEL CONTROL
3. Fuel m eter b o d y -th ro ttle a tt a c h in g screw

assemblies that above been coated with locking
compound.
^ Tighten 'f l T T l E
f \ r i N / B
Attaching screw assemblies to 4.0 N-m (3.50 J |---- -
lb.in.) w t s r - c n
1
3 ^ -
4. T B I unit onto intake manifold, as p re vio u sly
described. [7] FUEL INJECTOR (TOP VIEW )
[ a ] PART NUMBER
[ ] BUILD DATE CODE |~D~| DAY
[ c l m onth [~e ] y e a r
1-9 (JAN -SEPT)
0 ,N ,D (OCT,NOV,DEC)
8P0913-AS
Figure 4-36 - Fuel Injector Part Number Location
TBI 700
TBI 700 COMPONENT SERVICE

FUEL INJECTOR ASSEMBLY-TBI 700
(Figures 4-34 through 4-36)
The fuel injector (see Figure 4-34) is serviced only

as a complete assembly.
NOTICE: Use care in r e m o v in g in jector, to

p re ven t d a m a g e to the e l e c t r i c a l
connector on top of the injector, and
nozzle. Also, because the fuel injector
P H SCREW AS SE M B LY
is an electrical component, it should
fT l RETAINER
not be immersed in anv type o f liquid
fT l FUEL METER AS SE M B LY
solvent or cleaner, as dam age may
m LOWER " O " RING
occur.
I 5 | UPPER " 0 RING
[T ] INJECTOR 7S3416-6E
Figure 4-34 - Fuel Injection Parts (TBI 700) 1. Electrical connector to fuel injector.
2. Injector retainer screw and retainer.
3. Using a fulcrum, place a screwdriver blade under
ridge opposite connector end and ca refu lly pry
injector out (see Figure 4-35).
Remove upper and lower o-rings from injector and
in fuel injector cavity and discard.
Inspect
Fuel injector filter for evidence o f dirt and
contamination. If present, check for presence
of dirt in fuel lines and fuel tank.
Important
Be sure to replace the injector with an identical
part. Injectors from other models can fit in the
Model 700 TBI, but are calibrated for different
flow rates. (See Figure 4-34 for part number
location.)
FUEL CONTROL 4-25
CAUTION: The pressure regulator

Install or Connect contains a large s p r i n g u n d e r
0 heavy compression. Use c a r e
l. Lubricate new upper and low er o-rin g s w ith
when r e mo v i n g the s c r e w s to
automatic transmission fluid and place them on
prevent personal injury.
injector. (Make sure upper o-ring is in groove and
lower one is flush up against filter.)
2. Pressure regulator cover assembly.
2. Injector assembly, pushing it straight into fuel
3. Pressure regulator spring.
injector cavity.
4. Spring seat.
5. Pressure regulator diaphragm assembly.
I? Inspect
Pressure regulator seat in fuel meter body
ca vity for pitting, nicks, or ir r e g u la r itie s .
(Use magnifying glass if necessary.) If any of
above is present, the whole fuel body casting
must be replaced.
Install or Connect
1. N ew pressure regu lator diaphragm a s s e m b ly ,
PRESSURE REGULATOR COVER
making sure it is seated in groove in fuel meter
SCREW ASSEMBLY
body.
SPRING - SEAT
2. Regulator s p rin g seat and sp r in g into c o v e r
SPRING
assembly.
DIAPHRAGM
3. Cover assembly over diaphragm, while a lig n in g
FUEL METER ASSEMBLY 7S3421-6E
mounting holes.
Figure 4-37 - TBI 700 Pressure Regulator
Important
Be sure the electrical co nnector end on the
injector is facing in the general direction of the
cut-out in the fuel m e te r body for the w ir e
grommet.
3. Injector retainer, using appropriate thread locking-

compound on retainer attaching screw.
4. Electrical connect or to fuel injector.
[T1FUEL INJECTOR
Injector retainer attaching screw to 3.0 [~2~| INJECTOR RETAINER
N m (27.0 lb. in.).
[~3~1 FUEL METER BODY ATTACHING
5. W ith engine " O F F and ignition " O N , check for
SCREW & WASHER ASSEMBLY
fuel leaks.
[~4~1 FUEL METER ASSEMBLY
PRESSURE REGULATOR ASSEMBLY [~5~1 FUEL METER BODY TO THROTTLE BODY GASKET
(Figure 4-37) |~6~1 FUEL OUTLET NUT
1~7~1 FUEL LINE OUTLET NUT O-RING
NOTICE: To prevent leaks, the pressure regulator
diaphragm assembly must be rep laced p T ] FUEL NUT SEAL
whenever the cover is removed. f T I PRESSURE REGULATOR COVER ASSEMBLY
Q o ] AIR FILTER GASKET 8P0915-A S

1. Four pressure regulator attaching screws, while Figure 4-38 - Fuel M e te r Assem bly - TBI 700
keeping pressure regulator compressed.
4-26 FUEL CONTROL
NOTICE: Use care while installing the pressure

regulator to prevent misalignment of ^ Tighten
diaphragm and possible leaks. Inlet and outlet nuts to 27 N m (20 lb. ft.).
(Use back-up wrench J-29698-A, or
Four screw assemblies that have been coated with BT-8251-A to keep T B I nuts from turning.)
approp riate threa d loc k in g compound, w h ile
maintaining pressure on regulator spring. 7. Grommet with wires to fuel meter assembly.
8. Electrical connector to fue injector, making sure
it is fully seated and latche
Attaching screw assemblies to 2.5 N-m (22.0 9. With engine " O F F and ignition " O N , check for
lb. in.). leaks around fuel line nuts.
5. With engine " O F F and ignition " O N , check for THROTTLE POSITION SENSOR
fuel leaks (Figure 4-39)
FUEL METER ASSEMBLY 1. Electrical connector from TPS.
(Figure 4-38) 2. Screw assemblies and TPS.
Remove or Disconnect NOTICE: The th rottle position sensor is an

Electrical connector from fuel injector. electrical component, and should not
Grommet with wires from fuel meter assembly. be immersed in any type o f liq u id
3. Inlet and outlet fuel line nuts, using backup solvent or cleaner, as damage may
wrench J-29698-A, or BT-8251-A. result.
4. Fuel line o-rings from nuts and discard.
5. TB I mounting hardware. + 4- Install or Connect
6 . Two fuel meter body attaching screw and washer 1. With throttle valve in normally closed position,
assemblies. in s t a ll T P S on t h r o t t l e s h a f t a nd r o t a t e
Fuel meter assembly from throttle body assembly. counterclockwise to align mounting holes.
Fuel meter body to throttle body g a s k e t and 2. Attaching screw and washer assemblies.
discard.
Install or Connect
1. N e w fuel meter body to throttle body gasket.
Match cut-out portions of gasket with openings in
throttle body assembly.
2. Fuel meter assembly.
3. Two fuel meter body attaching screw and washer
assemblies that have been coated with appropriate
locking compound.
Attaching screws to 6.0 N m (53 lb. in.). I 1 I FUEL METER ASSEMBLY

|~2~| THROTTLE BODY ASSEMBLY
4. Throttle body injection unit mounting hardware. r~3~l THROTTLE POSITION SENSOR
|~4~l TPS ATTACHING SCREW &
WASHER ASSEMBLY 8P 0916-AS
Figure 4-39 - Throttle Position Sensore (TPS) - TBI 700

Mounting hardware to 17 N m (12 lb. ft.
5. New o-rings on fuel line nuts.

6. Fuel line inlet and outlet nuts by hand.
FUEL CONTROL 4-27
Important
On T B I Model 700, the IA C v a l v e is fla n g e -
mounted, with dual taper, 10 mm diameter pintle.
I f replacement is necessary, only an IA C v a lv e
identified with the correct part number (h a v in g
the appropriate pintle shape and diameter) should
be used.
[ T l IACV ATTACHING SCREW ASSEMBLY Remove or Disconnect

r~i~| EXTERNAL IACV O-RING 1. Electrical connector from IAC valve.
2. Screw assemblies and IAC valve.
H T l GRIME SHIELD
3. IAC valve o-ring and discard.
8P 0917-AS
IJJI Clean
IAC valve seating surfaces on throttle body to
Figure 4-40 - Flange-M oun t IAC Valve - TBI 700
assure proper seal o f new o-ring and contact of
IAC valve flange.
NOTICE: If the IAC valve has been removed during

service , its o p e r a t io n m a y be t e s t e d
electrically with the I AC/ISC Motor Tester
(J-37027, or BT-8256K). However, if the
valve pintle is extended ele ctrica lly , it
must also be retracted electrically. Before
installing an I A C v a lv e , m ea su re the
distance b etw een the tip o f the v a lv e
pintle and the mounting surface. I f the
dimension is g rea te r than 28 mm (1.10
inches) it must be reduced to p r e v e n t
damage to the valve. This may be done
e le c t r ic a lly u sing an IA C / IS C M o t o r
Tester (J-37027 or BT-8256K) or manually
be ex ertin g firm pressure as shown in
Figure 4-41, with a slight side to-side
movement on the valve pintle to retract it.
-- Important
Screw assemblies to 2.0 N m ( 18.01b. in.)
No physical a d ju s t m e n t o f the I A C v a l v e
assembly is required after installation. The IA C
3. Electrical connector to TPS.
valve pintle is reset by the ECM. W hen the
4. Check for T P S output as follows:
vehicle is operated at normal engine temperature
Connect A L D L scanner to read T P S output
at approximately 30 mph (48 km/hr ), the EC M
voltage.
causes the valve pintle to seat in the throttle body.
With ignition " O N and engine stopped, T P S
The ECM then has a rest procedure to set the
voltage should be less than 1.25 volts. If more
correct pintle position. Proper idle regu lation
than 1.25 volts, replace TPS.
should result.
IDLE AIR CONTROL (IAC) VALVE Install or Connect

(Figure 4-40)
1. Lubricate new o-ring with transmission fluid and
NOTICE: The IAC valve is an electrical component install on IAC valve.
and must not be soaked in any liquid 2. IAC valve to throttle body.
cleaner or solvent. Otherw ise dam age
could result.
4-28 FUEL CONTROL
^ Tighten
Screw assemblies to 3.0 N m (28.0 lb. in.).
THROTTLE BODY ASSEMBLY

(Figure 4-43)
NOTICE: Procedures related to replacement of the

individual components b e lo w h a v e been
d e s c r ib e d p r e v i o u s l y a n d s h o u l d be
| ~ r | THROTTLE BODY ASSEMBLY followed, or damage could occur.
HI TUBE MODULE ASSEMBLY GASKET
|~3~1 TUBE MODULE ASSEMBLY
|~4~| TUBE MODULE SCREW ASSEMBLY 1. Throttle body injection (TB I) unit, as described
below.
8P 0918-AS
2. Fuel meter body-to-throttle body a tta ch in g screw
Figure 4-42 - Tube M odule Assem bly - TBI 700 and washer assemblies.
3. Fuel meter assembly.
NOTICE: New IAC valves that have been preset
4. Fuel meter body to throttle b o d y g a s k e t and
at the factory should be installed in
discard.
the t h r o t t l e b o d y in an " a s i s
condition, without any adjustment.
3. IA C valve attaching screw assemblies that have

been coated w ith a p p ro p ria te thread loc k in g
compound.
Screw assemblies to 3.2N-m (28.0 lb. in.).
4. Electrical connector to idle air control valve.

5. Start engine and allow engine to reach operating
temperature.
TUBE MODULE ASSEMBLY

(Figure 4-42)
4~* Remove or Disconnect [~ n IDLE AIR CONTROL VALVE

|~ 2 l IDLE STOP SCREW PLUG
1. Tube module assembly attaching screws. m SCREW AND WASHER ASSY.
2. Tube module assembly. F T ] SPRING
3. Tube module assembly gasket and discard. [ T l THROTTLE LEVER
[~6~1 THROTTLE BORE
Clean T l THROTTLE BODY ASSEMBLY
Old gasket material from surface of throttle T l THROTTLE POSITION SENSOR
body assembly to insure proper seal o f new T l GASKET
gasket. To] TUBE MODULE ASSY. 75 3 7 1 5-6E
Install or Connect Figure 4-43 * Throttle Body Assembly

4-
1. N ew tube module assembly gasket.

2. Tube module assembly.
3. Tube module assembly attaching screws.
FUEL CONTROL 4-29
Disassemble
TPS, IAC valve and tube module assembly
from old throttle body assembly, according to
previous instructions.
* Assemble
TPS, IAC valve, and tube module assem bly
onto replacement t h r o ttle body a ssem bly ,
according to previous instructions.
-4- Install or Connect

1. N ew fuel meter body to throttle body gasket.
2. Fuel meter assembly on throttle body assembly.
and washer assemblies.
Q Tighten
Screws to 6.0 N.m (53 lb. in.)
4. TB I unit onto engine, as described below.

5. Check minimum idle speed of engine as described
below.
FUEL PUMP
(Figure 4-44)
NOTICE: Care should be taken not to fold over or
Remove or Disconnect twist the strainer, when insta lling the
1. Relieve full system pressure (2.5L Engine only). sending unit as this will restrict fuel flow.
2. Raise the vehicle on a hoist.
3. N ega tive battery cable. 2. Sending unit and fuel pump assembly into the fuel
4. Fuel tank. tank.
5. Sender unit and pump by turning the cam lock Use a new o-ring seal.
counterclockwise using tool J-36608 or J-24187. 3. Cam lock assembly.
6. Fuel pump from the sending unit. Turn the cam lock clockwise to lock i ' .
Pull the fuel pump up into the attaching hose 4. Fuel tank.
w h ile p u llin g o u t w a r d fr o m the b o tto m 5. Negative battery cable.
support.
Do not damage the rubber insulator or the FUEL PUMP RELAY
strainer. (Figure 4-45 through 4-50)
Inspect Remove or Disconnect

1. F u e l pu m p a t t a c h i n g h o s e f o r s i g n s o f 1. Protective cover (CK).
deterioration. 2. Retainer, if installed.
2. Rubber sound insulation at the bottom o f the 3. Electrical connector.
pump. 4. Relay by depressing bracket clip at rear o f relay,
or removing bolts from retaining bracket.
1. Fuel pump assem bly into the atta ch in g hose.
4-30 FUEL CONTROL
PH ELECTRICAL CONNECTOR
F T 1 OIL PRESSURE RELAY
[~3~| A C RELAY
H I RETAINER [ T ] BRACKET
[~4~1 RELAY BRACKET
|~2~| FUEL PUMP RELAY [ T ] ELECTRICAL
Fin BULKHEAD CONNECTOR
I T l PLENUM PANEL CONNECTOR ?s 3?5g _6E
f i l FUEL PUMP RELAY
Figure 4-45 - Fuel Pump Relay (ST) Figure 4-48 - Fuel Pump Relay (RV)
I T l ELECTRICAL CONNECTOR [ T ] PLENUM PANEL

m FUEL PUMP RELAY [ T ] BRACKET
HT| RETAINER 7S 3757-6E
Figure 4-49 - Fuel Pump Relay (G)
m RETAINER [ J ] DO W NSHIFT RELAY

IT l FUEL PUM P RELAY [T j FUEL PUM P FUSE
[T 1 DASH PANEL
7S3756-6E
Figure 4-47 - Fuel Pump Relay (CK) Figure 4-50 - Fuel Pump Relay (P)
FUEL CONTROL 4-31
Install or connect
1. Relay.
3. Retainer.
4. Protective cover (CK).
FUEL MODULE
1. Electricalconnector.
2. Fuel Module.
Install or connect
1. Fuel Module.
m SEAT RISER
f T l FUEL MODULE
m ELECTRONIC CONTROL MODULE
m ALDL CONNECTOR 7S 3786 6E
Figure 53 - Fuel Module (G)
OIL PRESSURE SWITCH

m BRAKE PEDAL BRACKET
2. Oil Pressure Switch using w ren ch J -28H37-A or
[~ n FUEL MODULE
7S 3790-6E BT-8220 if required.
Figure 4-51 - Fuel Module (RV)

Install or connect
1. Oil Pressure Switch.
fT 1 ELECTRONIC CONTROL MODULE

[T 1 FUEL MODULE
[T 1 ELECTRONIC CONNECTOR
8S4613-6E
Figure 4-54 - Oil Pressure Sw itch (2.5L)
Figure 4-52 - Fuel M odu le (CK)
4-32 FUEL CONTROL
FUEL FILTER
In-Line Filter Replacement

On 2.5L engine, relieve fuel system pressure.
1. Fuel filler cap.
2. Fuel feed nuts.
3. Clamp bolt.
4. Filter and clamp.
5. Clamp from filter.
+ 4- Install or connect
1. Clamp to filter.
2. Clamp bolt.
3. Fuel feed nuts.
4. Fuel filler cap.
In-Tank Filter Replacement
Refer to fuel pump replacement, i f the in-tank

filter required service.
m FITTING
IT] OIL PRESSURE SW ITCH 7S 3814-6E [Tl FUEL FEED PIPE-TIGHTEN N U T TO 26 N m
(20 FT. LBS.)
Figure 4-56 - Oil Pressure Switch (4.3L/V8) m O-RING
m IN-LINE FUEL FILTER
m FUEL FEED HOSE-TIGHTEN N U T TO
26 N m (20 FT. LBS.)
IT I FUEL RETURN HOSE-TIGHTEN N U T TO
26 N m (20 FT. LBS.) 7S 3645-6E
Figure 4-57 - Fuel Filter - 2.5L

FUEL CONTROL 4-33
m RIGHT FRAME C E CLAMP

SIDE MEMBER
m REAR FUEL FEED m INTERM EDIATE FUEL
FEED PIPE-TIGHTEN
PIPE-TIGHTEN N U T TO NU T TO 2 6 N m
26 N m (20 FT. LBS.) (20 FT. LBS.)
m BOLT-TIGHTEN TO
16 N m (24 FT. LBS.)
m TR A N SM ISSIO N
SUPPORT
m IN-LINE FUEL
FILTER 7S 3 6 4 4 - 6 E
Figure 4-60 - Fuel Filter (RV)

[T l FUEL RETURN PIPE
|~2~| CLAMP
m FUEL RETURN HOSE
l~4~| IN-LINE FUEL FILTER
[~5~1 CLAMP (DOUBLE)
l~6~| FUEL FEED HOSE
m O-RING
IT ] FUEL FEED PIPE-TIGHTEN N U T TO
26 N m (20 FT. LBS.) 7S3646-6E
Figure 4-58 - Fuel Filter - 2.8L (ST)
rn cup
I 2 t LEFT FRAME SIDE M EMBER
1 3 [ FRONT FUEL FEED HOSE-TIGHTEN N U T TO
26 N m (20 FT. LBS.)
[ ~ 4 l IN-LINE FUEL FILTER
I 5 I REAR FUEL FEED HOSE-TIGHTEN N U T TO
26 N m (20 FT. LBS.) 7S 3650-6E
Figure 4-61 Fuel Filter (CK)
m REAR FUEL FEED PIPE-TIGHTEN NUT

TO 26 N m (20 FT. LBS.)
H I FUEL FEED PIPE-TIGHTEN NUT TO [Tl IN-LINE FUEL FILTER
___ 26 N m (20 FT. LBS.)
m CLAMP
f~2~l IN-LINE FUEL FILTER
I 3 1 LEFT FRAME SIDE MEMBER
m INTERM EDIATE FUEL FEED PIPE-TIGHTEN
N U T TO 26 N m (20 FT. LBS.)
DO FRONT FUEL FEED PIPE-TIGHTEN N U T TO fin RIGHT FRAME SIDE M EMBER
26 N m (20 FT. LBS.) 75 3647-6E.
Figure 4-62 - Fuel Filter (P)
Figure 4-59 - Fuel Filter (M )
4-34 FUEL CONTROL
fTI REAR FUEL FEED PIPE-TIGHTEN NUT

fTI BOLT TIGHTEN TO 18 N m (12 LBS. FT.)
TO 26 N m (20 FT. LBS.)
I 2 I IN-LINE FUEL FILTER f T I FUEL TANK SELECTOR VALVE
[T1 BRACKET f X l FUEL FEED
l ~ 4 l VAPOR PIPE m FUEL RETURN
m FUEL RETURN PIPE f c l RH FUEL RETURN PINK
m INTERMEDIATE FUEL FEED PIPE-TIGHTEN l~ D l RH FUEL FEED ORANGE
N U T TO 26 N m (20 FT. LBS.) m LH FUEL RETURN BLUE
[7 ] R i g h t f r a m e s id e m e m b e r
fTI LH FUEL FEED YELLOW 7S 3843-6E
Figure 4-63 - Fuel Filter (G) Figure 4-64 - Selector Valve - (RV)
AUXILIARY FUEL TANK CONTROL FUEL HOSEAND PIPE ASSEMBLIES
The auxiliary fuel tank is controlled by a selector Materials

valve and m eter switch and selector switch. The
diagnosis of these components are part o f the fuel Fuel Lines - These are welded steel tubes, meeting
pump circuit and can be found in Section "3 . GM Specifications 124-M, or its equivalent. The fuel
feed line is 3/8 diameter and the fuel return line is
5/16 diam eter. Do not use copper or alu m in u m
Selector Valve and Meter Switch tubing to replace steel tubing. Those materials do not
(Figure 4-64) have satisfactory durability to w ith sta n d norm al
vehicle vibration.
|++| Remove or Disconnect Coupled hose - These are not to be repaired and
1. Battery. are replaced only as an assembly.
U ncou pled Hose - Use o n ly r e i n f o r c e d fu rl
2. Hose shield, i f required.
resistant hose, made of "Fluoroelastomer material.
3. Electrical connector from valve and switch.
Do not use a hose within 4 inches (100 mm) o f any part
4. Fuel feed and return hose. Note position and color
o f the exhaust system, or within 10 inches (254 mm) of
of hoses.
the catalytic converter. The hoses inside diam eter
5. Selector valve and meter switch from frame.
must match the outside diameter of the steel tubing.
Clamps These are stainless steel, screw bank-
type clamps, #2494772. or equivalent.
+ 4* Install and Connect
1. Selector valve and meter switch.
Fuel Line Repair
2. Fuel feed and return hoses.
1. Cut a piece o f fuel hose 4 inches (100 mm) longer
4. Hose shield.
than the section of line to be removed. I f more
5. Battery.
than 6 inches (152 mm) is to be removed, use a
combination o f steel pipe and hose. Th e hose
length should not be more than 10 inches total.
FUEL CONTROL 4-35
2. Cut a section of the pipe to be replaced with a tube Replacement

cutter. Use the first step of a double flaring tool to Figures (4-65 through 4-82)
form a bead on the ends of the pipe and, also, on
the new section of pipe, if used. |*+] Remove or Disconnect
3. Slide the hose clamps onto the pipe and push the 1. Fuel from the fuel tank.
hose 2 inches (51 mm) onto each portion of the fuel 2. Clamps from filler neck hose and vent line.
pipe. Tighten a clamp on each side of the repair. 3. Fuel tank retaining straps.
4. Secure fuel line to the frame. Support the fuel tank.
4. Sender unit wires, hoses, and ground strap.
FUELTANK Lower the fuel tank to gain access.
5. Fuel tank from the vehicle.
Draining 6. Fuel sender and pump from the fuel tank.
7. Purge tank, if being repaired.
1. Disconnect the negative battery cable.
H a ve a dry c h e m ic a l (C la s s B) fire [-<-[ Install or Connect
extinguisher nearby.
1. Fuel sender and pump into fuel tank.
2. Fuel tank into the vehicle.
CAUTION: N ev e r d ra i n or store gasol ine or
3. Sender unit wires, hoses, and ground straps.
diesel fuel in an open container,
4. Fuel tank retaining straps with insulator strips in
d ue to the p o s s i b i l i t y o f fire or
place.
explosion.
5. Clamp to filler neck hose and vent line.
6. Bolts and nuts.
2. Use a hand operated pump device to drain as much
fuel as possible through the filler neck. On some
^ Tighten
fuel tank installations, the filler neck is too long to
gain access to the fuel. I f the tank is not full, Bolts, as shown in the illustrations.
disconnect filler neck nose, at the fuel tank, to
gain access to the fuel. Purging
Alternate method:
a. Disconnect fuel feed pipe and attach a hand The fuel tank should be purged, before b e in g
operated pump device. repaired.
Energize the fuel pump relay.
c. With fuel pump running, operate hand pump Remove or Disconnect
to remove fuel. 1. ?uel tank from the vehicle.
3. After servicing fuel tank, install removed hose, 2. Fuel gage sending and pump unit.
lines, and fuel filler cap. 3. All remaining fuel from the tank.
JG Inspect
Fuel tank for any remaining fuel.
H I VENT PIPE [T ] FUEL FILLER CAP

[~2~l FILLER PIPE [T ] G RO UND STRAP
[ T 1 HO USING 7S 3823-6E
Figure 4-65 - Filler Neck - ST Utility

4-36 FUEL CONTROL
[T1 VENT PIPE [7] G RO UND STRAP

i~2~1 FILLER PIPE [T ] SUPPORT
fTl FUEL FILLER PIPE [T] SHIELD 7S 3825-6E
Figure 4-68 - Filler Neck - ST Chassis Cab
~T~| FUEL TANK

~2~1 N U T TIGHTEN TO 45 N m (33 FT. LBS.)
~3~] BOLT TIGHTEN TO 35 N m (26 FT. LBS.)
i~4~l STRAP
m N U T TIG HTEN TO 7 N m (5 FT. LBS.)
L 6J BRACKET 7S 3821-6E
Figure 4-66 - Fuel Tank - ST Utility
m FUEL TANK
m BOLT TIGHTEN TO 18 N m (13 FT. LBS.)
m
GD
STRAP
fT l VENT HOSE [7 ] FUEL FILLER CAP PROTECTOR
[~2~| FILLER PIPE |T ] GRO UND STRAP m BOLT TIGHTEN TO 35 N m (26 FT. LBS.)
|~3~1 HOUSING 7S 3824-6E E BOLT TIGHTEN TO 35 N m (26 FT. LBS.)
Figure 4- 67 - Filler Neck - ST Pickup

m N U T TIG HTEN TO 7N m (5TT. LBS.) 7S3820-6E
Figure 4-69 - Fuel Tank - ST (except Utility)
4- Install or Connect 3. Water to the fuel tank.

Refer to the emulsifying agent specifications
1. Tap water into the tank,
for the mixture ratio.
Move the tank to the flushing area (wash
Agitate the mixture for ten minutes.
rack.)
Drain the tank completely.
Agitate the water vigorously, and then, drain
Fill the tank with water, until it overflow.
it.
Completely flush out any remaining mixture.
2. Gasoline emulsifying agent into the tank.
Drain the fuel tank.
Use an available emulsifying agent, such as
Use an explosion meter (i f available) to check
Product-Sol No. 913, or equivalent.
for a negative reading.
Perform the required service work.
FUEL CONTROL 4-37
4. Repair fuel tank.

5. Fuel gage sending and pump unit.
6. Fuel tank into vehicle.
FUEL SYSTEM CLEANING
2. Engine harness connector on the distributor.
H a v e a d r y c h e m i c a l ( C l a s s B) fi re
extinguisher near the work area.
3. Fuel system pressure (2.5L engine only)
4. Fuel from the fuel tank.
5. Fuel tank.
6. Fuel gage sending and pump unit.
7. Purge fuel tank.
rn VENT PIPE [T] HO USING

m INSULATOR [T ] FILLER PIPE 7S3822-6E
Figure 4-70 - Filler Neck - M Figure 4-73 - Filler Neck - RV Utility & Suburban
[T1 FUEL FILLER CAP

l~2~l H O USING
[ T 1 FILLER PIPE
f T ] VEN T PIPE
f~5~l G R O UN D STRAP 7S3840-6E
Figure 4-71 - Filler Neck - CK

4-38 FUEL CONTROL
m N U T TIG HTEN TO 12N m (10FT. LBS.)

m BOLT TIG HTEN TO 12 N m (10 FT. LBS.)
I 3 I BOLT TIG HTEN TO 33 N m (24 FT. LBS.)
ITl FUEL TANK
ITl SHIELD
m REAR STRAP
[T1 FRONT STRAP
Figure 4-76 - Fuel Tank - CK Chassis Cab
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.
m INSULATOR
I T ] LOWER SHIELD
I T ] STRAP
m FUEL TANK
INSTALLATION SEQUENCE m REAR STRAP
[ T ] BOLT TIGHTEN TO 35 N m cm FRONT STRAP

(26 FT. LBS.)
" H BOLT TIGHTEN TO 3.4 N m
m BOLT TIG HTEN TO 12 N m (10 FT. LBS.)
(30 IN. LBS.) cn FUEL TANK 7S3830-6E

T ] NUT TIGHTEN TO 35 N m in SHIELD
Figure 4-77 - Fuel Tank - CK (except Chassis Cab)
Figure 4-75 -Fuel Tank - M

FUEL CONTROL 4-39
DU B0LT TIGHTEN TO 9.5 N m (85 IN. LBS.)

fT I STRAP
D U SUPPORT BASE (LEFT) FUEL TANK LOCATION
IHUSUPPORT AUXILIARY (RIGHT) FUEL TANK LOCATION [T 1 FUEL TANK
G U NUT TIGHTEN TO 7 N m (60 IN. LBS.) R 1 LOWER N U T TIGHTEN TO 14 N m (10 FT. LBS.)
AND THEN TIGHTEN UPPER N U T f T I TO cc
[ T ] BOLT TIGHTEN TO 33 N m (22 FT. LBS.) 7S 3817-6E 14 N m (10 FT. LBS.) 1----- ' /S 3 8 1 6 -6 E
Figure 4-78 - Fuel Tank - RV Pickup Figure 4-80 - Fuel Tank - G
DU STRAP
fT I N U T TIGHTEN TO 12 N m (10 FT. LBS.)
D U UPPER N U T TIG HTEN TO 35 N m (23 FT. LBS.)
AND THEN TIG HTEN LOWER N U T [ T ]
TO 35 N m (25 FT. LBS.)
|~5U FUEL TANK 7S 3839-6E
Figure 4-79 - Fuel Tank - RV U tility & Suburban Figure 4-81 - Fuel Tank - P (32)
4-40 FUEL CONTROL

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 (1/2 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.
Leak Test
If fuel is leaking, from the tank, the tank should

be replaced. Make sure that the fuel lines are not
leaking onto the tank.
1. Remove the fuel tank.
2. Drain the tank.
3. Plug all of the outlets.
4. A pply 7 to 10 kPa (1 to 1| psi) a ir pressure
PTl STRAP through the vent tube.
[T ] LOWER N U T TIGHTEN TO 12 N m \ jT \ FUEL TANK 5. T e s t fo r leaks, w ith a soap s o lu t io n , or by
(10 FT. LBS.), THEN TIGHTEN rT l
MIDDLE N U T @] TO 58 N m LZJ INSULATOR submersion.
(42 FT. LBS.) A N D THEN TIGHTEN [T ] NUT 6. Replace the tank, if a leak is found.
LOWER A N D UPPER N U T E TIGHTEN TO
___ TO 58 N m (42 FT. LBS.) 58 N m (42 FT. LBS.)
|5 | N U T TIGHTEN TO 58 N m 7S3841-6E ACCELERATORCONTROL
(42 FT. LBS.)
Figure 4-82 - Fuel Tank - P (42) Accelerator Control Cable

There are no linkage adjustments. The throttle
cable must be replaced with an identical replacement
In-Line Fuel Filter
part.
L Inspect All linkages and cables must be checked, to assure

In-Line fuel filter, for contamination.
free movement, with no rubbing, chafing, or binding.
Replace the filter, if it is plugged
The throttle must operate freely, without binding
between full closed and side open throttle.
Clean Observe the following, when performing service
1 Fuel lines, by applying air pressure in the on the accelerator control cable.
opposite direction of fuel flow. The retainer must be installed with the tanks
secured over the head o f the stud.
-- Install or Connect The conduit fitting, at both ends of the cable,
N ew strain er ( i f n ecessary) on the fuel g a g e must have the locking tanks expanded and
sending and pump unit.. locked into the attaching holes.
The braided portion of the cable must not come
NOTICE: Care should be taken not to fold over or into contact with the front o f dash s e a le r
twist the strainer, when in stalling the during replacement.
sending unit, as this will restrict fuel flow. Flexible components (hoses, wires, conduit,
2. Fuel gage sender and pump unit, with a new seal etc.) must not be routed within 50 mm (2
into the fuel tank. inches) of the moving parts of the accelerator
3. Fuel tank. l i n k a g e , u n le s s r o u t i n g is p o s i t i v e l y
4. Disconnect the fuel feed line at the front o f the controlled.
vehicle.
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.
FUEL CONTROL 4-41
f T ] RETAINER [T1 ROD

m SPRING F IT ] RETAINER
m SUPPORT m PLATE
[~4~1 CABLE m PEDAL
7S 3787-6E
Figure 4-83 - Control Cable - 2.8L Figure 4-85 - Control Cable - 2.5L
1. Retainer from throttle le v e r stud or on 2.5L
release cable from pulley.
2. Retainer locking tangs from support bracket.
3. Retainer from accelerator pedal rod or release
cable from rod.
4. Retainer locking tanks from dash panel.
Install or Connect
1. Retainer to dash panel.
2. Retainer to accelerator pedal rod or connect cable
in rod slot.
3. Retainer to support bracket.
4. Retainer to throttle lever stud or connect cable to
pulley.
Accelerator Pedal
fT l RETAINER T h e a c c e le r a to r pedal controls the t h r o t t l e ,
[~2~| LUBRICANT through a cable. There are not linkage adjustment.
F T l THROTTLE LEVER STUD The throttle cable must be replaced with an identical
n n SPRING replacement part.
fTl CABLE All linkages and cables must be checked, to assure
H I SUPPORT free movement with no rubbing, chafing, or binding.
7S 3791-6E
The throttle must operate freely, without bin ding,
between full closed and wide open throttle.
Figure 4-84 - Control Cable - 4.3L & V-8
4-42 FUEL CONTROL
r n SPRING PLATE m ped al m SUPPORT

m ROD [T ] PIN m pin |~6~| CABLE
I T ] CABLE | T ] PEDAL m SPRING m RETAINER

m RETAINER 7S 3836-6E m ROD m PLATE 7S 3837-6E
Figure 4-86 - Accelerator Pedal -ST Figure 4-87 - Accelerator Pedal - M
Observe the following, when performing service

on the accelerator pedal.
The mounting surface between the support
and the dash panel, must be free o f insulation.
Th e carpet and padding in the pedal and
tunnel area must be positioned to lay flat and
be free o f wrinkles and bunches.
Slip the accelerator control cable through the
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
cable if not kinked, or damaged.
Th e linkage must operator freely, without
binding, b e tw ee n closed th r o tt le and full
throttle.
W i r e , hoses, c a b le , a n d o t h e r f l e x i b l e
components, must not be placed within 13 mm
(0.52 inch) of the cable or rod, at any point, in
their travel.
m PEDAL n n suppo rt
m pin I 6 [ CABLE
m SPRING m RETAINER
m ROD fin PLATE 7S 3837-6E
Figure 4-88 - A ccelerator Pedal - RV

FUEL CONTROL 4-43
5 U - S ]
V j
'v i & k
j -
m PIN GO ROD
l~2~l SPRING GO RETAINER
f T l SUPPORT [ T ] PLATE
1 4 | CABLE [ 8 | PEDAL 7S 3832-6E
Figure 4-91 - A ccelerator Pedal -P (42)
m RETAINER m ROD
|~2~1 SPRING m RETAINER
[Tl SUPPORT m PLATE
m CABLE GO PEDAL 7 S 3788-6E
Figure 4-89 - A ccelerator Pedal - CK
m RETAINER m ROD
[~2~] SPRING fin RETAINER
m SUPPORT m PLATE
f T l CABLE m PEDAL 7S 3787-6E
Figure 4-92 - A ccelerator Pedal -P (32)
PARTS INFORMATION
PART NAME GROUP
Cover, w/Regulator, Fuel Meter:
n~| PIN [T ] CABLE Part of Meter Kit, F u e l ............................. ..3.734
IT I SPRING [T ] REINFORCEMENT Injector, Fuel: Part of
m ROD [T ] PEDAL Pump, Fuel (In Tank) ....................................3.774
l~4~1 RETAINER 7S 3835-6E Relay, Fuel Pump .......................................... ..3.990
Switch, Oil Press.................................................1.800
Figure 4-90 - Accelerator Pedal - G
Throttle Body Injection Unit ....................... ..3.725
Valve Asm, Idle A ir Control: Part of
Control Kit, Idle A ir V a l v e .........................3.820
4-44 FUEL CONTROL
CONTROLLED IDLE SPEED
Engine Transmission Gear Idle Speed IAC Counts* Open/Closed
_________________ _________(D/N)___________(RPM)_______________________Loop**
2.5L Man. N 900(ST) 5-20 CL

800(M)
Auto. D 800(S) 15-40 CL
650(T)
750(M)
2.81 Man. N 800 5-20 OL
Auto. D 800 5-30 OL
4.3L Man. N 500-550 2-12 CL
A u to D 500-550 10-25 CL
A uto.(1) D 500-550 2-20 CL
5.0L Man. N 600 5-30 OL
A uto. D 500 5-30 OL
A u to .(2) D 550 5-30 CL
5.7L Man. N 600 5-30 OL
(under 8500
GVW) A uto. D 500 5-30 OL
5.7L Man. 650 5-30
(over 8500
GVW) M an.(3) N 600 5-30 OL
A u to D 550 5-30 OL
7.4L Man. N 800 5-30 OL
Auto. D 750 5-30 OL
* Arid 2 counts for engines with less than 500 miles Add 2 counts for every 1000 ft. above sea level (4.3 L and V8)
Add 1count for every 1000 ft above sea level (2 5L and 2.8 L).
** Le* engine idle until proper fuel controi status (open/dosed loop) is reached
(1) 4 .5 ST senes
(2) 1 speed Auto inaCIOPickupw/ Fed emissions and no AIR system.
M) G van or Suburban with a single catalytic converter.
MINIMUM IDLE AIR RATE
Engine Transmission Gear Engine Speed Open/Closed
_________________________________________ (D/N)___________ (RPM)___________ Loop*
2.5L Man. N 600 50 CL

A u to . N 500 + 50 CL
2.8L Man. N 700 50 OL
A uto . N 700 50 OL
4.3L Man. N 450 + 50 CL
A uto. D 400 50 CL
A uto.(1) N 475 50 CL
5 0L Man. N 500 25 OL
A u to. D 425 + 25 OL
A u to .(2) D 425 + 25 CL
5.7L Man. N 500 + 25 OL
(under 8500 GVW) A uto. D 425 + 25 OL
5.7L Man. N 550 + 25 CL
(over 8500 GVW) A uto. D 450 + 25 CL
7.4L Man. N 700 + 25 OL
A uto. D 700 + 25 OL
* Let engine idle until proper fuel control status (open/closed loop) is reached
( 1 ) 4 3L ST senes
'2) 5 0L without AiR system
EVAPORATIVE EMISSION CONTROL 5-1
SECTION 5
EVAPORATIVE EMISSION CONTROL SYSTEM (EECS)
CONTENTS
GENERAL DESCRIPTION.................................... 5-1 FUNCTIONAL TESTS.........................................5-3
PURPOSE.......................................................... 5-1 A ltitu d e C a n is te r .........................................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
A ltitu d e 4.3 L & V 8 ............................... 5-2 VAPOR CANISTER H O SES............................. ..5-3
Evaporative S ystem -A ltitude 4.3L & V8 . 5-2 VAPOR P IP E ..................................................... ..5-4
Tank Pressure C ontrol Valve ................. 5-3 Vapor Pipe Repair .................................... ..5-4
D IA G N O S IS .......................................................... 5-3 FUEL C A P .......................................................... ..5-4
RESULTS OF INCORRECT O P E R A T IO N ____5-3 PARTS INFORMATION .........................................5-4
VISUAL CHECK OF CANISTER........................ 5-3
GENERAL DESCRIPTION
PURPOSE
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
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
the normal combustion process.
The fuel tank has a fuel cap that is not normally
vented to the atmosphere, but has a va lve which
allows both pressure and vacuum relief.
OPERATION
Evaporative System
2.5L, 2.8L & 4.3L (ST) (Figure 5-5)
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
speed. A timed vacuum source is applied to the vapor
canister tube labeled "canister purge to draw fresh
air through the bottom o f 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
(T V S ) installed in the intake manifold coolant passage
to sense engine coolant temperature This T V S has
two ports and is located between the canister and the
5-2 EVAPORATIVE EMISSION CONTROL
7S3474-6E
Figure 5*2 - Vapor Canister - 4.3L & V8 Figure 5-3 - Vapor Canister - 4.3L & V8 - Altitude
Except Altitude
TBI unit. When the engine is below 46 C (115 F), the Evaporative System - Altitude
T V S is closed preventing purge of the canister. When 4.3L& V 8 (Figure 5-8)
engine temperature is above 46 C (115 F), the T V S 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
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 o f 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 TB I throttle valve.
canister and forces the vapors out the purge line. The The rate of purge is controlled through this port by
canister used on the 4.3L M application functions as throttle valve location (throttle opening).
described above, but has a 5/16 diameter "fuel tank
tube. All other applications have a canister with a
1/4 diameter fuel tank tube.
VISUAL CHECK OF VAPOR CANISTER
Replace vapor canister if cracked or damaged.

Replace vapor canister if fuel is leaking from
bottom and check o p e r a tio n o f the t o t a l
system.
Replace filter at the bottom o f the canister if
dirty, plugged or damaged. (2.5L, 2.8L & 4.3L
(ST) only).
FUNCTIONAL TESTS
Vapor Canister - Altitude Only
Apply a short length of hose to the lower tube o f

purge valve, and attempt to blow through it. Little or
no air should pass into the canister. (A small amount
of air will pass if the canister has a constant purge
hole).
With hand vacuum pump, apply vacuum (15 Hg.
or 51 kPa) to the control valve tube (upper tube). If
1 DIAPHRAGM the diaphragm does not hold vacuum for at least 20
2 VENT RESTRICTION seconds, the diaphragm is leaking, and the canister
3 TUBE TO MANIFOLD VACUUM must be replaced.
4 TUBE TO FUEL TANK I f the diaphragm holds vacuum, again try to blow
5 TUBE TO CANISTER 10-1-85 through the hose connected to the lower tube while
*6S 2971-6E vacuum is still being applied. An increased flow o f air
Figure 5-4 Fuel Tank Pressure Control Valve should be observed. If not, the canister must be
replaced.
Tank Pressure Control Valve
Tank Pressure Control Valve
The tank pressure control valve (Figure 5-4), used
only on altitude applications, allows vapors to flow Install a short piece of hose on the valve inlet tube
from the fuel tank into the system. When fuel tank (fuel tank side) and blow into hose. You should feel
pressure exceeds the spring pressure on the va lve the diaphragm pop open and air should pass through
diaphragm (4.3 kPa), the va lve opens and a llow s the valve. I f the valve does not open, it should be
vapors to enter the canister or go directly to the engine replaced.
when purge is enabled. The tank pressure control
valve is located in the engine compartment on C & K
applications, and near the fuel tank on the others.
ON-VEHICLE SERVICE
VAPOR CANISTER
DIAGNOSIS
|+->| Remove or Disconnect
RESULTS OF INCORRECT OPERATION
1. Hoses from canister. Mark hoses for installation
Poor idle, stalling and poor d r iv e a b ility can be on new canister.
caused by: 2. Screw from bracket and canister.
Damaged canister.
Hoses split, cracked and or, not connected to + 4- Install or Connect
the proper tubes.
1. Canister and bracket screw.
Evidence of fuel loss or fuel vapor odor can be
? Hoses to canister.
caused by:
Liquid fuel leaking from fuel lines or TBI unit.
VAPOR CANISTER HOSES
Cracked or damaged vapor canister.
Disconnected, misrouted, kinked, deteriorated
Refer to Vehicle Emission Control Inform ation
or damaged vapor pipe, or canister hoses.
label for routing of canister hoses. When replacing
A ir cleaner or air cleaner gasket improperly
h os es , use hose i d e n t i f i e d w i t h t h e w o r d
seated.
T'luoroelastomer .

(2
t #
TBI UNIT a FUEL TANK El VAPOR PIPE
VAPOR CANISTER FUEL CAP

VAPOR RESTRICTION
5-21-86
CANISTER HOSE 7S3513-6E
Figure 5-5 Evaporative Emissions Control System Schematic - 2.5L & 4.3L(ST)
VAPOR PIPE 2. Cut ends o f pipe remaining on vehicle square with

a tube cutter. Using the first step o f a double
The vapor pipe is secured to the underbody with flaring tool, form a bead on the end of both pipe
clamp and screw assemblies. F lex ib le hoses are sections. If pipe is too corroded to withstand bead
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.
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 o f fuel pipe.
R e p a ir va por pipe in sections u s in g b r a ze d Tighten clamps on each side of repair.
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
Do not use copper or aluminum tub ing 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 m alfunctioning o f the
have satisfactory d u r a b ilit y to w ithstand system.
normal vehicle vibrations.
Do not use rubber hose within 4" (100mm) of PARTS INFORMATION
any part o f the exhaust system or within 10"
(254mm) o f the catalytic converter. Hose PART NAME GROUP
inside d ia m e te r must match steel tu b in g
outside diameter. Canister, Fuel Vapor .................................... 3.130
1. In repairable areas, cut a piece o f 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 o f steel tubing and
hose so that hose lengths will not be more t han 10
inches (254mm).
0 0
E l
n
r
\ ' \\
U T T Z A
TBI UNIT [T 1 FUEL TANK |T 1 FUEL CAP
El VAPOR CANISTER |~4~1 VAPOR RESTRICTION [7 | VAPOR CANISTER

|T | THERMOSTATIC 5-23-87
[T ~ | VAPOR PIPE ULI VACUUM SWITCH 7S-3512-6E
Figure 5-6 Evaporative Emissions Control System Schematic - 2.8L
J
I---*
YSSS/a
----------------
* * * * * * *
? $
\
\
\
f %
TBI UNIT m VAPOR RESTRICTION m VAPOR PIPE
m VAPOR CANISTER m FUEL TANK FUELCAP
AIR INLET 6-5-87

m m m 7S-3514-6E
Figure 5-7 Evaporative Emissions Control System Schematic - 4.3L & V8 - Except A ltitu d e
IGNITION SYSTEM / EST 6-1
SECTION 6
IGNITION SYSTEM/EST
CONTENTS
GENERAL DESCRIPTION.................................... 6-1 EST PERFORMANCE CHECK
PURPOSE...........................................................6-1 ON-VEHICLE SERVICE............
OPERATION..................................................... .6-1 IGNITION S Y S T E M ............
Hall Effect Switch .................................... .6-2 SETTING TIMING ...............
DIA G N O S IS ...........................................................6-2 EST SYSTEM ......................
EST SYSTEM ....................................................6-2 Hall Effect Switch Test .
Results o f Incorrect EST O peration . . . 6-3 PARTS IN F O R M A T IO N .......... 6-8
CODE 4 2 ............................................................ 6-3
GENERAL DESCRIPTION
PURPOSE
The ignition system controls fuel combustion by

providing a spark top ignite the compressed air/fuel
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 T im in g
(EST) system.
Only the E S T system w ill be described here.
Additional information on the ignition system i f found
in Section "6D .
OPERATION
The ignition system has a distributor module with

four terminals for the EST system (Figure 6-1 and 6-2) Figure 6-1 - Module (Except 2.5L S/T Truck)
that are connected by the ECM.
To properly control ignition/combustion timing,
the ECM needs to know:
Crankshaft position
Engine speed (rpm)
Engine load (manifold pressure or vacuum)
Atmospheric (barometric) pressure
Engine coolant temperature
All engines except 2.5L S/TTruck
T h e E S T sy stem consists o f the d i s t r ib u t o 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 - M od u le (2.5L S/T Truck)

6-2 IGNITION SYSTEM/EST
These circuits perform the following functions:

TERMINAL A - Reference Ground Lo
Th is wire is grounded in the d is trib u to r 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
A t 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
position information.
TERMINAL D -E S T
This circuit triggers the module. The ECM does
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.
Therefore, i f the base timing is set incorrectly, the
engine spark curve will be incorrect.
S/T Truck with 2.5L
The EST system consists of a hall effect switch, the

distributor module, an ECM, and connecting wires.
The four terminal connector is lettered A-B-C-D.
These circuits perform the following functions: Hall Effect Switch
TERMINAL A - EST (Figure 6-3)
This circuit triggers the module. The ECM does 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
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 o f a magnetic field on an
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.
position in fo r m a t io n throu gh the hall effe ct
switch.
TERMINAL C - Bypass
DIAGNOSIS
A t about 400 rpm, the ECM applies 5 volts to this
The description and operation o f the i g n it io n
circuit to switch spark tim in g control from the
system can be found in Section "6 D .
module to the ECM. An open or ground bypass
Refer to charts in this section for ignition system
circuit will set a Code 42 and the engine will run
check.
at base timing, plus a small amount of advance
built into the module.
EST SYSTEM
TERMINAL D - Reference Ground Lo
Th is wire is grounded in the d is tr ib u to r and
Code 12 is used during the System C heck in
makes sure the ground circuit has no voltage drop
Section 3 procedure to test the code display ability of
which could affect performance. If it is open, it
the ECM. This code indicates that the ECM is not
may cause poor performance.
receiving the engine rpm (Reference) signal.
The " R e fe r e n c e signal also t r ig g e r s the fuel
injection system. Without the "Reference signal, the
engine cannot run.
IGNITION SYSTEM / EST 6-3
Results of Incorrect EST Operation
The ECM used information from the M A P and

coolant sensors in addition to rpm to calculate spark
advance as follows:
Low M A P output voltage = More spark advance
Cold Engine = More spark advance
High M A P Output Voltage = Less spark advance
Hot engine = Less spark advance
Therefore, detonation could be caused by high
M A P output or low resistance in the coolant sensor
circuit.
Poor performance could be caused by high M A P
output or low resistance in the coolant sensor circuit.
CODE 42
A fault in the EST system will usually set a Code Figure 6-4 - Timing Connector (2.8L)
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
Set timing according to instructions on V eh ic le
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
T im ing specifications for each engine are listed on
the EST mode.
the Vehicle Emissions Control Information label on
When the rpm for EST is reached (about 400 rpm),
the radiator support. When using a tim in g light,
the ECM applies 5 volts to the bypass line and the EST
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 plu g lead. Once the
If the bypass line is open, the module w ill not
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. A lw a y s follow V e h ic le
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 a g n e tic t i m i n g
may or may not be set.
probe hole for use with special ele ctron ic t i m i n g
An open in the EST circuit will set a Code 42 and
equipment. Consult manufactures instructions for
cause the engine to run on the distributor module
use of this equipment.
timing. This w ill 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
engine by connecting terminal " B to " A at the A L D L
engine will not run.
connector. On the V6 and V8 engines, the system w ill
go into Bypass mode by disconnecting the t im in g
EST PERFORMANCE CHECK connector. This is a single wire sealed connector that
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 o f the engine w irin g
the A L D L 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 o f a taped
the diagnostic terminal not grounded. Then, ground
section below the h e a ter case in the p a s s e n g e r
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 o f

distributor, pick-up coil, distributor cap, ignition coil,
hall effect switch, rotor, or distributor module.
ECM
PICK-UP COIL HALL
O J EFFECT
SWITCH
------ 423 W HT - D4 EST

IGNITION
430 PPL/WHT - B5 REFERENCE
MODULE
424 TAN/BLK - D5 BYPASS
453 BLK/RED - B3 GROUND
EST CONNECTOR
7S3643-6E
8-3-87 IGN 7-8-86
IGNITION SYSTEM CHECK

(REMOTE COIL)
2.5LS/T TRUCK
Test Description: Numbers below refer to circled 5. A p p ly in g a vo lta g e (1.5 to 8 volts) to m odule
numbers on the diagnostic chart. terminal " P should turn the module " O N and the
1. Two wires are checked, to ensure that an open is tach. term, voltage should drop to about 7-9 volts.
not present in a spark plug wire. This test will determine whether the module or
1A. I f spark occurs with 4 t e r m in a l d is t r ib u t o 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 " O N . This
low for EST operation. test can be performed by using a DC battery with a
2. A spark indicates the problem must be the rating of 1.5 to 8 volts. The use o f the test light is
distributor cap or rotor. mainly to allow the " P term in al to be probed
3. Normally, there should be battery voltage at the more easily.
" C and " + term in a ls . Low v o lt a g e w ou ld Some digital m ulti-m eters 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 m eter may
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
coil or ignition coil primary winding is open. ohms position can be checked by using a second
4. Checks for a shorted module or grounded circuit m e t e r or by c h e c k i n g th e m a n u f a c t u r e s
from the ignition coil to the module. The dist. specification o f the tool being used.
module should be turned " O F F , so normal voltage 6. This should turn " O F F " the module and cause a
should be about 12 volts. spark. If no spark occurs, the fault is most likely in
If the module is turned " O N , 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 m odule te s te r (J24642) co u ld
With an open ignition coil prim ary winding, a determine which is at fault.
small amount of voltage w ill 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 "E C M Intermittent Codes or
Performance .
IGNITION SYSTEM/EST 6-5
Perform System Check before proceeding w ith this test. (If a
tachom eter is connected to the Tach term ., disconnect it before

proceeding w ith the test).
IGNITION SYSTEM
Check spark at plug w ith spark tester J-26792 or equivalent (ST-125)
w hile cranking (if no spark on one w ire, check a second w ire ) A fe w CHECK
sparks and then nothing is considered no spark.
(REMOTE COIL)
No Spark Spark
2 .5 L S /T TR U C K
T ------ ' ~i
>Disconnect 4 term , distributor Check fuel.spark plugs, etc.
connector and check for spark. See Section 2 symptoms. TEST LIGHT
No spark
I
L
Spark
n
JSU TO D.C.
POWER SUPPLY
(1.5 to 8V)
(Leave spark tester connected to coil w ire for Steps 3-6).

i ---------------------------------------- ... _
nnnn
PNERl
n n n
1+ C E 1
No Spark Spark
r ..... I J
Disconnect distributor 2 term . "C / + " connector. Inspect cap for w a te r, cracks,
Ignition switch "o n". Engine stopped.
Check volts at " + " and "C" term 's, of dist. harn. conn.
etc. If OK, replace rotor. Fig. 1

Both term's. 10 volts or more Both term 's, under 10 volts Under 10 volts "C" term , only

Reconnect dist. 2 term . conn.

W ith ign. "O N ", check voltage from tach. term ,
to g n d . (term , m ay be taped back in harness).
Repair w ire from module " + " term ,
to "B" term , of black Ign. coil
connector or primary ckt. to ign. sw.
Check fo r open or gnd. in ckt.
from "C" term , to ign. coil. If Ckt.
is OK, fa u lt is. ign. coil or conn..

O verlO volts Under 1 volt 1 to 10 volts
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 fro m coil as in Step 6.
I
~T~~T
Light on steady Spark No Spark
T
blinks
HZ

Disconnect distributor 4 term , connector.
Remove dist. cap.
Disconnect pick-up coil connector from module.
System
OK
Replace ign. coil,
it too is fau lty
Connect voltm eter from tach. term , to ground.

Ignition on.
Insulate a test light probe to 1/4" from tip and note Replace ignition coil and recheck
voltage, as test fight is m om entarily connected from a for spark w ith spark tester. If still
voltage source (1.5 to 8V) to module term . "P". (Fig. 1). no spark, re-install original coil
and replace dist. module..
Voltage drops No drop in voltage

T X
Check for spark from coil w ire w ith spark tester

as test light is rem oved from module term .
Check module ground.
If OK, replace module.
I
No Spark Spark
E - n
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 L----- ..... ____
HZ
No Spark Spark OK Bad
~1---------
Ign. coil rem oved is OK, System OK Check coil w ire Replace
reinstall coil and check coil from cap to coil. If module
w ire from dist. cap. if OK, OK, replace coil. 7S 3 6 5 9
replace dist. module. 7-8-86
PICK-UP
COIL,
IGNITION ECM
MODULE
DISTRIBUTOR
GBRE
UUUL DISTRIBUTOR 4 TERM

IGN. CONNECTOR
IGN. COIL ' B GRY. 423 W HT - D4 --------- EST

CONN.
2- 424 TAN/BLK H D5 - BY-PASS

SET TIMING
CONNECTOR (EXCEPT 2.5L)
------------------------------------- 453 BLK/RED H B3
TACH.LEAD
7S 3 6 4 2 -6E
7-23-87 7-8-86
IGNITION SYSTEM CHECK

(REMOTE COIL / SEALED MODULE CONNECTOR DISTRIBUTOR)
ALL ENGINES EXCEPT 2.5L S/T TRUCK
Test Description: Numbers below refer to circled I f the module is turned " O N , the voltage would be
numbers on the diagnostic chart. low, but above 1 volt. T h is could cause the
1. Tw o wires are checked, to ensure that an open is ignition coil to fail from excessive heat.
not present in a spark plug wire. With an open ignition coil prim a ry winding, a
1A. I f spark occurs with EST connector disconnected, small amount of vo lta ge w ill leak through the
pick-up coil output is too low for EST operation. module from the "Bat. to the tach terminal.
2. A spark in d ica tes the prob lem must be the 5. Checks for an open module, or circuit to it. 12
distributor cap or rotor. volts applied to the module " P terminal should
3. Normally, there should be battery voltage at the turn the module " O N and the voltage should drop
"C and " + ter m in a ls . Low v o lta g e would to about 7-9 volts.
indicate an open or a high resistance circuit from 6. This should turn " O F F the module and cause a
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
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 d e te r m in e
4. Checks for a shorted module or grounded circuit which is at fault.
from the ig n it io n coil to the m odu le. The
distributor module should be turned "OFF1 , so Diagnostic Aids:
normal voltage should be about 12 volts.
The "Scan tool does not have any ability to help
diagnose an ignition system check.
Refer to Section "2 for "E C M Intermittent Codes or
Performance .
IGNITION SYSTEM/EST 6-7
Perform System Check before proceeding w ith this test. (If a

tachom eter is connected to the Tach term ., disconnect it before
proceeding w ith the test).
IGNITION SYSTEM
CHECK
Check spark a t plug w ith spark tester J-26792 or equivalent (ST-125)
w hile cranking (if no spark on one w ire , check a second w ire) A fe w (REMOTE COIL / SEALED MODULE
sparks and then nothing is considered no spark.
CONNECTOR DISTRIBUTOR)
3L ALL ENGINES
No Spark
I
Spark
3
EXCEPT 2.5L S/T TRUCK
Disconnect 4 term , distributor Check fuel,spark plugs, etc.
connector and check for spark. See Section 2 symptoms. TEST LIGHT
"L
TO D C.
No spark Spark POWER SUPPLY
1----- r = (1.5 to 8V)
Check for spark a t coil w ire w ith tester w hile cranking. Replace pick-up coil
(Leave spark tester connected to coil w ire for Steps 3-6).
No Spark Spark
I ~1
Disconnect distributor 2 term . "C / + " connector. Inspect cap for w a te r, cracks,
Ignition switch "on". Engine stopped.
Check volts at " + " and "C" term's, o f dist. harn. conn.
etc. If OK, replace rotor.
| Both term's. 10 volts or more Both term's, under 10 volts Under 10 volts "C" term , only
Reconnect dist. 2 term . conn.

Repair w ire from module " + " term , Check for open or gnd. in ckt.
W ith ign. "O N ", check voltage from tach. term ,
to "B" term , of black Ign. coil from "C" term , to ign. coil. If Ckt.
to gnd. (term , may be taped back in harness).
connector or prim ary ckt. to ign. sw. is OK, fa u lt is. ign. coil or conn..
a
O verlO volts Under 1 volt 1 to 10 volts
I
Connect test light from tach. term , to ground. Repair open tach. lead or Replace m odule and check for
Crank engine and observe light. conn and repeat test # 4 . spark from coil as in Step 6.
L _
Light on steady Light Spark No Spark
blinks
I

Disconnect distributor 4 term , connector.
Remove dist. cap.
Disconnect pick-up coil connector from module.
System
OK
Replace ign. coil,
it too is fau lty
Connect voltm eter from tach. term , to ground.

Ignition on.
Insulate a test light probe to 1/4" from tip and note voltage, as test light Replace ignition coil and recheck
is m om entarily connected from a voltage source (1.5 to 8V) to module fo r spark w ith spark tester. If still
term . "P". (Fig. 1). no spark, re-install original coil
and replace dist. module..
Voltage drops No drop in voltage

X 1
Check for spark from coil w ire w ith spark tester

as test light is rem oved from module term .
Check module ground.
If OK, replace m odule.
No Spark Spark
1
>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 m agnetized?
I
No Spark Spark OK Not OK Yes No
3 ------- r I H I H
Ign. coil rem oved is OK, System OK Check coil w ire Replace Check pick-up coil Replace pole
reinstall coil and check coil from cap to coil. If module or conns. (Coil piece and
w ire from dist. cap. if OK, OK, replace coil. resistance should shaft assy.
replace dist. module. be 500-1500 ohms
7S 3660-6E
and not grounded).
7-8-86
6-8 IGNITION SYSTEM / EST
EST SYSTEM
Refer to Section " 6 D for rep la c e m e n t o f 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 rem ove 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
blade against magnet. Replace switch if above 0.5
volts.
4. W ith blade against magnet, voltage should be
within 0.5 volts of battery voltage. Replace switch
if there is a low voltage reading. E E H A LL EFFECT SWITCH
CE M AG NET
CE INSERT KNIFE BLADE IN
PARTS INFORMATION T H IS AREA W ITH BLADE
S TR A IG H T DOWN AG AINST
THE M AGNET
PART NAME GROUP T E R M IN A L (U N D E R N E A T H )
i s BATTERY
Distributor ..................................................... 1.150
E VO LTM ETER
Module, D is t r ................................................... 2.383 6S2717-6E
Coil, D istr..........................................................2.170
Figure 6-5 - Hall Effect Switch
ELECTRONIC SPARK CONTROL 7-1
SECTION 7
ELECTRONIC SPARK CONTROL (ESC)
ALL ENGINES EXCEPT 2.5L AND 7.4L
CONTENTS
GENERAL DESCRIPTION......................................... 7-1 ON-VEHICLE SERVICE.............................................. ..7-1
PURPOSE.............................................................. 7-1 ESC KNOCK SENSOR............................................ ..7-1
OPERATION.......................................................... 7-1 ESC MODULE AND BRACKET ........................... ..7-4
DIA G N O SIS.............................................................. 7-1 PARTS IN F O R M A T IO N ............................................ ..7-4
CODE 4 3 ................................................................. 7-1
GENERAL DESCRIPTION When the knock sensor detects spark knock, the
module turns "O F F the circuit to the ECM. The EC M
PURPOSE then retards EST to reduce spark knock.
The electronic spark control (E S C ) system is DIAGNOSIS

designed to retard spark timing up to 20 to reduce
spark knock (detonation) in the engine. This allows Loss o f the ESC knock sensor signal or loss o f
the engine to use maximum spark advance to improve ground at ESC module would cause the signal to the
driveability and fuel economy. ECM to remain high. This condition would cause the
V a ry in g octane levels in todays 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 kn ocking could
spark knock. 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
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
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 ( F ig u r e 7-1) d e te c ts a possible cause o f excessive spark knock, refe r to
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
receives the knock sensor information and sends a
signal to the ECM . T h e E C M then adjusts the Code 43 indicates that the ECM is receiving less
ele ctron ic spark t im in g ( E S T ) to reduce sp ark than 6 volts for a 4 second period w ith the e n gin e
knocking. running. I f 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
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 Icoated to the lower left
of the engine block, below the spark plugs for the 4.3L
engine and the lower right o f the engine block for the
2.8L, 5.0L and 5.7L engine.
|<~>| Remove or Disconnect

2. W iring 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
7-30-87
ELECTRONIC SPARK CONTROL SYSTEM CHECK

ALL ENGINES EXCEPT 2.5L AND 7.4L
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 " O F F and this signals
the ECM to retard timing, if engine rpm is over about 900.

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
there should not be any detonation, and if knock is if the ESC module is functioning, knock signal should
indicated, an internal engine problem may exist. display "yes , whenever detonation is present. Th e
2. U su ally a knock s ig n a l can be g e n e r a te d by knock retard position on the "Sca n displa ys the
tapping on the right exhaust manifold. This test amount of spark retard the FXM is commanding. The
can also be performed at idle. Test number 1 was ECM can retard the tim ing up to 20 degrees.
run at 1500 rpm to determine if a constant knock If the ESC system checks O K, but detonation is
signal was present, which would affect engine the complaint, refer to Detonation/Spark Knock in
performance. Section "2 .
3. This tests whether the knock signal is due to the This check should be used after other causes o f
sensor, a basic en g in e p rob lem , 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.
module will not function correctly. The test light
should light indicating the ground circuit is OK.
5. Contacting C K T 496, with a test light to 12 volts,
should generate a knock sig n a l to d e te r m in e
whether the knock sensor is faulty, or the ESC
module cant recognize a knock signal.
ELECTRONIC SPARK CONTROL 7-3
7-4 ELECTRONIC SPARK CONTROL
Figure 7-2 - ESC Knock Sensor - 4.3L Figure 7-4 - ESC Module - ST Series
m ESC KNOCK SENSOR

m ESC MODULE
6 S 2892-6E
fTl ELECTRICAL CONNECTOR
7S3713-6E
| 2 1 ELECTRICAL CONNECTOR
Figure 7-3 - ESC Knock Sensor - 2.8L, 5.0L, 5.7L Figure 7-5 - ESC Module - CK RV MP Series
Install or Connect
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
sensor.
ESC MODULE AND BRACKET

|++| Remove or Disconnect

1. ESC module connector.
2. Attaching screws.
Tl ESC MODULE [T] SEAT RISER
3. ESC module.
Tl ELECTRICAL CONNECTOR 7S 3714-6E
Figure 7-6 - ESC Module - G Series

|+7| Install or Connect
1. ESC module. PARTS INFORMATION
2. Attaching screws.
3. ESC module connector. PART NAME GROUP
Sensor, ESC Knock ........................................ ..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 & 4.3L (S/T SERIES)
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 S IS ............................................................8-2 AIR PUMP.......................................................... 8-6
AIR SYSTEM.......................................................8-2 AIR CONTROL V A L V E ..................................... 8-6
A ir P u m p .......................................................8-3 CHECK V A L V E ................................................ 8-6
Check V a lv e ................................................ ..8-3 AIR INJECTION PIPE ASSEMBLY .................. 8-6
Hoses And P ip e s ...........................................8-3 PARTS INFORMATION ....................................... 8-10
AIR MANAGEMENT CHECK C H A R T ............ ..8-5
GENERAL DESCRIPTION
PURPOSE
The air management system is used to reduce

carbon monoxide and hydrocarbon emissions.
This system, air injection reaction (A IR ), under
certain conditions, adds air (oxygen) to the exhaust
manifold to continue combustion after the exhaust
gases leave the combustion chamber. This added air
also brings the catalytic converter up to operating
temperature more quickly when the engine is cold.
1 AIR PUMP
m EAC VALVE
m AIR TO AIR CLEANER
E AIR TO EAC VALVE
DO AIR TO EXHAUST PORTS
[I] MANIFOLD VACUUM SIGNAL
m AIR INJECTION PIPES (7.4L SHOW N. 4.3L, 5.0L
AND 5.7L HAVE ONE INLET PIPE AT THE FRONT OF
EACH M ANIFOLD)
[8 j ECM
[~9~ EAC SOLENOID
rro- CHECK VALVES 6S2714-6E
Figure 8-2 - AIR System - 4.3L & V8

'^ iX l
rn airpump AIR OPERATION
f~2~l EAC VALVE
I 3 I AIR TO AIR CLEANER The system consists of an air pump, an (electric)
[~4~~l AIR TO EAC VALVE air control valve with solenoid, check v a lv e (s ), and
I 5 [ AIR TO E X H A U ST PORT necessary plumbing.
I 6 [ M ANIFO LD V A C U U M SIGNAL A belt driven air pump supplies air through a
m ecm centrifugal filter fan to the electric air control (E A C )
I 8 I EAC SOLENOID valve 2.8L (Figure 8-3) or an electric air control valve
l ~ 9 l CHECK VALVE with relief tube (EC T) 4.3L and V8 (Figure 8-4). 'Phis
H o i EXH AU ST M ANIFOLD valve, directs the air to either the en gin e exhaust
6S3040-6E
manifold ports or to the air cleaner.
Figure 8-1 - AIR System - 2.8L
8-2 AIR MANAGEMENT
NOTICE: On the EAC valve, th? divert and signal

tube locations are rev erse d 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. A t 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
manifold vacuum signal, air is directed to the air
cleaner.
A Check valve, on the air injection pipe, prevents
~T1 ELECTRIC AIR m DIVERT ASSIST
back flow of exhaust into the air pump if there is an CONTROL VALVE W ITH ORIFICE
exhaust backfire or pump drive belt failure.
[~2~1
RELIEF TUBE
OUTLET SEAT
m DIAPHRAGM & GUIDE
ASSEM BLY
If the engine is operating under a rich condition or m M ETERING VALVE m DIAPHRAGM SPRING
the "Service Engine Soon lamp lights, the solenoid is CHAMBER Hoi VA C U U M CHAMBER
| 4 | RELIEF VALVE &
de-energized and air goes to the air cleaner. BODY ASM m M ANIFO LD VA C U U M
SIGNAL TUBE
fTI PRESSURE PASSAGE
rnn DIAPHRAGM COVER
| 6 [ BAND CLAMP ASSEM BLY
7S 3613-6E
Figure 8-4 - ECT Valve
DIAGNOSIS
AIR SYSTEM
Refer to A ir Managem ent Check ch art for the

diagnosis of the A IR system.
NOTICE: If the engine or underhood compartment is

to be cleaned with steam or high-pressure
detergent, the centrifugal filter fan should
be masked o ff to prevent liquids from
entering the pump.
If no air (oxygen) flow enters the exhaust stream at

the exhaust ports, HC and CO emission levels may be
too high.
Pi~] ELECTRIC AIR CONTROL [~~0~~|DECELTIMING CHAMBER A ir flowing to the exhaust ports at all times could
(EAC) VALVE f T I AIR TO AIR CLEANER cause a rich E C M co m m a n d and in c r e a s e d
m DECEL TIMING ASSEMBLY
pTl AIR FROM AIR PUMP temperature of the converter.
f T I MANIFOLD VACUUM [~9~~|AIR TO EXHAUST PORTS The A IR system is not completely noiseless. Under
SIGNAL TUBE OR MANIFOLD normal conditions, noise rises in pitch as engine speed
PH ELECTRICAL TERMINAL flOl PRESSURE RELIEF increases. To determine if excessive noise is the fault
[ 5 ] EAC SOLENOID ASSEMBLY 6S2609-6E of the A IR system pump, m om entarily operate the
engine with the pump drive belt removed.
Figure 8-3 - EAC Valve
AIR MANAGEMENT 8-3
I f noise is caused by the A IR system pump, check ON-VEHICLE SERVICE

for :
A seized air pump. DRIVE BELT
Proper mounting and bolt torque o f 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 co m p ressor, a i r pump, g e n e r a t o r , and
Air Pump crankshaft pulleys.
The air pump is a positive displacement vane type PUMP CENTRIFUGAL FILTER FAN
which is perm anently 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.
observe air flow from hose. If air flow increases as
engine is accelerated, pump is operating satisfactorily. CAUTION: C e n trifu g a l fan s h o u l d not be
If air flow does not increase or is not present, proceed r e m o v e d f r o m p u m p u n l e s s it is
as follows: da m a ge d , as re mov a l will d es tr o y
the fan.
Inspect
Before starting replacement note the following:
1. For proper drive belt tension.
Do not allow any filter fragments to enter the air
2. For a leaky pressure relie f valve. A ir may be heard
pump intake hole.
leaking with the pump running.
Do not remove filter fan by inserting a screwdriver
Check Valve between pump and f ilt e r fan. A i r d a m a g e to
sealing lip pump will result.
Inspect Do not remove metal drive hub from filter fan
It is seldom possible to rem ove the filte r fan
1. A check valve should be inspected whenever the without destroying it.
hose is disconnected from it or whenever check
va lv e failure is suspected (A pump that had [++| Remove or Disconnect
become inoperative and had shown indications of
(Figure 8-5)
having exhaust gases in the pump would indicate
check valve failure).
1. A ir pump.
2. Remove the check valve.
2. Pump pulley.
3. B low throu gh the check v a l v e t o w a r d the
3. Insert needle nose pliers and pull filter fan from
exhaust manifold side. A ir should pass freely.
pump hub.
Tu rn the v a lv e around and a ttem p t to blow
through the valve toward the air pump side. No
-4- Install or Connect
air should pass through the valve.
4. Replace valve which does not operate properly. 1. N ew filter fan on pump hub.
2. Spacer and pump pulley a gainst c e n t r if u g a l
Hoses and Pipes filter fan.
3. Pump pulley bolts and tighten equal to torque
Inspect spec, in Figure 8-6. This w ill 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. A l l hoses or pipe c o n n e c tio n s , and c la m p 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 0.1).
wear. sealing lip has worn in. This may require a short
4. I f a leak is suspected on the pressure side of the period o f pump operation at va r io u s e n g in e
system, or i f a hose or pipe has been disconnected speeds.
on the pressure side, the connections should be 4. A ir pump.
checked for leaks with a soapy water solution.
W ith the pump running, bubbles will form if a
leak exists.
8-4 AIR MANAGEMENT
SOLENOID CONNECTOR
ELECTRIC
AIR CONTROL
TO AIR SOLENOID
CLEANER A B
DJTJC
FULL
MANIFOLD GE
VACUUM *V X CHECK VALVE S i CHECK
(2.8L .4.3L & V-8) VALVE
(4 .3 L & V -8 )
TT TT
TO TO
EXHAUST EXHAUST ECM
PORTS PORTS
B
A 1
PNK/BLK
C2
436 BRN
IGNITION * # 1
GAGE
FUSE IP
CONNECTOR
ALDLCONNECTOR 7-23-87
7-23-87 *7 S 3612-6E
AIR MANAGEMENT CHECK

(ELECTRONIC AIR CONTROL VALVE)
An electric air control valve solenoid directs air into the exhaust ports or the air cleaner During cold start
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 cleaner. If the system is not operating properly, check
manifold vacuum signal (10 Hg/34kPa) at the valve and check the electrical circuit from the solenoid to the
ECM.
Test Description: Numbers below refer to circled 3. Checks for an open control circuit. Grounding
numbers on the diagnostic chart. diagnostic terminal will energize the solenoid, if
1. This is a system performance test. When vehicle ECM and circuits are normal. In this step, if test
goes to "Closed Loop , air will switch from the light is " O N , circuits are normal and fault is in
ports and divert to the air cleaner. valve connections or valve.
2. Tests for a groun ded e le c t r ic d iv e r t circuit. 4. Checks for voltage from battery through a fuse to
Normal system light will be " O F F . the solenoid.
AIR MANAGEMENT 8-5
AIR MANAGEMENT CHECK

(ELECTRONIC AIR CONTROL VALVE)
7-27-87
*6 S 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 at various e n g in e
speeds.
6 . Pump drive belt and adjust.
7. Check a ir m a n a g e m e n t s y s t e m for p r o p e r
operation (see A ir Management Check chart).
AIR CONTROL VALVE

(Figures 8-7 thru 8-11)
4-+ Remove or Disconnect

l. Battery ground cable.
2. Electrical connector on control valve.
3. Manifold vacuum signal hose.
4. A ir inlet and outlet hoses from valve.
5. Control valve.
f T l A IR PUMP
[~2~] PU LLEY BOLT + 4- Install or Connect
T IG H T E N TO
10 N-m 1. Control valve.
(90 IN. LBS.)
2. A ir inlet and outlet hoses to valve.
[T ]P U L L E Y
3. Manifold vacuum signal hose.
[ T ] FILTER FAN 4. Electrical connector on control valve.
5. Battery ground cable.
6 . Check system operation (See A ir Managem ent
5S 1616-6E Check chart).
Figure 8-5 - Pump Filter Fan Service

CHECK VALVE
(Figures 8-7 thru 8-11)
AIR PUMP (Figure 8-6)
|~| Remove or Disconnect
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.
2. Loosen bolt, holding pump to mounting brackets, 3. Unscrew check valve from air injection pipe.
release tension on drive belts.
3. Move belts out of the way, then remove pump -- Install or Connect
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.
filter fan from hub (see Figure 8-5). 3. Any parts removed for access.
Install or Connect AIR INJECTION PIPE ASSEMBLY
1. A ir pump assembly, and tighten mounting bolts. Remove or Disconnect

2. Hose.
3. N ew filter fan on pump hub. 1. Hose.
4. Spacer and pump pulley aga inst c e n t r ifu g a l 2. Check Valve.
filter fan. 3. Nuts attaching pipes-to-manifold.
5. Pump pulley bolts and tighten equally to torque 4. Pipe Assembly.
spec, in Figure 8-6. T h is w ill com press the
Install or Connect
centrifugal filter fan onto the pump hole. Do not
drive filter fan on with a hammer. A slig h t

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
m AIR PU M P [T ] BRACE [F j BOLT - TORQUE TO 30 N m (22 FT. LBS.)

fTl PULLEY [T] SUPPORT [W] BOLT - TORQUE TO 40 N m(29 FT. LBS.)
FT] SPACER [T] BOLT - TORQUE TO 15 N m (11 FT. LBS.) QT] BOLT - TORQUE TO 80 N m (59 FT. LBS.)
fT l BRACKET [T ] BOLT - TORQUE TO 25 N m (18 FT. LBS.) [T F ] NUT - TORQUE TO 30 N m (22 FT. LBS.)
7S 3615-6E
Figure 8-6 - AIR Pump M ou n tin g

8-8 AIR MANAGEMENT
rn a i r p um p m AIR INJECTION PIPE TIGHTEN NUTS TO 28 N m (20 FT. LBS.)

m SILENCER |7 l BOLT TIGHTEN TO 15 N m (11 FT. LBS.)
m EAC VALVE [ 8 |GASKET
I 4 l HOSE I 9 I SHIELD
I 5 I CHECK V A L V E - - TIGHTEN TO 85 N m (26 FT. LBS.) I10 I PORT VAC UUM HARNESS 6 S 2897-6E
Figure 8-7 - A I R System - 2.8L
p Z j AIR PUM P E E ] d iv e r t e r v a l v e or EAC VALVE

[ T ] ADAPTER A N D SEAL - TIG HTEN SCREWS TO 25 N m (18 FT. LBS.) [ T ] AIR CLEANER
[T ] AIR INJECTION PIPE TIGHTEN NUTS TO 28 N m (20 FT. LBS.) [T ] BOLT - TIGHTEN TO 34 N m (25 FT. LBS.)
[T ] CHECK VALVE - TIGHTEN TO 25 N m (18 FT. LBS.) [F ] NUT-TIG HTEN TO 34 N m (25 FT. LBS.)
7S 3309-6E
Figure 8-8 - A I R System - 4.3L - G & M Series

AIR MANAGEMENT 8-9
F T l AIR PUM P m DIVERTER VALVE OR EAC VALVE

fTl ADAPTER A ND SEAL - TIGHTEN SCREWS TO 25 N m (18 FT. LBS.) m AIR CLEANER
fTl AIR INJECTION PIPE TIGHTEN NUTS TO 28 N m (20 FT. LBS.) fTl BOLT - TIG HTEN TO 34 N m (25 FT. LBS.)
fTl CHECK VALVE - TIG HTEN TO 35 N m (26 FT. LBS.) [~8l N U T - TIGHTEN TO 34 N m (25 FT. LBS.)
7S 3412-6E
Figure 8-9 - A I R System - 4.3L, 5.0L, 5.7L - C, K, P, R, & V Series
fTl AIR PU M P \ T } DIVERTER VALVE OR EAC VALVE

f T l ADAPTER A N D SEAL - TIGHTEN SCREWS TO 25 N m (18 FT. LBS.) [F | AIR CLEANER
fTl AIR INJECTION PIPE TIG HTEN N UTS TO 28 N m (20 FT. LBS.) [T] B 0LT * TIG HTEN TO 3 N m (26 IN. LBS.)
fTl CHECK VALVE - TIGHTEN TO 25 N m (18 FT. LBS.)
Figure 8-10 - A I R System - 5.0L, 5.7L - G Series

8-10 AIR MANAGEMENT
m AIR PUM P [] DIVERTER VALVE OR EAC VALVE

m ADAPTER AND SEAL - TIGHTEN SCREWS TO 10 N m (88 IN. LBS.) [T ] AIR CLEANER
[~3~| AIR INJECTION PIPE TIGHTEN NUTS TO 28 N m (20 FT. LBS.) [T ] BOLT - TIGHTEN TO 10 N m (88 IN. LBS.)
[T l CHECK VALVE - TIGHTEN TO 25 N m (18 FT. LBS.) [T ] N U T - TIGHTEN TO 34 N m (25 FT. LBS.)
7S 3413-6E
Figure 8-11 - A IR System - 7.4L - All Series
PARTS INFORMATION
PART NAME GROUP
Adapter, A IR Inj Cont V l v ............................. ..3.671

Bracket, A IR Inj Pump Supt ......................... ..3.655
Bracket, A IR Inj P u m p .................................... ..3.655
Fan, A IR P u m p ............................................... ..3.665
Gasket, A IR Inj Dvtr V lv E l ........................... ..3.671
I larness, A IR Inj Cont V lv V a c .........................3.675
Hose, A IR Inj Cont V l v .................................... ..3.675
Hose, A I R Inj Cont V lv D v t r ........................... ..3.675
Pulley, A IR Inj P u m p ...................................... ..3.650
Pump, A IR I n j ................................................. ..3.660
Valve, A I R Inj C o n t ........................................ ..3.670
Valve, A IR Inj E n g C h k ....................................3.670
Valve, A IR Inj Control ( D iv e r t).........................3.670
Valve, A I R Inj S w i t c h i n g ............................... ..3.670
EXHAUST GAS RECIRCULATION 9-1
SECTION 9
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
CONTENTS
GENERAL DESCRIPTION.................................... ..9-1 D IA G N O S IS .......................................................... ..9-3
PURPOSE ....................................................... ..9-1 RESULTS OF INCORRECT O P E R A T IO 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 M a n ifo ld P a ssa g e ................................9-3
Negative Backpressure V a lv e ................. ..9-2 EGR SYSTEM HOSES....................................... .. 9-8
EGR VALVE IDENTIFICATION ................... ..9-2 EGR SOLENOID .............................................. .. 9-10
PARTS IN F O R M A T IO N ....................................... .. 9-10
GENERAL DESCRIPTION
PURPOSE
The EGR system is used to lower NOx (oxides of

nitrogen) emission levels caused by high combustion
temperatures. The EGR valve feeds small amounts of
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 in tak e
manifold.
OPERATION
The EGR valve is opened by vacuum to let exhaust

gas flow into the intake manifold. The exhaust gas
then m oves w ith the air/fuel m i x t u r e into the
combustion chamber. I f too much exhaust gas enters,
combustion will not occur. For this reason, very little
exhaust gas is allowed to pass through the valve,
especially at idle. Th e E G R va lve is usually open
H I EGR VALVE [T1 AIR BLEED
F T I PINTLE VALVE HOLE
under the following conditions:
[ 3 INTAKE AIR r~7~l SMALL SPRING
CD
Warm engine operation
Above idle speed VACUUM PORT m LARGE SPRING
Q D DIAPHRAGM 6S 2608-6E
EGR CONTROL
Figure 9-1 - Negative Backpressure EGR Valve 2.5L,
4.3L (except ST), 5.0L& 5.7L (under 8500 GVW)
2.5L( 4.3L (except ST), 5.0L & 5.7L (under 8500 GVW)
To regulate EGR flow an ECM controlled solenoid EVRV 2.8L, 4.3L (ST), 7.4L & 5.7L (over 8500 GVW)
is used in the vacuum line. This is a normally closed T o r e g u la t e E G R flo w , an E C M c o n t r o l l e d
solenoid vacuum valve which is opened when the ECM electronic vacuum regulator valve ( E V R V ) solenoid is
completes the ground. The ECM will en ergize the used in the vacuum line. The ECM uses information
EGR solenoid (EG R " O N ) when the engine is warm from the following sensors to regulate the solenoid:
and above idle. There is little EGR flow at wide open Coolant Temperature
throttle due to lack o f vacuum. Throttle Position (TFS)
2.5L only P/N switch
On cold engine start-up the ECM receives input Distributor (rpm Signal)
from the M A T sensor (Manifold A ir Tem peratu re), The EGR vacuum control has an E V R V solenoid that
and i f the M A T 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 " O N and " O F F many tim es a
(176F). If there is a malfunction of the M A T sensor second and varies the amount of " O N time '"pulse
then the ECM receives input from the coolant sensor width ) to varv the amount o f EGR.
9-2 EXHAUST GAS RECIRCULATION
TYPES OF EGR VALVES
Tw o types o f E G R v a lv e s are used on these

engines:
Port (2.8L, 4.3L (ST), 7.4L & 5.7L over 8500
GVW)
Negative backpressure (2.5L, 4.3L (except ST),
5.0L & 5.7L under 8500 G V W )
Port EGR Valve
This valve is controlled by a flexible diaphragm

which is spring loaded to hold the v a lv e closed.
Vacuum applied to the top side o f the diaphragm
overcomes the spring pressure and opens the valve in
the exhaust gas port. This allows exhaust gas to be
pulled into the intake manifold and enter the engine
cylinders.
p H EGR V A L V E | 7 I MAP SENSOR
f T l EXHAUST GAS [~Fl CO O LA NT TEM PERATURE
SENSOR
n IN TA K E A IR
n T H R O TT LE POSITION
r n DIAPHRAGM SENSOR
m M A N IF O L D VACUUM
[Tol ELECTRONIC CO NTROL
p n VAC UUM SO LENO ID M ODULE
6S 2861-6E
Figure 9-3 - EGR System - w ith Solenoid
PH EGR V A L V E j 5 | DIAPHRAG M
f T l EXH AUST GAS |~6~1 V A L V E OPEN
1~3~| IN T A K E AIR [T l V A L V E CLOSED
[~4~| VACUUM PORT 1 8 | SPRING
4S 0536-6E
Figure 9-2 Port EGR Valve

2.8L, 4.3L (ST). 7.4L & 5.7L(over 8500 GVW)
[T l ASSEMBLY PLANT CODE
Negative Backpressure EGR Valve [ 2 | PART NUMBER
| T 1 DATE B UILT
The negative backpressure EG R va lve has the m LOOK HERE FOR LETTER
P * PO SITIVE BACK PRESSURE
bleed valve spring below the diaphragm, and the valve N = N E G A T IV E BACK PRESSURE
is normally closed. The negative backpressure valve BLANK = PORT V A L V E 7 S 3219-6E
varies the am ount o f ex h au st gas flow into the
Figure 9-4 - EGR Valve Identification
m a n ifo ld d e p e n d in g on m a n ifo ld va cu u m and
variations in exhaust back pressure.
The diaphragm on this valve has an internal air EGR VALVE IDENTIFICATION
bleed hole which is held closed by a small spring when
there is no exhaust backpressure. Positive backpressure EGR valves will have a " P
Engine vacuum opens the EGR valve against the stamped on the top side o f the valve after the part
pressure of a large spring. When manifold vacuum number.
combines with negative exhaust backpressure, the Negative backpressure EGR valves will have a
vacuum bleed hole opens and the EGR valve closes. " N stamped on the top side of the valve after the
This valve will open if vacuum is applied with the part number.
engine not running. Port EGR valves have no identification stamped
after the part number.
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 li t t le or no E G R flow a llo w s combustion
temperatures to get too high during acceleration and fT I EGR VALVE fT I PORTED M ANIFO LD
V A C U U M (PORT F)
load conditions. This could cause: fT I V A C U U M HARNESS
fT I BOLT TIGHTEN TO
Spark knock (detonation). [~3~| EGR SOLENOID 4 N m (35 LBS. IN.)
Engine overheating. 7S 3029-6E
Figure 9-5 - EGR & Solenoid (2 .5L)

SYSTEM CHECK
Diagnosis o f the EGR system is covered in the

following charts. These charts begin on page 9-4.
EGR System Check on a 2.5L, 4.3L (except ST),
5.0L & 5.7L (under 8500 G V W ) engine.
EGR System Check on a 2.8L, 4.3L (ST), 7.4L &
5.7L (over 8500 G V W ) engine.
ON-VEHICLE SERVICE
EGR VALVE
|-| Remove or Disconnect fT I EGR VALVE
1. A ir Cleaner. [~2~| VA C U U M HARNESS

fT I EGR SOLENOID
2. EGR valve vacuum tube at valve. (Figure 9-5
to 9-10). (T 1 M ANIFOLD VA C U U M 6 S 2934-6E
3. Bolts or nuts.
Figure 9-6 - EGR ,& Solenoid (2.8L)
4. E G R v a l v e and g a s k e t f r o m m a n i f o l d
(Figures 9-11 to 9-15). Discard gasket.
Important
Do not wash EGR valve in solvents or degreaser -
permanent damage to valve diaphragm may result.
Also, sand blasting o f the valve is not recommended
since this can affect the operation of the valve.
EGR Manifold Passage
ft Inspect
I f EG R passage indicates excessive build-up o f P H EGR VALVE f T I BOLT TIGHTEN
deposits, the passage should be cleaned. Care should m VAC UUM HARNESS TO 2 N m (18 IN. LBS.)
[~6~| HARNESS CONNECTOR
be tak en to ensure that all loose p a r tic le s a re I T ] EGR SOLENOID
completely removed to prevent them from clogging the f T I M ANIFOLD V A C U U M
(PORT-J) 7S3459-6E
EGR valve or from being ingested into the engine.
Figure 9-7 - EGR & Solenoid (4 .3L except ST)
TO EGR VALVE
GRY 435
GRY 435
7-15-87
7-31-87 7 S 3737
EGR SYSTEM CHECK

2.5L, 4.3L (EXCEPT ST), 5.0L & 5.7L (UNDER 8500 GVW)
The ECM operates a solenoid to control the exhaust gas recirculation (E G R ) valve. 'Phis solenoid is
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 25C.
T P S - " O F F idle
MAP
If Code 24 is stored, use that chart first.
Code 32 will detect a faulty solenoid, vacuum supply, EGR Valve or plugged passage. This chart checks for
plugged EGR passages, a sticking EGR valve, or a stuck open or inoperative solenoid.

1. Checks for solenoid stuck open. Before replacing ECM, use an oh m m e te r and
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. Refer to E C M QL)R check
and vacuum should drop. procedure in Section " 3 . See EC M w i r i n g
4. Negative backpressure valve should hold vacuum diagram for coil term. 1.1), o f solenoid(s) and
with engine " O F F . relay(s) to be checked. Replace any solenoid where
5. When engine is started, exhaust backpressure resistance measures less than 20 ohms.
should cause vacuum to bleed off and valve to fully
close.
EGR SYSTEM CHECK

2.8L, 7.4L, 4.3L (ST), & 5.7L (OVER 8500 GVW)
The EGR valve is controlled by a normally closed solenoid (allows a vacuum to pass when energized). The
ECM pulses the solenoid to turn " O N and regulate the EGR. The ECM diagnoses the system using an internal
EGR test procedure.
The ECM control of the EGR is based on the following inputs:
Engine coolant temperature - above 25C.
T P S - " O F F idle
MAP
If Code 24 is stored, use that chart first.
Code 32 will detect a faulty solenoid, vacuum supply, EGR V alve or plugged passage. This chart checks for
plugged EGR passages, a sticking EGR valve, or a stuck open or inoperative solenoid.

1. W ith the ignition " O N , e n gin e stopped, the Before replacing ECM use ohmmeter and check
solenoid should not be energized and vacuum resistance o f each EC M co n tr o lle d r e la y and
should not pass to the EGR valve. solenoid coil. Refer to ECM QDR Check in Section
2. Grounding the diagnostic terminal will energize "3 .
the solenoid and allow vacuum to pass to valve. See EC M w i r i n g d ia g r a m fo r c o il t e r m i n a l
3. Checks for plugged EGR passages. If passages are identification o f solenoid(s) and relay(s) to be
plugged, the engine may have severe detonation checked. Replace any relay or solenoid if the coil
on acceleration. resistance measures less than 20 ohms.
4. The EGR solenoid will not be energized in Park or
N e u t r a l . T h i s t e s t w i l l d e t e r m i n e i f the
Park/Neutral switch input is being received by the
ECM.
m EGR VALVE DU EGR VALVE

m VA C U UM HARNESS V A C U U M HARNESS
m EGR SOLENOID (M O U N TED ON TOP SIDE OF m EGR SOLENOID (M O U N TED ON TOP SIDE OF
BRACKET ON G-SERIES) BRACKET ON G-SERIES)
m M ANIFOLD VA C U U M (PORT-J) m M ANIFOLD V A C U U M (PORT-S)
m BOLT TIGHTEN TO 2 N m (18 IN. LBS.) m BOLT TIG HTEN TO 4 N m (35 LBS. IN.)
E HARNESS CONNECTOR ta HARNESS CONNECTOR

m BRACKET BRACKET
7S 3460-6E 7S3461-6E
Figure 9-8 - EGR & Solenoid Figure 9-9 - EGR & Solenoid
(5.0L & 5.7L under 8500 GVW) (4.3L (ST) & 5.7L over 8500 GVW)
IJJI Clean
1. W ith a wire wheel, buff the exhaust deposits from
the mounting surface and around the valve.
2. Look for exhaust deposits in the v a lv e outlet.
Remove deposit build-up with a screwdriver.
3. Clean mounting surfaces of intake manifold and
valve assembly.
*- Install or Connect
1. N ew EGR gasket.
2. EGR valve to manifold. m EGR VALVE [T ] M ANIFO LD VA C U U M
(PORT-S)
3. Bolts or nuts. ee V A C U U M HARNESS r ->
HARNESS CONNECTOR
4. Vacuum tube to valve. m EGR SO LENOID '------1
5. A ir cleaner. 7S 3462-6E
SYSTEM HOSES Figure 9-10 - EGR & Solenoid (7 .4L)
Refer to Vehicle Emission Control Inform ation

label for routing of system hoses.
When replacing hoses, use hose identified with the
word "Fluoroelastromer .
m EGR VALVE
m EGR VALVE m GASKET
[~ n GASKET [~3~| STUD
fTl BOLT TIGHTEN TO 25 N m (18 FT. LBS.) 7s 3455-6E m NUT-TIGHTEN TO 20 N m (15 FT. LBS.) ?
Figure 9-11 - EGR Valve (2.5L) Figure 9-14 - EGR Valve (5.0L & 5.7L)
m EGR VALVE [T 1 EGR VALVE

I 2 [ GASKET |~2~| GASKET
f~3~| BOLT-TIGHTEN TO 25 N m (18 FT. LBS.) 6S 2899-6E m NUT TIGHTEN TO 20 N m (15 LBS. FT.) ?s 3 4 5 8 .6E
Figure 9-12 - EGR Valve (2.8L) Figure 9-15 - EGR Valve(7.4L)
[~T1 EGR VALVE

m GASKET
I 3 I STUD
f T l NUT-TIG HTEN TO 20 N m (15 FT. LBS.) 7S 3456-6E
Figure 9-13 - EGR Valve (4.3L)

EGR SOLENOID EGR VACUUM SOLENOID

2.8L, 4.3L (ST), 7.4L 8t 5.7L (over 8500 GVW) 2.5L, 4.3L, 5.0L St 5.7L (under 8500 GVW)
Figure 9-16 Figure 9-17
|++| Remove or Disconnect Remove or Disconnect

l. Negative battery cable. l. Negative battery cable.
2. A ir 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
l. Solenoid. See Figures 9-5 thru 9-10 for torque
4- Install or Connect
specification.
1. Filter, if required. 2. Vacuum hoses
2. Solenoid. Tighten bolts to 3. Electrical connector.
24 N *m (17 ft. lbs). 4. Negative battery cable.
3. Vacuum hoses.
5. Air cleaner, if removed
EGR FILTER CLEANING / REPLACEMENT
1. Grasp and pull filter off with a rocking motion.

2. Push new filter on making sure cut-out for
wires is properly aligned.
Figure 9-17 EGR Control Solenoid

(2.5L,4.3L (except ST), 5.0L&5.7L Under 8500 GVW)
PARTS INFORMATION
PARTS NAME GROUP
Valve, EGR ................................................. 3.670
Valve, Elect Vac Reg ................................ 3.670
Solenoid, EGR C o n t ...................................... 3.670
Gasket. EGR V a l v e ...................................... 3.680
(2.8L.4.3L (ST), 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...............................................10-8
TCC System ................................................10-1 D IA G N O S IS ........................................................ ..10-10
O p e r a tio n ........................................... ..10-1 TCC SYSTEM ................................................. ..10-10
D ow nshift C o n t r o l.................................. ..10-1 DOWNSHIFT CONTROL SYSTEM............... ..10-10
M ANUAL TRANSMISSION.............................10-1 SHIFT LIGHT SYSTEM .................................. ..10-10
S hift Light System .................................... ..10-1 ON-VEHICLE SERVICE....................................... ..10-10
TCC ELECTRICAL DIAGNOSIS TCC SYSTEM ...................................................10-10
2 .5L& 2.8L ................................................10-2 DOWNSHIFT CONTROL S Y S TE M ............... ..10-10
4 .3 L & V -8 ................................................10-4 SHIFT LIGHTSYSTEM .................................. ..10-10
DOWNSHIFT CONTROL DIAGNOSIS ____10-6 PARTS INFORMATION .......................................10-10
GENERAL DESCRIPTION Downshift Control System

W hile operating a vehicle equipped with a T H M
AUTOMATIC TRANSMISSION
TCC System 400 transmission, at speeds below 70 mph, a forced or
The transmission converter clutch (TCC) system, de te n t d o w n s h ift is possib le, by d e p r e s s in g the
used on a 7004R tra n sm ission , uses a solenoid accelerator fully.
operated valve, to couple the engine flywheel to the The ECM w ill recognize the rapid increase in
output shaft o f the transmission through the torque M A P sensor v o lta g e , due to a drop in m a n ifo ld
converter. This reduces the slippage losses in the vacuum and turn on the downshift control relay. The
converter, which increases fuel economy. relay will, then, send battery voltage to the detent
solenoid, in the transmission, which opens an orifice
Operation and forces a transmission downshift.
For the converter clutch to apply, two conditions

MANUAL TRANSMISSION
must be met:
Shift Light System
Internal transmission fluid pressu re must be
correct. For inform ation on internal transmission A vehicle, with manual transmission, has a shift
operation, see Section 7A. This section will cover only light, on the instrument panel, to indicate the best
the electrical operation o f the TCC system. shift point for maximum fuel economy. The light is
The ECM completes a ground circuit to energize a c o n tr o lle d by the E C M and is tu rned " O N by
TCC apply solenoid in the transmission which moves a grounding C K T 456.
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 T C C apply solenoid by
looking at several sensors:
Coolant tem perature sensor. E n g in e must be
warmed up, before clutch can apply.
Throttle position sensor (TPS). A fter the converter
clutch applies, the ECM uses the information from
the T P S to release the clutch, when the vehicle is
accelerating, or decelerating at a certain rate.
Brake Switch. This switch in the T C C circuit
opens, when the brake pedal is depressed. This de
energizes the TC C solenoid.
Pulse switch. This is a downshift 4-3 pulse switch,
w h ic h o p e n s th e T C C s o l e n o i d c i r c u i t ,
momentarily, during a downshift.
Vehicle Speed Sensor. The VSS signals vehicles
speed to ECM.
10-2 TRANSMISSION CONTROLS
TRANSMISSION CONVERTER CLUTCH (TCC)

(ELECTRICAL DIAGNOSIS)
2.5L AND 2.8L ENGINES
The purpose of the automatic transmission converter clutch feature is to eliminate the power loss o f the
torque converter stage when the vehicle is in a cruise condition. This allows the convenience of the automatic
transmission and the fuel economy of a manual transmission.
Fused battery ignition is supplied to the TC C solenoid through the TCC brake switch.
The ECM will engage TCC by grounding C K T 422 to energize the solenoid.
TC C will engage when:
Vehicle speed above 24 mph (39 km/h.)
Engine at normal operating temperature (above 65C) (149F).
Throttle position sensor output not changing, indicating a steady road speed.
Brake switch closed.
3rd or 4th gears.

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 " D r i v e r . R efer to E C M Q D R check in
G r o u n d in g the d ia g n o s tic c o n n e c to r should Section "3 . Using an ohm meter, check the solenoid
energize the relay and cause the light to go out. coil resistance of all ECM controlled solenoids and
3. This test by-passes the TCC solenoid and checks relays, before installing a replacement ECM. Replace
for an open or short in C K T 422. any solenoid, or relay, that measures less than 20
ohms resistance.
TRANSMISSION CONVERTER
CLUTCH (TCC)
2.5L AND 2.8L ENGINES
9-5-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO 'SERVICE ENGINE SOON" LIGHT. 7S 3858-6E
TRANSMISSION CONVERTER CLUTCH (TCC)

4.3L, 5.0L AND 5.7L (UNDER 8500 GVW)
The purpose o f the automatic transmission torque converter clutch feature is to eliminate the power loss of
the torque converter stage when the vehicle is in a cruise condition. This allows the convenience o f the
automatic transmission and the fuel economy of a manual transmission.
Fused battery ignition is supplied to the TCC solenoid through the TCC brake switch.
The ECM will engage TCC by grounding C K T 422 to energize the solenoid.
TCC will engage when:
Vehicle speed above 30 mph (48 km/h.)
Engine at normal operating temperature (above 65C) ( 149F).
Throttle position sensor output not changing, indicating a steady road speed.
Brake switch closed.
3rd or 4th gears.

1. A test light on indicates ba ttery v o lta g e and Solenoid coil resistance must measure more than
continuithy through the TCC solenoid is OK. 20 ohms. Less resistance will cause early failure of
2. Checks for vehicle speed sensor signal to ECM the ECM " D r i v e r . Refer to ECM QD R check in
using a "Scan tool. Section "3 . Using an ohm meter, check the solenoid
3. Checks for 4th gear signal to ECM. This signal coil resistance of all ECM controlled solenoids and
will not prevent TCC engagement, but could cause relays before installing a replacement ECM. Replace
a change in the engage and d is e n g a g e speed any solenoid or relay that measures less than 20 ohms
points. resistance.
BRAKE
ECM/IGN SWITCH
ECM
DOWNSHIFT
A7
a
CONTROL RELAY ORN
C & K SERIES
IGN/GAGE
IGN .
12V A * ECM
20 A
DOWNSHIFT
A7
R ,V ,G , & P SERIES
7-28-87
7-31-87 7S3861-6E
THM 400 TRANSMISSION DOWNSHIFT CONTROL

When the accelerator pedal is fully depressed, manifold vacuum in the engine drops causing the M A P sensor
signal voltage to increase to approximately 4 volts. The ECM responds by grounding C K T 422 to turn " O N the
downshift control relay. The relay then sends battery voltage to the detent solenoid, which causes a forced
transmission downshift.
Diagnostic Aids: Relay coil resistance must measure more than 20

ohms. Less resistance will cause early failure of
I f problem is diagnosed as b e in g an in tern a l the ECM " D riv e r . Refer to EC M QD R Check
tra n s m is sio n problem , see S e ctio n 7 o f the (Figure 3-18). Using an ohm meter, check the coil
appropriate series Service Manual as listed in the resistance of all ECM controlled solenoids and
Forward. relays before in s ta llin g a r e p la c e m e n t E C M .
Replace any solenoid or relay that measures less
than 20 ohms resistance.
TH M 400 TRANSMISSION
THIS CHART ASSUMES THERE IS NO
CODE 33 OR 34 STORED DOWNSHIFT CONTROL
NO FORCED DOWNSHIFT TRANSMISSION WILL NOT UPSHIFT
9-5-86
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO 'SERVICE ENGINE SOON" LIGHT.
7S 3862-6E
ECM
IGNITION
IGN/GAGE
FUSE
20 A
PNK/BLK 39
Sk SHIFT LIGHT
I.P. CONNECTOR
------- --------
ECM
IGN/GAGE
FUSE I.P. CONNECTOR
IGNITION ---------- ' X / * - PNK/BLK 39 ------- --------

20 A SHIFT LIGHT
ECM
ECM/IGN
FUSE I.P. CONNECTOR
IGNITION ---------- PNK/BLK 439 - f f l . ------- --------

10 A SHIFT LIGHT
8-19-86
7S3863-6E
7-31-87
MANUAL TRANSMISSION SHIFT LIGHT CHECK

ON ALL VEHICLES BELOW 8500 GVW
The ECM uses information from the following inputs to control the shift light:
Coolant temperature
TPS
VSS
RPM
The ECM uses the meassured rpm and the vehicle speed to calculate what gear the vehicle is in. Its this
calculation that determines when the shift light should be turned on.
Test Description: Numbers below refer to circled 2. This should turn " O N the shift light.
numbers on the diagnostic chart. 3. This checks for an open in the shift light circuit, or
1. This should not turn " O N the shift light. If the a faulty ECM.
light is " O N , there is a short to ground in C K T
456 wiring, or a fault in the ECM.
MANUAL TRANSMISSION
SHIFT LIGHT CHECK
ON ALL VEHICLES BELOW 8500 GVW
8-19-86
* 7S 3864-6EA
DIAGNOSIS
TCC SYSTEM
If the converter clutch is applied at all times, the

engine will stall immediately, just as in a manual
transmission with the clutch applied.
I f the c o n v e rt e r clutch does not apply, fuel
economy may be lower than expected. If the vehicle
speed sensor fails, the TCC will not apply. If the 4th
gear switch does not operate, the TCC will not apply at
the right time.
The transmission converter clutch (TCC) system
has d if fe r e n t o p e r a t in g ch ara cteristics than an m RETAINER [T ] DO W NSHIFT RELAY
automatic transmission without TCC. I f the driver fT l FUEL PUM P RELAY [T ] FUEL PUM P FUSE
complains of a "chuggle" or "su rg e" condition, the m DASH PANEL

vehicle should be road tested and compared to a 7S 3756-6E
similar vehicle to see if a real problem exists. The
O w ners Manual section on TCC operation should be Figure 10-2 - Downshift Control Relay (CK)
reviewed with the driver. A nother T C C complaint
may be a downshift felt when going up a grade,
especially with cruise control. This may not be a
downshift, but a clutch disengagem ent due to the
change in TP S to maintain cruising speed.
The electrical diagnosis o f the TC C system is
covered in the appropriate "Transmission Converter
Clutch Electrical Diagnosis chart.
I f the ECM detects a problem in the VSS system, a
Code 24 should set. In this case see Code 24 Chart.
DOWNSHIFT CONTROL SYSTEM
I f the downshift control system is " O N , at all

times, the transmission will not upshift. 0 3 CONNK&R E PLENUM PANEL
If the downshift control system is inoperative, a [ T 1 D O W NSHIFT CONTROL P Q BRACKET
'------ RELAY .' [ T ] FUEL PUM P RELAY
forced downshift o f the transmission will not occur.
In either case, refer to the "TH M400 Transmission m i r e ta in e r 8SJl699
Downshift Control Electrical Diagnosis chart.
Figure 10-3 - Downshigt Control Relay (except CK)
SHIFT LIGHT SYSTEM Downshift Control Relay
Figures 10-2 and 10-3.
If the manual transmission shift light does not
illuminate, or is " O N all the time, while driving the Remove or Disconnect
vehicle, refer to "Manual Transmission Shift L ight
Check chart. 1. Harness connector
2. Retaining bolt(s).
ON-VEHICLE SERVICE -4- Install or Connect

1. Retaining bolt(s).
TCC SYSTEM 2. Harness connector.
Refer to Section 3, for repair of wiring. SHIFT LIGHT SYSTEM

Refer to Section 3, for replacement of the ECM.
For replacement o f the TC C solenoid, veh icle Refer to Section "3, for repair of wiring.
speed sensor, or bra k e sw itch, r e f e r to the Refer to Section "3, for replacement o f the ECM.
appropriate series Service Manual, as listed in the
forward.
PARTS INFORMATION
DOWNSHIFT CONTROL SYSTEM PART NAME GROUP
Refer to Section 3, for repair of wiring. Sensor. VSS ( 1 ) ............................................. 9.761

Refer to Section 3, for replacement of the ECM. Valve. Clutch and Cruise Vac. Sw .............. 3.885
Solenoid. TCC ............................................... 4.122
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 IA G N O S IS .......................................................... 11-1 ON-VEHICLE SERVICE............................................ 11-2
RESULTS OF INCORRECT O P E R A T IO N ____11-1 PARTS INFORMATION ............................................. 11-2
GENERAL DESCRIPTION DIAGNOSIS

A positive crankcase ventilation (P C V ) system is RESULTS OF INCORRECT OPERATION
used to p r o v id e m ore c o m p le t e s c a v e n g i n g o f
crankcase vapors. Fresh air from the air cleaner A plugged valve or hose may cause:
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.
crankcase ventilation ( P C V ) va lve into the intake Oil leaks.
manifold (Figure 11-1 or 11-2). Oil in air cleaner.
The primary control is through the P C V va lve Sludge in engine.
(F ig u r e 11-3), w hich m eters the flow at a rate
depending on manifold vacuum.
To maintain idle quality, the PC V valve restricts
the flow when intake manifold vacuum is high. I f
abnormal operating conditions arise, the system is
designed to allow excessive amounts o f blow-by gases
to back flow through the crankcase vent tube into the
air cleaner to be consumed by normal combustion.
CLEAN AIR
- VOLATILE OIL FUMES

MIXTURE OF AIR AND FUMES
m PCV V A L V E
ta A IR CLEANER
f i n CRANKCASE
1------1 V E N T HOSE
( T 1 PCV V A L V E 4S 0067
------ HOSE
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

P C V valve, dirty vent filter or air cleaner element, or
plugged hose. Replace as required. Use the following
procedure:
1. Remove P C V valve from rocker arm cover.
2. Run the engne at idle.
3. Place your thumb over end of valve to check for
vacuum. I f there is no vacuum at valve, check for
plugged hoses, manifold port at TBI unit, or P C V
valve. Replace plugged or deteriorated hoses or
plugged PC V valve. Figure 11-4 - Crankcase Vent Filter
4. Turn " O F F the engine and remove PC V valve.
Shake va lve and listen for the rattle o f check
needle inside the valve. I f valve does not rattle,
ON-VEHICLE SERVICE
replace valve.
An engine can be damaged if it is operated without
With this system, any blow-by in excess of the
crankcase ventilation. Therefore, it is important to
system capacity (from a badly-worn engine, sustained
perform the "Functional Check at intervals shown in
heavy load, etc.) is exhausted into the air cleaner and
Section OB of the appropriate Service Manual or the
is drawn into the engine.
vehicles maintenance schedule.
Proper operation of the PC V system is dependent
Replace P C V components as diagnosis requires.
upon a sealed engine. I f oil sludging or dilution is
The recommended replacement parts are listed in the
noted and the P C V system is functioning properly,
Specifications section of the vehicles owners manual.
check engine for possible cause and correct to ensure
Periodically, inspect the hoses and clamps and
that system will function as intended.
replace any showing signs of deterioration.
PARTS INFORMATION
PART NAME GROUP
A ir C l e a n e r ...................................................... 1.150
Tube, C/Case V e n t ........................................... 2.383
Hose, C/Case Vent V l v .................................... 2.170
Figure 11-3 - PCV Valve Cross Section

POSITIVE CRANKCASE VENTILATION 11-3
VIEW A
P T I TUBE ASSEM BLY

m PCV VALVE
m G RO M M ET
m BOLT TIGHTEN TO 25 N m
(18 LBS. FT.)
!T 1 CONNECTOR
rn h o se
7S3629
Figure 11-5 - PCV System (2.5L)
f n PCV VALVE
m GROMMET
i n TUBE ASSEM BLY
n TBI U N IT - PORT C "
fT I AIR CLEANER FITTING -

r n M AP SENSOR
7S3630

11-4 POSITIVE CRANKCASE VENTILATION
4.3L, 5.0L & 5.7L
m PCV VALVE | T ] HOSE ALTITUDE ONLY

| 2 | GROMMET [ T ] TUBE ASSEM BLY
[T 1 HOSE a i r CLEANER EXTENTIO N
5.0L & 5i7L
[ T ] TBI U N IT - PORT "C " 7S 3631-6E
Figure 11-7 - PCV System (4.3L, 5.0L & 5.7L)
[ T ] PCV VALVE m HOSE - ALTITUDE ONLY

m GROMMET [ T ] TUBE ASSEM BLY
[~F1 HOSE m AIR CLEANER FITTING
|~4~l TBI U N IT - PORT "C' 7 S 3632

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 E LE M E N T ......................
D IA G N O S IS .......................................................... 12-1 AIR CLEANER ............................................................................ ____ 12-4
RESULTS OF INCORRECT O P E R A T IO N ____ 12-1 VACUUM DIAPHRAGM M O T O R ____ ____12-4
THERMAC AIR CLEANER SENSOR................................................... ____ 12-4
FUNCTIONAL CHECK ............................... 12-3 PARTS INFORMATION .............................
VACUUM MOTOR FUNCTIONAL CHECK . . 12-3
GENERAL DESCRIPTION
PURPOSE
A heated intake air system is used to give good

d r i v e a b i l i t y under v a r y i n g c lim a tic co n d itio n s .
H aving a uniform inlet air temperature improves fuel
vaporization.
OPERATION
All Except S/T Series
The T H E R M A C system (Figure 12-1) regulates

I T ] TEMPERATURE SENSOR ACTUATOR
incoming air temperature without the use of vacuum.
fT I DAMPER ASSEM BLY
The air regulating damper is controlled by means of a 7S3810-6E
self-contained, wax-pellet actuated assembly mounted
in the air cleaner. When incoming air is cold, the wax Figure 12-1 - THERMAC Air Cleaner
m a t e r i a l s e a le d in the a c t u a t o r is in a so lid All Except S/T Series
(contracted) phase and the damper closes o ff the cold
air inelt. This causes all incoming air to be heated by
the exhaust manifold. As the incoming air warms, the
wax material expands by changing to liquid phase DIAGNOSIS
which forces out a piston to reposition the damper
allowing a cold and hot air mix or all cold air to enter RESULTS OF INCORRECT OPERATION
the engine.
S/T Series
Hesitation during warm-up can be caused by:
Th e T H E R M A C system ( F ig u r e 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 co n trols the vacuum m o to r w h ic h in turn Missing air cleaner cover seal.
positions the damper. When the incoming air is cold, Damper door does not close.
the sensor w ill apply manifold vacuum to the vacuum Lack o f 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.
A s 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
[~T~1 VACUUM DIAPHRAGM

MOTOR
[~2~| TEMPERATURE SENSOR
IT l VACUUM HOSE (TO
MANIFOLD VACUUM) m SNORKEL
[~4~1 HEAT STOVE DUCT m W A X PELLET ACTUATOR
[T1 SNORKEL m PISTON
f~6 | LINKAGE m CALIBRATED SPRING
m AIR BLEED VALVE m HOT AIR INLET
|~8~1 AIR CLEANER ASM. m REGULATING DAMPER

ASSEM BLY
I~9~l DAMPER DOOR 4S 0648-6E COLD AIR INLET 7S3811-6E
Figure 12-2 - THERMAC Air Cleaner - S/T Series Figure 12-3 - THERMAC Operation
CDVACUUM DIAPHRAGM MOTOR

B DIAPHRAGM SPRING
m TEMPERATURE SENSOR
AIR BLEED VALVE-CLOSED
[4B] AIR BLEED V A L V E -
PARTIALLY OPEN
4C AIR BLEED VALVE-OPEN
B VACUUM HOSES
B DIAPHRAGM
B HEAT STOVE
B HOT AIR (EXHAUST MANIFOLD)
B DAMPER DOOR
------------- --- r?oiOUTSIDE INLET AIR
Q D SNORKEL
C D -v
A - HOT AIR DELIVERY MODE
B REGULATING MODE
C - OUTSIDE AIR DELIVERY MODE
4S 0073-6E
Figure 12-4 - THERMAC O peration - S/T Series

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 l. With engine " O F F , disconnect vacuum hose at
to snorkel). vacuum diaphragm motor.
No manifold vacuum. 2. Apply at least 23 kPa (7 in. Hg.) o f vacuum to the
Damper door does not move. vacuum diaphragm motor. Damper door should
Missing air cleaner to TB I seal. completely block o ff to outside air when vacuum is
Missing air cleaner cover seal or loose cover. applied. I f not, check to see if linkage is hooked up
Loose air cleaner. correctly.
Lack o f power, sluggish, or spongy (on a hot 3. W it h vacuum s t ill applied, t r a p v a c u u m in
engine) can be caused by: vacuum d ia p h ra g m m otor by b e n d in g hose.
Damper door does not open to outside air. Damper door should remain closed. I f not, replace
Temperature sensor doesnt bleed off vacuum. vacuum diaphragm motor assembly. (Failure of
the vacuum diaphragm motor assembly is more
THERMAC AIR CLEANER FUNCTIONAL CHECK likely to be caused from binding link age or a
corroded snorkel than from a failed diaphragm .
All Except S/T Series This should be checked first, before replacing the
diaphragm.)
1. Remove air cleaner assembly and cool to below 4C 4. I f vacuum motor checks OK, check vacuum hoses
(40F). The damper door should be closed to and connections. If O K, replace the temperature
outside air (cold air). sensor.
2. Check for presence and condition o f air cleaner to
throttle body gasket. TEMPERATURE SENSORCHECK
3. Reinstall air cleaner assembly and be sure heat
stove tube is connected at air cleaner snorkel and S/T Series
exhaust manifold.
4. Start engine. Watch damper door in air cleaner 1. Start test with air cleaner temperature below 86F
snorkel. As air cleaner warms up, damper door (30C). If engine has been run recently, remove
should open slowly to outside air (cold air). air cleaner cover and place thermometer as close
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 86F (30C) about 5 to
is not binding. If O K, replace wax pellet actuator 10 minutes. Reinstall air cleaner on engine and
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
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 131F (55C).
deteriorated hoses. 3. I f the damper door is not open to outside air at
2. Check for presence and condition o f air cleaner to tem perature indicated, tem p e ra tu re sensor is
throttle body gasket seal. malfunctioning and must be replaced.
3. W ith 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 o f f outside air. As air
cleaner warms up, dam per door should open Remove or Disconnect
slowly to outside air.
1. A ir cleaner cover.
5. I f the air cleaner fails to operate as described
2. Old element.
above, p e r fo r m vacuum m o to r ch eck . I f it
3. Clean Housing.
operates, the door may not be moving at the right
temperature. If the driveability problem is during
Install or Connect
warm-up, make the tem perature sensor check
below. 1. N ew element.
2. A ir cleaner cover. Do not over-torque nuts ( install
finger-tight).
AIR CLEANER WAX PELLET ACTUATOR
Refer to F ig u r e s 12-8 to 12-13 for rep a ir or Ali Except S/T Series

replacement o f air cleaner. (Figure 12-6)
VACUUM DIAPHRAGM MOTOR Remove or Disconnect

1 A ir cleaner.
S/T Series
2. Spring.
(Figure 12-5)
3. Rivits retaining actuator
4. Actuator.
l. A ir cleaner. |+4-[ Install or Connect
2. Vacuum hose from motor.
1. Actuator.
3. Drill out the two spot welds initially with a 1.6mm
2. Spring.
(1/16 ) drill, then enlarge as required to remove
the retaining strap. Do not damage the snorkel 3. Rivits
4. A ir cleaner.
tube.
4. Motor retaining strap.
5. Lift up motor, cocking it to one side to unhook the SENSOR
motor linkage at the control damper assembly.
S/T Series
+ 4- Install or Connect (Figure 12-7)
1. D rill a 2.8mm (7/64 ) hole in snorkel tube at Remove or Disconnect

center of vacuum motor retaining strap.
1. A ir cleaner.
2. V acu um m otor lin k a g e into control d a m p e r
2. Hoses at sensor.
assembly.
3. Pry up tabs on sensor retaining clip. Remove clip
3. Use the motor retaining strap and sheet metal
and sensor from air cleaner. N ote position of
screw provided in the motor service package to
sensor for installation.
secure motor to the snorkel tube. Make sure the
screw does not interfere with the operation o f the
Install or Connect
damper assembly. Shorten screw if required.
4. Vacuum hose to motor and install air cleaner. 1. Sensor and gasket assembly in original position.
2. Retainer clip on hose connectors.
3. Vacuum hoses and air cleaner on engine.
f T ] SPOT WELDS
[ T ] MOTOR ASM.
f~3~l R E T A IN IN G STRAP
m IN STA LL REPLACEM ENT SENSOR ASM. . r n - . n - _ Figure 12-6 - Replacing W ax Pellet Actuator
I N SAME POSITION AS O R IG IN A L ASM. 4S 0649-6E
All except S/T Series
Figure 12-5 - Replacing THERMAC Vacuum M o to r
S/T Series
n~l SENSOR R E T A IN IN G CLIP

4S 0650-6E
Figure 12-7 - Replacing THERMAC Sensor - S/T Series
PARTS INFORMATION
PART NAME GROUP
A ir C l e a n e r ........................................................3.402
Element (P a p e r )............................................... ..3.410
Nut, A / C l.......................................................... ..3.403 i~T1 AIR CLEANER |T ] SUPPORT
i | a s s e m b l y n n b o lt-tig h te n t o
Seal, A ir C l e a n e r ...............................................3.403
[ I ] N UT-TIG HTEN TO 50 N m (37 FT. LBS.)
Sensor, A / C l........................................................3.415 r------ 1-2 N ' m (18 IN ' LBS> [ T ] BOLT-TIGHTEN TO
iMotor, A/Cl Vac D i a p h .................................... ..3.415 L_3J SEAL 30 N m (22 FT. LBS.)
Tube, Eng A ir Heat S t o v e ............................... ..3.417 [ T ] ADAPTER 7S 3701-6E
Stove, Eng A i r H e a t ........................................ ..3.417
Figure 12-9 - Air Cleaner (2.5L - M Series)
fin NUT TIGHTEN TO 6 N m (50 IN. LBS.) , " T | AIR CLEANER ASSEM BLY
FTI AIR CLEANER fT I SEAL
n n PCV FILTER fT I STUD
m GASKET REMOVE PAPER FROM NEW SEAL
[T ] NUT-TIG HTEN TO 2 N m (18 IN. LBS.)
[ T ] FULL M ANIFOLD VAC UUM HOSE 6S
fT I TUBE ASSEM BLY 7S 3702-6E
Figure 12-8 - A ir Cleaner (2 .5L - S/T Series) Figure 12-10 - A ir Cleaner (2.8L - S/T Series)
m AIR CLEANER ASSEM BLY

m AIR CLEANER ASSEM BLY
m SEAL
m SEAL
m EXTENSIO N
m EXTENSION
Q U STUD [~T1 STUD
[E NU T-TIG H TEN TO 2 N m (18 IN. LBS.) 7S3703-6E |~5~| NUT-TIG HTEN TO 2 N m (18 IN. LBS.) 7S 37 0 4 -6E
Figure 12-11 - Air Cleaner Figure 12-13 - Air Cleaner

(4.3L, 5.0L & 5.7L - M & G Series ) (4.3L, 5.0L & 5.7L - C. K, Pf R & V Series)
r n AIR cleaner a s s e m b ly
rn s e al m AIR CLEANER ASSEM BLY

r n EXTENSION r n seal
r n stud m STUD
f n N U T TIGHTEN TO 2 N m (18 LBS. IN.)
i n NUT-TIG HTEN TO 2 N-m (18 IN. LBS.) 7S 3705.6E
Figure 12-12 - Air Cleaner (4.3L - ST Series) Figure 1 2 - 1 4 - A ir Cleaner (7 .4 L - A ll)

SPECIAL TOOLS 13-1
SECTION 13
SPECIAL TOOLS
CONTENTS
GENERAL.............................................................. ..13-1 IAC (Idle A ir C o n tro l).................................. 13-3
"SCAN" TOOL .....................................................13-1 Injector Pulse W id t h .................................. ..13-3
"SCAN" TOOL M O D E S ....................................13-1 Integrato r and Block L e a rn ...................... ..13-3
Normal (Open) M ode ............................. ..13-1 Knock R e ta rd .............................................. ..13-3
ALDL M ode ................................................13-1 Knock S ig n a l.............................................. ..13-3
Factory Test M o d e .................................... ..13-1 MAT S e n s o r...................................................13-3
"SCAN" TOOL LIMITATIONS AND USE____13-1 MAP S e n s o r...................................................13-3
In te rm itte n t C o n d itio n s .............................13-2 M o d e ...............................................................13-3
"SCAN" TOOL POSITIONS............................. ..13-2 M PH ............................................................... ..13-3
A/C C lu tc h ..................................................... 13-2 O x y g e n ........................................................ ..13-3
A/C R e q u e s t................................................ ..13-2 Park/Neutral S w itc h .................................. ..13-4
AD B a t .......................................................... ..13-2 Power Steering Pressure S w it c h ...............13-3
Block Learn M em ory (BLM) C e ll...............13-2 PPSW...............................................................13-4
Closed Loop/Open L o o p ............................. 13-2 PROM I D ..................................................... ..13-4
Codes............................................................ ..13-2 R PM ............................................................... ..13-4
C oolant T e m p e ra tu re ..................................13-3 S hift L i g h t ................................................... ..13-4
Desired RPM ................................................ ..13-3 T h ro ttle A n g le ..............................................13-4
EGR (D uty C ycle)......................................... ..13-3 TPS ............................................................... ..13-4
EGR P o s itio n ................................................ ..13-3 Transmission C onvertor Clutch (TCC) . . 13-4
4th G e a r..........................................................13-3
GENERAL In som e cases, S c a n t o o l s w i l l p r o v i d e

information that is e it h e r e x t r e m e l y d i f f i c u l t or
The special tools required to service the fuel and impossible to get with other equipment.
emission systems are illustrated in F ig u r e s 13-1
through 13-3. A "SCAN" TOOL THAT DISPLAYS FAULTY
You should know how to use a test light, how to DATA SHOULD NOT BE USED AND THE
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
light or voltmeter must be used when specified in the "S C A N " TO O L CAN RESULT IN
procedures. They must N O T be interchanged. Care MISDIAGNOSIS AND UNNECESSARY PARTS
should be taken to not deform terminals when testing. REPLACEMENT.
You should be familiar with the Digital Volt-Ohm
Meter, particularly essential tool J-29125-A, J34029A T re e Code C harts 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 A L D L Scan tool where possible.
resistance, and current and know how to use the meter Some Electronic C on trol M odu les h a ve t h r e e
correctly. modes for transmitting inform ation but some only
read data in the open mode.
"SCAN"TOOL The following information will describe each o f
the three modes where applicable and the affects they
The Computer Command Control A L D L connector may cause.
under the dash, has a variety o f 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
Not all systems will transmit information on the
charts unnecessary. They do not tell exactly where a
problem is in a given circuit. H o w e v e r , w ith an Serial Data Line while in this mode.
understanding o f what each position on the equipment On systems that can be monitored in the open
mode, it allows certain param eters to be obtained
measures, and knowledge o f the circuit involved, the
w ith o u t ch a n g in g the en g in e o p e ra tin g
tools can be very useful in getting information which
characteristics. The parameters capable o f being read
would be more tim e consuming to get with other
equipment. vary from engine fa m ily to engine fam ily. Most
13-2 SPECIAL TOOLS
Scan tools are programmed so that the system will The Scan tool is also a useful and quick way o f
go directly into the special mode i f the "open mode is comparing operating parameters o f 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 tim e 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 try in g to diagnose as w ell as an
modified as follows. u n dersta n d in g o f the Scan t o o ls l i m i t a t i o n s .
Closed loop timers in ECM are bypassed T h e r e fo r e , the tech nician should rea d th e to o l
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 o f the
rpm (On 5.0L engine the control engine idle is Scan" tool positions and how they can be helpful in
850 rpm 50 rpm. diagnosis.
P/N restrict functions will be disabled
"SCAN" TOOL POSITIONS
Factory Test (Back-up or 3.9 K) Mode
The following positions may not be applicable to
When in this mode, the ECM is operating on the all engines:
fuel back-up logic and calibrated by the Calpak Mem-
Cal. The Calpak Mem-Cal is used to control the fuel A/C Clutch
delivery if the ECM fails. This mode verifies that the
back-up feature is OK. The parameters that can be Displays " O N when the ECM has commanded the
read on a Scan tool in this mode are not of much use A/C clutch " O N .
for service.
A/C Request
"SCAN" TOOL LIMITATIONS AND USE
Displays the state of the A/C signal line to the
The Scan tool allows a quick check of sensors ECM. Should read " Y E S whenever the A/C is
and switches which are inputs to the ECM. However, requested.
on some applications the data update rate makes the
tool not as effective as a voltm eter when try in g to Battery Voltage
detect an intermittent which lasts for a very short
time. However, the Scan tool allows manipulation of This displays the battery voltage detected at the
wiring harnesses or components under the hood while ECM ignition input.
observing the Scan readout. This helps in locating
intermittents with the engine not running. Closed Loop/Open Loop
Interm ittent Conditions This position w ill indicate whether the engine
control system is operating in "O p en or "C lo sed
The Scan tool is helpful in cases o f intermittent Loop . Most systems go "Closed Loop after a certain
operation. The tool can be plugged in and observed amount of run time, when coolant tem perature is
while driving the vehicle under the condition where high enough, and the oxygen sensor becomes active.
the light comes " O N " m om entarily, or the engine
d r iv e a b ility is poor m om entarily. I f the problem Block Learn Multiplier (BLM) Cell - or -
seems to be related to certain areas that can be Block Learn Memory (BLM)
checked on the S c an tool, then those are the
positions that should be checked while d r iv in g the T h e r e a r e up to s i x t e e n d i f f e r e n t c e l l s ,
vehicle. If there does not seem to be any correlation corresponding to ranges o f rpm and e n g in e load
between the problem and any specific circuit, the (indicated by M A P signal), and other conditions, such
Scan tool can be checked on each position, watching as A/C or P/N switch " O N or " O F F , etc. The ECM
for a period o f time to see if there is any change in the learns how much adjustment is needed in each cell,
readings that indicates intermittent operation. and retains it in memory, so that the adjustment will
immediately be made when the engine operates in
that cell (or rpm/load range). Th is param eter w ill
display what cell the ECM is currently using for the
fuel calculation
SPECIAL TOOLS 13-3
Codes The integrator is short term corrective action while

the block lea rn portion (w h ic h is a lo n g t e r m
W ill 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 o f time.
Coolant Temperature
Knock Retard
E n g in e coolant t e m p e ra tu r e is d is p la y e d in
C e ls iu s d e g r e e s . A f t e r e n g i n e is s t a r t e d the Indicates the number o f d e g re e s the E C M is
temperature should rise steadily to about 85-95 C retarding the Electronic Spark Timing.
then stabilize when the thermostat opens.
Knock Signal
Desired RPM
Displays a " Y E S when knock is detected by the
Indicates the rpm to which the ECM is trying to ECM and displays a " N O when knock is not detected.
control the idle.
Manifold Air Temperature (MAT) Sensor
EGR (Duty Cycle)
Displays temperature of the intake manifold air.
The EGR system uses a va lve 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
to control formation o f NOx. Like all ECM outputs the temperature increases.
S c a n tool o n ly in d ic a t e s t h a t the E C M has
commanded the function and does not indicate that Manifold Absolute Pressure (MAP) Sensor
the function has really happened.
The M A P Sensor produces a low signal vo lta g e
EGR Position when manifold pressure is low (high vacuum) and a
high voltage when the pressure is high (low vacuum).
Indicates the position of the EGR pintle. With the ignition " O N and the engine stopped,
the m a n ifold pressure is eq u al to a t m o s p h e r i c
4th gear pressure and the signal voltage will be high. T h is
information is used by the ECM as an indication o f
Displays state of the 4th gear switch. Yes = 4th v e h ic le a l t i t u d e and is r e f e r r e d to as B A R O .
gear. Comparison o f this B AR O reading with a known good
vehicle with the same sensor ** is a good way to check
IAC (Idle Air Control) accuracy of a "suspect sensor. Readings should be the
same .4 volt.
This system is used to control engine idle speed to
the desired rpm, for different operating conditions. In ** A M A P Sensor has a colored plastic insert visible in
this mode, the numbers will indicate what position the the connector cavity. Sensors with the same insert
ECM thinks the valve is in. The ECM moves the IAC color are id e n tic a l in c a lib r a tio n . T h e h a rness
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.
Injector Pulse W idth Mode
In th is p o s it io n , th e r e a d i n g is g i v e n in Check with the manufacturer to determine what

milliseconds which is the on time that the ECM is the function o f 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
Normal readings for these positions are around Displays vehicle speed. Useful in Checking TC C
128, if higher, it indicates that the ECM is adding lock up speed or speedometer accuracy.
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 (O2) Sensor RPM
The reading will be read out in millivolts (mv) Displays en gin e rpm. O ften useful i f e x t r a
with a range from 1 to 999 mv. I f the reading is reference pulses are suspected. A sudden high R P M
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 (E M I) in the reference circuit.
co n s is te n tly above 550 (550 m v), the system is This interference is usually caused by ECM wires too
running rich. clo se to i g n i t i o n s e c o n d a ry w ir e s or an o p e n
distributor ground circuit.
Park/Neutral Switch
Shift Light
T h e ind ication in this mode may va r y w ith
manufacturer so the type o f reading for a particular Displays " Y E S when the ECM is com m anding
tool should be checked in the operators manual. The the shift light to turn " O N .
important thing is that the the reading changes state
(switches) when the gear selector is moved from Throttle Angle
park/neutral to drive or reverse.
Displays in percent the amount the th rottle is
Power Steering Pressure Switch open. 0% is closed throttle and 100% is wide open
throttle.
Displays the state of switch. This reading may
vary with the tool used and the type of switch installed Throttle Position Sensor (TPS)
on the vehicle. The important thing is that the reading
changes state (switches) when the steering is moved Values read will be the voltage as seen by the
against the stops. ECM. The voltage should be the T P S specification
with the throttle closed and go up to about 5 volts
PROM ID with throttle wide open (WOT).
In this position, information is used for assembly Transmission Convertor Clutch (TCC)
verification only. PROM ID is useful only when the
vehicle is equipped with the original ECM and PR O M In this position, the tool will indicate when the
or Mem-Cal. Refer to parts information for correct TCC has been commanded by the ECM to turn on.
Prom. This does not necessarily mean that the clutch was
engaged but only that the ECM grounded the circuit
internally. The best way to determine if the clutch has
engaged is to monitor engine R P M when the T C C
comes O N .
SPECIAL TOOLS 13-5
VOLTMETER - Voltage Position Measures am ount of

voltage. When connected in parallel to an existing
circuit. A digital voltmeter with 10 meg ohm input
impedence is used because this type of meter will
not load down the circuit and result in fa u lty
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
and range. DC is used for most autom otive
measurements.
OHMMETER - Measures resistance of circuit directly

in ohms. Refer to meter for more information.
OL Display in all ranges indicates open circuit.
Zero display in all ranges indicates a short
circuit.
In te rm itte n t connection in circuit may be
indicated by d ig ita l reading th a t w ill n o t
stabilize on circuit.
Range Switch.
200Q - Reads ohms directly
HIGH IMPEDANCE MULTIMETER
2K,20K,200Kfi - Reads ohms in thousands
(DIGITAL VOLTMETER-DVM)
2M and 20MQ - Reads ohms in millions
J34029-A/BT8623
VACUUM PUMP (20 IN. HG. M IN IM U M )
Use gage to monitor manifold engine vacuum and the
hand pump to check vacuum sensors, solenoids and
valves.
J23738-A/BT8334
UNPOWERED TEST LIGHT

Used to check wiring for complete circuit and short to
ground or voltage.
J34142-A
TACHOMETER
Use inductive trigger signal pickup type to check RPM.
C0O
CONNECTOR TEST ADAPTER KIT

Used to make electrical test connections in current
W eather Pack, Metri - Pack and Micro-Pack style
terminals.
J35616/BT8256
7S3534-6E
Figure 13-1 Special Tools (1 o f 3)

13-6 SPECIAL TOOLS
OXYGEN SENSOR WRENCH

Used to rem ove or install the oxygen sensor
J29533A/BT8127
IDLE AIR CONTROL WRENCH

Used to rem ove or install IAC valve on throttle body.
J33031/BT8130
INJECTOR TEST LIGHT

/ BT8320 \ Used to check electrical circuit to a TBI 220 fuel injector
BT8320
INJECTOR TEST LIGHT

Used to check electrical circuit to a TBI 700 fuel injector.
Qv L J34730-2A/
BT8329A
CIRCUIT TESTER
Used to check all relays and solenoids before connecting them
to a new ECM. Measures the circuit resistance and indicates
pass or fail via green or red LED. Am ber LED indicates current
polarity. Can also be used as a non-powered continuity checker.
^ ^ ^ ^ ^ ^ ^ ^ J 3 4 6 3 6 /B T 8 4 0 5
OIL PRESSURE TRANSDUCER WRENCH

Used to rem ove or install oil pressure transducer on engine.
J28687-B/BT8220
METRI-PACK TERMINAL REMOVER

Used to rem ove 150 series M etri-Pack "pull-to-seat" terminals
from connectors. Refer to wiring harness service in Section " 3
for removal procedure.
J35689/BT8446
WEATHER PACK TERMINAL REMOVER

Used to rem ove term inals from W eather Pack connectors. Refer
to wiring harness service in Section 3 for removal procedure.
J28742-A/BT8234-A
ECM CONNECTOR TERMINAL REMOVER

Used to rem ove term inal from Micro-Pack connectors. Refer to
wiring harness service in Section "6E " for removal procedure.
1
J33095/BT8234-A
7S3535-6E
Figure 13-2 Special Tools (2 of 3)

SPECIAL TOOLS 13-7
SPARK TESTER
Gff 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.
J29698-A BT8251
MINIMUM AIR RATE ADJUSTING WRENCH

Used to adjust throttle stop screw on TBI unit.
J33179-20
FUEL PRESSURE GAGE

Used to check and monitor fuel line pressure.
J29658-B/BT8205
FUEL PRESSURE GAGE

Used to check and monitor fuel line pressure.
J34020
FUEL TANK SENDING AND PUMP UNIT

Used to remove and install cam lock nut on the fuel tank sending and
pump unit in Section 4.
J36608(CK)/J24187
IGNITION MODULE TESTER

Used to test ignition module in Section 6 .
J24642-F/BT7220
7S3536-6E
Figure 13-3 Special Tools (3 o f 3)
13-8 SPECIAL TOOLS
SPECIFICATIONS
SPECIFICATION LOCATION OF INFORMATION
Engine Tim ing Vehicle Emission Control Information label.
Idle Speed, ECM Not adjustable. ECM controls idle.

Controlled
Spark Plug Type See Owners Manual, Section "7.
Spark Plug Gap Vehicle Emission Control Information label.
Engine Code 8th digit of V I N number. See Section "O A. Also O w n ers
Manual, Section "7.
Engine Fam ily Vehicle Emission Control Information label.
Filter Part Numbers See Owners Manual, Section "7.
Part Numbers of WDD-GM Parts Book.

Major Components
Replacement of WDD-GM Label Catalog.

Vehicle Emission
Control Information
7-28-87
Label
8S4703-6E
ABBREVIATIONS-14-1
SECTION 14
ABBREVIATIONS AND GLOSSARY OF TERMS

Abbreviations used in this manual are listed COOLANT TEMPERATURE SENSOR - Device that
below in alphabetical order with an explanation of the senses the engine coolant tem perature, and passes
abbreviation. There are some variations in the use of that information to the electronic control module.
periods and in capitalization (as mph, m.p.h., Mph,
CONV. - CATALYTIC CONVERTER - C o n t a in in g
and M P H ) for abbreviations used in this Section but
platinum and palladium to speed up conversion o f HC
all types are acceptable.
and CO.
A/F - AIR/FUEL (A/F RATIO) - The amount o f air-to-
CO - CARBON MONOXIDE - One o f the pollutants
fuel for combustion o f fuel. Ideal ration is 14.7 parts of
found in engine exhaust.
air to 1 part of fuel.
CURRENT OR AMPERAGE - Th e rate o f How o f
AIR - AIR INJECTOR REACTION SYSTEM - A ir flow
electrons is similar to gallons of w ater per minute
from pump is directed into engine exhaust manifold
flowing in a water pipe.
and/or converter to reduce exhaust emissions.
DIAGNOSTIC CODE - P a ir of numbers obtained
ALDL - ASSEMBLY LINE DIAGNOSTIC LINK - Used
from fla s h in g " S e r v i c e E n g in e S o o n l i g h t , or
at assembly to evaluate Computer Command Control
displaying on a "Scan tool. This code can be used to
and for service to flash the "S ervic e Engine Soon
determine the system malfunction.
light if there are trouble codes. Also used by "Scan
tools to obtain ECM serial data. DIAGNOSTIC TERM. - Grounding terminal " B of
A L D L Connector will flash or display a code. When
ANALOG SIGNAL - An electrical signal that varies
grounded with the engine running w ill e n te r the
in voltage within a given parameter.
"Field Service Mode .
Bat + - Battery Positive Termin al (12 Volts)
DIGITAL SIGNAL - An electrica l signal that is
BLOCK LEARN - ECM m em ory that adjusts the either " O N or " O F F with no in between.
air/fuel ratio on a semipermanent basis.
DIODE - A n electrical device that restricts current
CAPACITOR - An electrical device used to store a flow in one direction.
temporary charge.
DRIVER - A n electrical device, usually a power
CALPAK - A device used with fuel injection to transistor, that operates like a switch; that is, it turns
allow fuel delivery in the event o f a PR O M or ECM something " O N or " O F F .
malfunction.
DVM (10 M e g .) - D ig it a l V o l t m e t e r w ith 10
CALIBRATOR - (PROM) - An electronic component Million ohms resistance - used for m easurem ent in
which can be specifically programmed to meet engine electronic systems.
operating requirements for each vehicle model. It
EAC - ELECTRIC AIR CONTROL - U sed on A I R
plugs into the Engine Control Module (ECCM).
System to direct air flow to A ir Switching v a lv e or
CCC - COMPUTER COMMAND CONTROL - has an atmosphere.
electronic control module to control air/fuel and
ECM - ELECTRONIC ENGINE CONTROL MODULE -
emission systems.
A metal case (located in passenger com p artm ent)
CCP - CONTROLLED CANISTER PURGE - E C M containing electronic circ u itry w h ich e l e c t r i c a ll y
controlled solenoid v a lv e that p e r m its m an ifold controls and monitors air/fuel and emission systems
vacuum to purge the evaporative emissions from the on Computer Com m and Control, and turns on the
charcoal canister. " S ervic e Engine Soon ligh t when a m a lfu n c tio n
occurs in the system.
CID - CUBIC INCH DISPLACEMENT - Used to
describe engine size. ECU - ENGINE CALIBRATION UNIT - An electronic
component which can be specifically programmed to
C/LOOP - CLOSED LOOP - Designed with feedback
the design of each vehicle model to control the M/C
information to the ECM to maintain an optimum
solenoid. The ECU plugs into the electronic control
air/fuel ratio (14.7:1), output.
module (ECM). The ECU is usually called a PROM.
14-2 ABBREVIATIONS
EFI - ELECTRONIC FUEL INJECTION - Computer IDEAL MIXTURE - The air/fuel ratio which provides
Command Control using throttle body fuel injection. the best performance, while maintaining m axim u m
conversion of exhaust emissions, typically 14.7/1.
EGR - EXHAUST GAS RECIRCULATION - Method of
reducing N O x emission levels. IGN - IGNITION - Refers to ig n ition switch and
lock.
EECS - EVAPORATIVE EMISSIONS CONTROL
SYSTEM - Used to prevent gasoline vapors in the fuel INPUTS - I n f o r m a t i o n f r o m s o u r c e s (s u c h
tank from entering the atmosphere. as,coolant te m p e ra tu r e sensors, exhau st o x y g e n
sensor, etc.) that tell the ECM how the systems are
EMI OR NOISE - An unwanted signal interfering
performing.
with another needed signal; like an electrical razor
upsets a television picture, or d riv in g under high INTERMITTENT - Occurs now and th en ; not
voltage power lines upsets the A M radio in a vehicle. continuously. In e l e c t r i c a l c i r c u i t s , r e f e r s to
occasional open, short, or ground.
ENERGIZE/DE-ENERGIZE - When current is passed
through a coil (energized) such as a solenoid, a plunger I.P. - INSTRUMENT PANEL - Contains instrument
is pulled or pushed. When the voltage to the solenoid gages and indicator lights to indicate performance of
is turned off, (de-energized), a spring raises or lowers the vehicle.
the plunger.
KM/H - KILOMETER PER HOUR - A metric unit
ESC - ELECTRONIC SPARK CONTROL - Used to measuring distance (1000 meters) in one hour.
sense detonation and retard spark advance when
L - LITER - A metric unit of capacity.
detonation occurs.
LOW - Operates the same as ground and may, or
EST - ELECTRONIC SPARK T IM IN G - ECM
may not, be connected to chassis ground.
controlled timing of ignition spark.
L4 - FOUR CYLINDER IN-LINE ENGINE
EVRV - ELECTRONIC V A C U U M REGULATOR
VALVE - Controls EGR vacuum. MALFUNCTION - A probl em that causes the
system to operate incorrectly. Typical malfunctions
FED - FEDERAL - Vehicle/Engine available in all
are; wiring harness opens or shorts, failed sensors, or
states except California.
circuit components.
FI - FUEL INJECTION - Computer Command Control
MAP - MANIFOLD ABSOLUTE PRESSURE SENSOR -
using throttle body fuel injection.
Reads pressure changes in in tak e m a n ifold w ith
GROUND - A W ire shorted to ground. A common reference to zero pressure. It puts out a voltage which
return path for an electrical circuit. A reference point is highest when the pressu re is h ig h e s t . The
from which voltage measurements may be made. maximum voltage is between 4-5 volts.
HC - HYDROCARBONS - One o f the pollutants MAT - MANIFOLD AIR TEMPERATURE SENSOR -

found in engine exhaust. Hydrogen and carbon in Measures temperature of air in the intake manifold.
gasoline.
MEM-CAL - Contains specific calibrations to meet
HIGH - A voltage more than ground or 0, like the the requirements of a specific engine..
output wire of an oxygen sensor is called __ voltage
MODE - A particular state of operation.
high, as compared to the ground, which is called
voltage low. In digital signals, high is " O N and low is MPH - MILES PER HOUR - A unit m e a s u r in g
"O FF. distance (5280 feet) in one hour.
HIGH IM PEDANCE VOLTMETER - Has h ig h N.C. - NORMALLY CLOSED - State o f relay contacts
opposition to the flow o f electrical current. Good for or solenoid plunger when no voltage is applied.
reading circuits with low current flow, such as found
Nm - NEWTON METERS (TORQUE) - A metric
in electronic systems.
unit which measures force.
HEI - HIGH ENERGY IGNITION - A distributor that
N.O. - NORMALLY OPEN - State of relay contacts
uses an electronic module and pick-up coil in place of
or solenoid plunger when no voltage is applied.
contact points.
NOx - NITROGEN, OXIDES OF - One o f the
Hg - MERCURY - a calibration material used as a
pollutants found in engine exhaust. N itr o g e n that
standard for vacuum measurement.
combines with oxygen to form oxdes of nitrogen.
IAC - IDLE AIR CONTROL - installed in the throttle
body of a fuel injected system and controlled by the
ECM to regulate idle speed.
ABBREVIATIONS-1 4 -3
O2 - OXYGEN (SENSOR) - Monitors the oxygen TACH - TACHOMETER - A device for indicating
content of the exhaust system and generates a voltage speed for rotation.
signal to the ECM.
TBI - THROTTLE BODY INJECTION (U N IT) - is
0 LOOP - OPEN LOOP - Describes EC M fuel controlled by the E C M to supply precise air/fuel
control without use of oxygen sensor information. mixture into the intake manifold.
OUTPUT - Functions, typically solenoids, that are TCC - TRANSMISSION / TRANSAXLE CONVERTER
controlled by the ECM. CLUTCH - ECM controlled solenoid in transm ission
which positively couples the tra n s m is s io n to the
OXYGEN SENSOR, EXHAUST - Device that detects
engine.
the amount of oxygen (O2) in the exhaust stream.
THERMAC - THERMOSTATIC AIR CLEANER -
POSITIVE CRANKCASE VENTILATION - Preven t
provides preheated air to intake manifold to provide
fumes in crankcase from passing into atmosphere.
better driveability when engine is cold.
P/N - PARK/NEUTRAL - Refers to switch used to
TPS - THROTTLE POSITION SENSOR - Device that
indicate to the ECM the position o f the automatic
tells the ECM the throttle position.
transmission.
TVS - THERMAL VA C U U M SWITCH - U sed to
PORT - EXHAUST OR INTAKE PORT
control vacuum in relationship to engine temperature.
PROM - PROGRAMABLE READ ONLY MEMORY-
V - VOLT - A measurement of electrical pressure.
an ele c tr o n ic term used to describ e the e n g in e
calibration unit. VOLTAGE - The pressure o f force pushing the
current in a circuit; like pressure in a water pipe.
PULSE WIDTH MODULATED - A device operated by
a digital signal that is controlled by the time duration V-6 - SIX CYLINDER ENGINE - Arranged in a "V ".
the device is turned " O N or " O F F .
V-8 - EIGHT CYLINDER ENGINE - A r r a n g e d in a
QUAD DRIVER - A "chip device that is capable of "V ".
operating four separate outputs. Some have digital
VACUUM - N e g a t iv e pressure; le s s than
and some have pulse width modulated outputs.
atmospheric pressure.
RESISTANCE - The ability o f a circuit to lim it
V A C U U M , M A N IF O L D - V a c u u m source in
current flow; like a restriction in a water pipe.
manifold below throttle plate.
RPM - REVOLUTIONS PER MINUTE - A measure of
VACUUM , PORTED - A vacu u m source a b ov e
rotational speed.
(atmospheric side ) of closed throttle plate.
SELF-DIAGNOSTIC CODE - The ECM can detect
VIN - VEHICLE IDENTIFICATION NUMBER - Appears
malfunctions in the system. If a malfunction occurs,
on a plate attached to the windshield pillar.
the ECM turns on the "Service Engine Soon light. A
d ia g n o s tic code can be ob tained from the E C M VSS - VEHICLE SPEED SENSOR - Sensor which
through the "Service Engine Soon light. This code sends vehicle speed information to the ECM.
will indicate the area o f the malfunction.
WASTEGATE - A means of controlling the amount
SES - SERVICE ENGINE SOON LIGHT - Lights when of boost available for a Turbo Charged engine.
a malfunction occurs in Computer Command Control
WOT - WIDE OPEN THROTTLE - Refers to the
system.
throttle valve or accelerator pedal when fully open or
depressed.
14-4 ABBREVIATIONS
ELECTRICAL CIRCUIT IDENTIFICATION FOR WIRING DIAGRAMS
CIRCUIT CIRCUIT CIRCUIT NAME CIRCUIT CIRCUIT CIRCUIT NAME

NUMBER COLOR NUMBER COLOR
2 RED FEED, BATTERY-UNFUSED 442 LT BLUE/BLACK ELECTRONIC CONTROL

30 PINK FUEL GAGE MODULE TO IDLE AIR
39 PINK/BLACK FEED, IGN. SW. "O N AND CONTROL, COIL A, LOW
CRANK" CONTROLLED- 443 LT GREEN/WHITE ELECTRONIC CONTROL
FUSED MODULE TO IDLE AIR
55 ORANGE DO W N SHIFT SOLENOID CONTROL, COIL B, HIGH
FEED 444 LT GREEN/BLACK ELECTRONIC CONTROL
59 DARK GREEN COMPRESSOR FEED MODULE TO IDLE AIR
66 LIGHT GREEN FEED, A/C SELECTOR SW, CONTROL, COIL B, LOW
CONTROLLED (COMP.CT.) 446 LIGHT BLUE ECM TO HIGH GEAR SWITCH
120 TAN/W HT ELECTRIC FUEL PUMP FEED 450 BLACK/WHITE ECM POWER GRD.
150 BLACK GROUND CIRCUIT-DIRECT 451 WHITE/BLACK DIAGNOSTIC ENABLE
151 BLACK GROUND 452 BLACK LOW LEVELGROUND
340 ORANGE FEED, BATTERY-FUSED 453 BLACK/RED EST REF. PULSE LOW
410 YELLOW ECM TO COOLANT TEMP. 455 PURPLE M AP GROUND
SENSOR 456 TAN/BLACK M ANUAL SHIFT LAMP
412 PURPLE 0 2 SENSOR SIGNAL 458 BLUE A/C RELAY CONTROL
413 TAN 0 2 SENSOR LOW 459 DK GREEN/WHITE A/C SIGNAL
416 GRAY ECM 5V REFERENCE 461 ORANGE SERIAL DATA DIAGNOSTICS
VOLTAGE 465 DK GREEN/WHITE FEED, ELECTRIC FUEL
417 DARK BLUE ECM TO THROTTLE 467 BLUE LOW SIDE OF INJECTOR "A "
POSITION SENSOR SIGNAL 468 GREEN LOW SIDE OF INJECTOR B"
419 BROWN/WHITE ECM TO "SERVICE ENGINE 469 BLACK/RED MAP RETURN, LOW LEVEL
SOON" LP. GROUND
420 PURPLE IGN TO BRAKE SW. 472 TAN M ANIFOLD AIR TEMP
421 DK BLUE/WHITE ECM TO COLD START SIGNAL
PROGRAM MODIFIER 481 RED FEED, FOR INJECTOR "A "
422 TAN/BLACK ECM.TO TCC SOLENOID FUSED
423 WHITE (NAT) EST SIGNAL 482 WHITE FEED, FOR INJECTOR "B"
424 TAN/BLACK ESTBYPASS FUSED
430 PURPLE/WHITE ECM REF. PULSE HIGH 485 BLACK ESC SIGNAL
432 LIGHT GREEN ECM TO MAP SIGNAL 486 BLACK/RED ESC DISTRIBUTOR GROUND
434 ORANGE/BLACK ECM TO NEUTRAL PARK 490 RED FUEL PUMP TEST TERMINAL
SWITCH 495 BLUE/ORANGE POWER STEERING SWITCH
435 GRAY ELECTRONIC CONTROL 526 BROWN EGR VAC. DIG. SW. SIGNAL
MODULE TO EXHAUST GAS 551 TAN/WHITE SYSTEM GROUND TO ECM
RECIRCULATION SOLENOID 806 PURPLE/WHITE CRANK SIGNAL TO ECM
436 BROWN ECM TO AIR SWITCH 920 TAN FUEL TANK SW. TO VALVE &
SOLENOID PUMP
437 BROWN ECM TO VEHICLE SPEED 920 PINK/BLACK FUEL PUMP RELAY TO CKT
SENSOR 120 (CK)
439 PINK/BLACK FEED IGN. SWITCH "O N & 921 GRAY FUEL TANK SW. TO VALVE &
CRANK" CONTROLLED- PUMP
FUSED 930 PINK/WHITE LEFTTANK SENDING UNIT
440 ORANGE FEED, BATTERY-FUSED 931 PINK/BLACK RIGHT TANK SENDING UNIT
441 LT BLUE/WHITE ELECTRONIC CONTROL
MODULE TO IDLE AIR
CONTROL COIL A. HIGH
8S4349-6E
COMPUTER COMMAND CONTROL (NON-"SCAN") 15-1
SECTION 15
COMPUTER COMMAND CONTROL
(WITHOUT USING SCAN TOOL DIAGNOSIS)
CONTENTS
GENERAL DESCRIPTION.................................... ..15-1 FU ELM O D U LE................................................. ..15-5
"Scan" Tool ................................................15-1 COOLANT TEMPERATURE SENSOR............... 15-5
ALDL C o n n e c to r...........................................15-1 OXYGEN SENSOR............................................ ..15-5
W irin g Harness and C o n n e c to rs ............ ..15-2 MAP SENSOR ................................................. ..15-5
ELECTRONIC CONTROL M O D U L E .................15-2 THROTTLE POSITION SENSOR .................... ..15-5
In fo rm a tio n Sensors ............................... ..15-2 VEHICLE SPEED SENSOR..................................15-5
D IA G N O S IS ............................................................ 15-2 MAT SENSOR................................................... ..15-5
BULB CHECK .....................................................15-2 EGR SYSTEM ................................................... ..15-5
CODE S Y S T E M ................................................ ..15-2 IDLE AIR CONTROL............................................15-5
SYSTEM CHECK ................................................15-3 ELECTRONIC SPARK T IM IN G ...........................15-5
Diagnostic M o d e ......................................... 15-3 ELECTRONIC SPARK C O N T R O L.................... ..15-6
Engine Does Not Start ............................. .. 15-3 PARK/NEUTRAL SW ITCH ..................................15-6
Field Service M o d e .................................... .. 15-3 CRANK SIGNAL...................................................15-6
Clearing C o d e s........................................... .. 15-4 POWER STEERING PRESSURE S W IT C H _____15-6
ELECTRONIC CONTROL MODULE ................. 15-4 DISTRIBUTOR REFERENCE SIG N AL............... ..15-6
PROM ............................................................ 15-4 A/C CLUTCH C O N TR O L.................................. ..15-6
M EM -CAL..................................................... .. 15-4 A/C "O N " SIG N AL............................................ ..15-6
C A LP A K....................................................... .. 15-4 EXHAUST S Y S T E M ............................................15-6
FUEL PUMP CIRCUIT......................................... 15-5 ON-VEHICLE SERVICE............................................15-6
GENERAL DESCRIPTION
Th e C om p u te r C om m an d C on trol system has a some outputs. If a "Scan tool is available, refer to
computer (Electronic Control Module) to control the Section "3 .
fuel delivery, ignition timing, some emission control
s y s te m s and e n g a g e m e n t o f the t r a n s m is s io n ALDL Connector
converter clutch, downshift control or the manual (Figure 15-1)
transmission shift light. The Assembly Line Diagnostic Link ( A L D L ) is
The system, through the electronic control module wired to the ECM and is located under the instrument
(E C M ), monitors a number o f engine and ve h icle panel in the passenger compartment.
functions, and controls the following operations: This connector has term inals that are used to
Fuel Control diagnose the system with jumper wires. The following
Ignition/Electronic Spark Tim ing terminals are used:
Electronic Spark Control A - This terminal provides a ground circuit to other
A ir Management terminals.
Exhaust Gas Recirculation B - This terminal is the "diagnostic term inal for the
T r a n s m is s io n C o n v e r t e r C lu t c h , D o w n s h ift ECM. When grounded to " A t e r m in a l, the
Control or Manual Transmission Shift Light "Service Engine Soon light w ill flash codes (key
The diagnosis in this section is provided when a " O N and engine " O F F ) entering the Diagnostic
"Scan tool is not available, and the "Service Engine Mode, or flashes a Field Service Mode (en gin e
Soon light is illuminated, when the en g in e and running) to determine if system is in a "Closed
vehicle are running. Loop or "Open Loop operation.
Refer to Section "3 for additional diagnosis. C - This terminal, on some air management systems
is wired to the ground side o f the ele ctric air
control valve. It can be used to diagnose the air
"Scan" Tool
management system. Refer to Section "8 .
E - This term inal is the s e r ia l d a ta line on a ll
A "Scan tool is designed to interface with the
engines except 2.5L and is used by a "Scan tool
Computer Command Control system. It supplies a
to read various system data information
visual reading o f most inputs to the ECM, and also
15-2 COMPUTER COMMAND CONTROL (NON-"SCAN)
Crank signal
F E C B A Distributor reference signal
o H M
o Power steering pressure switch signal
G
TERMINAL IDENTIFICATION A/C control signal
0 GROUND
[~F~l T.C.C. (IF USED)
Transmission gear position signal
EGR vacuum signal
0 DIAGNOSTIC TERMINAL
[~G~| FUEL PUMP (CK)
Fuel module
0 A , , (IF USED)
Refer to Section "3 for additional information.
BRAKE SENSE
j E] SERIAL DATA (V6A/8) 0 SPEED INPUT (CK)
(SEE SPECIAL TOOLS) M SERIAL DATA (L4)
(SEE SPECIAL TOOLS)
DIAGNOSIS
The Computer Command C ontrol System has a
6-2-87 *7S 3541-6E
diagnostic system built into the ECM to indicate a
Figure 15-1 ALDL Connector
failed circuit. An amber "Service Engine Soon light
on the instrument panel will illuminate if a problem
F - This term inal is used to dia gnose the T C C
has been detected when the engine and vehicle are
system and is wired to the ground side of the TCC
running. This light is also used for a bulb and system
solenoid. Refer to Section "10 .
check.
G - This terminal is used to diagnose the fuel pump
The system requires a tachometer, test light,
circuit on all C K series. On all other vehicles the
oh m m eter, d ig it a l v o lt m e t e r w ith 10 m e g o h m s
fuel pump test lead is in the engine compartment
impedance (J-34029-A), vacuum gage and ju m p e r
near the fuel pump relay. Refer to C H A R T A-5,
wires for diagnosis. If a "Scan tool is available, refer
Section "3 .
to Section "3 .
H - This term inal is used to diagnose the brake
Refer to Section "13 for additional information
system on C K trucks. Refer to C K Light Duty
about special tools.
Service Manual for additional information.
M - This terminal is the serial data line for the 2.5L
BULB CHECK
engines and is used by a "Scan tool to read
various system data information.
With the ignition " O N and engine not running,
the lamp should be illuminated, which indicates that
Wiring Harness and Connectors
the ECM has completed the circuit to turn " O N the
light.
A wiring harness electrically connects the ECM to
If the "Service Engine Soon light is not " O N ,
various sensor, solenoid and relays within the system.
refer to C H A R T A-1 in Section " 3 for diagnosis.
Many connectors in the engine co m p a rtm en t are
When the engine is started, the light w ill turn
environmentally protected because of the systems low
" O F F . If the light remains " O N , refer to "System
voltages and current levels.
Check .
ELECTRONIC CONTROL MODULE

CODE SYSTEM
The Electronic Control Module (EC M ) is located in
The ECM self-diagnosis system detects system
the passenger compartment and is the control center
failure and aids the technician in finding the circuit at
o f the Computer Command Control System. Refer to
fault via a code.
Section "3 for additional information.
The ECM is really a computer. It uses sensors to
look at many engine operating conditions. It has a
Information Sensors
memory, and it knows what a certain sensor readings
should be under certain conditions. These conditions
In addition to the ECM, the Computer Command
are described on the facing page of each Code Chart in
Control System has the following information sensors:
Section "3 . If a sensor reading is not what the ECM
Oxygen sensor
thinks it should be, the ECM w ill turn on the "Service
Coolant temperature sensor
Engine Soon light on the instrument panel, and will
Throttle position sensor
store a code in the memory. T h e code tells which
Manifold absolute pressure sensor
C IR C U IT the trouble is in. A circuit consists o f a
Vehicle speed sensor
sensor (such as coolant temperature), the wiring and
Manifold temperature sensor
connectors to it, and the ECM.
Knock sensor
An "intermittent code is one which does not reset
and the following input signals: itself, and is not present while you are working on the
vehicle. This is often caused by a loose connection
Park/neutral switch signal
The facing page of a Code Chart in Section "3 will

co n ta in d i a g n o s t i c a id s to h e lp in d e t e c t i n g
intermittents.
A "hard code is one which is present when you are
working on the vehicle, and the condition still exists
while w orking on the vehicle. The chart with the
stored code number will lead you to the cause of the
problem.
SYSTEM CHECK
(Figure 15-2)
The system check is performed through the twelve
terminal Assem bly Line Diagnostic Link ( A L D L )
connector (Figure 15-1) under the instrument panel in
the passenger compartment.
The system check provides a starting point and a
method to determine if:
The "Service Engine Soon light illuminates.
The diagnostic system is working (Code 12).
A ny codes are displayed.
The fuel system is operating normally (Field
Service Mode).
W hen t e r m in a l " B (d ia g n o s tic t e r m in a l) is
jumpered to terminal " A (ground), the system will
enter either the Diagnostic Mode or the Field Service
Mode.
Diagnostic Mode
If the Diagnostic terminal " B in A L D L connector

is grounded with the ignition " O N and the engine
stopped, the system will enter the Diagnostic Mode.
With the key " O N and the engine " O F F , jumper
A L D L terminals " B to " A . Th e "S ervice Rngine
4-13-87
Soon light will flash Code 12 to indicate that the *8S 4348-6E
diagnostic system is working. Code 12 consists of "one
Figure 15-2 System Check
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. Engine Does Not Start
If Code 12 does not display, refer to C H A R T A-2 in
Section "3 . If the engine cranks but will not start, refer to
Any additional stored codes (F ig u re 15-3) will C H A R T A-3 through A-6 in Section " 3 to determine if
begin to flash after Code 12. An example is Code 34 it is a fuel or ignition problem.
which consists o f "three flashes followed bv a short
pause and then "four flashes . Each stored code will Field Service Mode
flash three times and then Code 12 will again begin to
flash in d ic a tin g a co m p lete cycle. I f a code is If the Diagnostic terminal is grounded with the
displayed, a code ch art is used to d ia g n ose the en gine running, the system w ill e n te r the F i e ld
problem. The chart will determine if the problem still Service mode. In this mode, the " S e r v ic e Engine
exists (hard failure) or if it is an intermittent problem. Soon light will show whether the system is in "Open
Codes only can be obtained with the engine not Loop or "Closed Loop and fuel system is operating
running. Grounding the Diagnostic terminal with the normally.
engine running will enter the "Field Service Mode . W ith the D ia gn o stic t e r m in a l grou n ded and
With the exception o f the fuel pump relay, all engine at normal operating temperature, run engine
ECM controlled solenoids and relays are energized in at 1400 to 1600 rpm for two minutes and note light.
the Diagnostic Mode. Fuel system is operating normally and system is
In the Diagnostic Mode, the IAC valve moves to in a "Closed Loop operation if the light is flashing at
the fully extended position. a rate of once per second.
15-4 COMPUTER COMMAND CONTROL (NON-"SCAN")
If the light flashes at a rate of 2.5 times per second, An in c o r r e c t E C M or P R O M / M e m - C a l

the fuel system is in a "Open Loop condition. application may cause a malfunction and may
"Open Loop indicates that oxygen sensor voltage or may not set a code.
signal is not usable to the ECM. Signal voltage is at a If the connector at the E C M is the possible
constant value between .35 and .55 volts. problem, the terminal may have to be removed
System will flash "Open Loop from 30 seconds to from the connectors in order to properly check
2 minutes after engine starts or until sensor reaches them.
normal operating temperature. If system fails to go Although the PROM / Mem-Cal rarely fails, it
"Closed Loop , see Code 13 for diagnosis. operates as part of the ECM, therefore, it could
A "Service Engine Soon light that is " O F F most be the cause of the problem.
o f the time indicates that the exhaust is lean. The A lthough a rare condition, the replacem ent
oxygen sensor signal voltage will be less than .35 volts ECM may be faulty.
and steady. See Code 44 for diagnosis. In the case of an intermittent problem, refer to
A "Service Engine Soon light that is " O N most of Section " 2 and m ake a c a r e f u l p h y s ic a l
the time indicates that the exhaust is rich. Th e inspection of the system involved.
oxygen sensor signal voltage will be above .55 volts A shorted solenoid, relay coil or harness may
and steady. See Code 45 for diagnosis. cause an ECM to fail, and a replacement ECM
A t idle, the 7.4L engine runs in an "Open Loop to fail when it is installed. Use a short tester,
condition. The 2.5L, 2.8L, 5.0L and 5.7L engines J-34696, B T 8405, or equ ivalent, as a fast,
should run in a "Closed Loop condition at idle. accurate means of checking for a short circuit.
The ECM "Closed Loop timer is by-passed and
new trouble codes can not be stored while the system PROM
is in the field service mode.
A P R O M th a t has f a i l e d or was i n s t a l l e d
Clearing Codes improperly will generally set a Code 51.
When the ECM sets a code, the "Service Engine MEM-CAL

Soon light will come " O N , and a code will be stored
in memory. I f the problem is intermittent, the light A M em -Cal that has fa ile d or was in s ta lle d
will go out after 10 seconds, when the fault goes away. improperly will set a Code 51.
However, the code will stay in the ECM memory for 50
starts or until the battery voltage to the ECM is CALPAK
removed. Removing battery voltage for 30 seconds
will clear all stored codes. A no start and run condition w ill result i f the
Codes should be cleared after repairs have been C A L P A K is not installed in the ECM. A C A L P A K
completed. Also, some Diagnostic Charts will tell you that is removed will set a Code 52.
to clear the codes before using the chart. This allows
the ECM to set the code while going through the chart, FUEL PUMP CIRCUIT
which will help to find the cause of the problem more
quickly. Code 54 indicates a failure in the fuel pump
circuit.
NOTICE: To prevent ECM damage, the key must be Two types of fuel pump relays are used on light
"O F F when d is c o n n e c tin g or duty trucks. The S, T and M series use one type and C,
reconnecting power to ECM (for example K, R, V, G and P series use the other type. Both relays
battery cable, EC M pigtail, ECM fuse, have the same function, but terminal arrangement is
jumper cables, etc.) different. Both relays have a terminal to test the fuel
pump operation. This is either a separate terminal
ELECTRONIC CONTROL MODULE (ECM) located near the relay or along the ECM harness or at
terminal " G in the A L D L connector. By ap p ly in g
The diagnosis o f the electronic control module voltage at this terminal, it can be determined if the
( ECM) starts with the system check. The code system fuel pump will operate. This terminal will also prime
indicates a failure of a specific circuit and diagnosis the fuel line to the TB I unit.
may indicate replacement of the ECM. A Code 55
indicates that the E C M has fa ile d and must be
replaced.
I f the ECM has been replaced and the condition
was not corrected, the following information may be
the cause:
COMPUTER COMMAND CONTROL(NQN-"SCAN") 15-5
FUEL MODULE EGR SYSTEM
An inoperative fuel module, if equipped, may be Code 32 indicates that there is a fa ilu re in the
the cause of a hot stall/no start condition. Check for EGR system circuit.
power and ground circuit to the fuel module and a
complete circuit to the pump from terminal " A . If OK IDLE AIR CONTROL (IAC)
and the pump does not run for the specified 20 seconds
at initial ignition " O N , replace the fuel module. Code 35 sets when there is an idle speed error on a
2.5L engine. Refer to diagnosis in Section "4 for idle
COOLANT TEMPERATURE SENSOR air control valve check for other engines.
System too lean. (H igh air/fuel ratio)
Code 14 or Code 15 indicates a failu re in the Idle speed may be too high or too low. En gin e
coolant temperature sensor circuit. speed may vary up and down, disconnecting IA C
does not help. May set Code 44. Check for low
OXYGEN SENSOR regulated fuel pressure or water in fuel. A lean
exhaust with an oxygen sensor output fixed above
Code 13 indicates an open in the oxygen sensor 800 mV (.8 volts) will be a contaminated sensor,
circuit. Code 44 indicates a shorted oxygen sensor usually silicone. This may also set a Code 45.
circuit. Code 45 indicates a high voltage in the oxygen System too rich. (Low air/fuel ratio)
sensor circuit. If a code is set, the engine will always Idle speed too low. System obviously rich and may
run in the "Open Loop mode. The oxygen sensor exhibit black smoke exhaust.
v o lta g e output can be m easured w ith a d i g i t a l Check:
v o lt m e t e r h a v in g at le a s t a 10 m e g o h m inp u t High fuel pressure.
impedance. Use of a standard shop type voltmeter will Injector leaking or sticking.
result in an inaccurate reading. Throttle body.
Remove IAC and inspect bore for foreign material
MAP SENSOR or evidence o f l A C valve dragging the bore.
A/C Compressor or relay failure.
Code 33 or Code 34 indicates a failure in the M A P See if A/C diagnosis circuit if shorted to ground. If
sensor circuit. Also refe r to M A P output check the relay is faulty, an idle problem may exist.
diagnosis (page 3-72) to check the M A P sensor i f there Refer to "Rough, U n s ta b le , In co rre ct Idle or
is no code. Stalling in Symptoms in Section 2
ELECTRONIC SPARK TIMING (EST)

THROTTLE POSITION SENSOR (TPS)
W hen the system is ru n n in g on the I g n itio n
Code 21 indicates that there is a shorted throttle Module, that is, no voltage on the by-pass line, the
position sensor circuit. Code 22 indicates that there is Ignition Module grounds the EST signal. The ECM
an open in the T P S circuit. When a code is set, the expects to see no voltage on the EST line during this
ECM will use an artificial value for throttle position condition. If it sees voltage, it sets Code 42 and will
and some engine performance will return. not go into the EST mode.
A broken T P S can cause intermittent bursts of When the rpm for EST is reached (about 400 rpm),
fuel from the injector(s) and an unstable idle, because and by-pass voltage applied, the EST should no longer
the ECM thinks the throttle is moving. be grounded in the ignition module so the EST voltage
should be varying.
VEHICLE SPEED SENSOR I f the by-pass line is open or groun ded , the
Ignition Module will not switch to EST mode so the
The vehicle speed sensor circuit diagnosis is in EST voltage will be low and Code 42 will be set.
Code 24 chart. If the EST line is grounded, the Ignition Module
will switch to EST, but because the line is grounded
MAT SENSOR there will be no EST signal. A Code 42 will be set.
Code 42 sets if there is an open or a short to ground
Code 23 indicates that there is an open in the M A T in the EST or by-pass circuit.
sensor circuit. Code 25 indicates that there is a short
to ground in the M A T sensor circuit.
15-6 COMPUTER COMMAND CONTROL (NON-"SCAN")
ELECTRONIC SPARK CONTROL (ESC) A/C "ON" SIGNAL
Code 43 sets if there is an open or short to ground The diagnosis o f the A/C " O N s ig n a l on a ll
in the ESC circuit. engines other than 2.5L is covered on page 3-88.
There should not be a knock at idle unless an
internal engine problem, or a system problem, exists. EXHAUST SYSTEM
SYSTEM OVERVOLTAGE Refer to Figure 3-17 for diagnosis o f a restricted

exhaust system.
Code 53 sets on a 2.5L engine if there is voltage
greater than 17.1 volts for two seconds at EC M ON-VEHICLE SERVICE
terminal B l. This indicates that there is a basic
generator problem. Refer to Section " 3 for on-vehicle service o f the
following components:
PARK/NEUTRAL SWITCH W ire harness
Electronic control module
Diagnosis of the park/neutral switch is on page PROM
3-74. Calpak
Mem/cal
CRANK SIGNAL Coolant temperature sensor
M A P sensor
The crank signal diagnosis procedure is on page 3- Oxygen sensor
76. If there is no crank signal to the ECM, the engine Throttle position sensor
may be hard to start. M A T sensor
E-Cell
POWER STEERING PRESSURE SWITCH Park/neutral switch
Power steering pressure switch
The diagnosis o f the power steerin g pressure
switch is covered on page 3-78. W irin g diagrams and ECM connector term in al end
views are also provided in Section "3 .
DISTRIBUTOR REFERENCE SIGNAL
The distributor reference signal is covered in

Section "6 of the ignition system and electronic spark
control.
A/C CLUTCH CONTROL
The diagnosis of the A/C clutch control on a 2.5L

engine is covered on page 3-80 and on page 3-84 for
2.8L engine.
CODE IDENTIFICATION
The SERVIC E E N G I N E S O O N light will only be " O N if the malfunction exists under the conditions
listed below. I f 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 - O2 Sensor Indicates that the Code 33 - M A P Sensor M A P 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 - M A P Sensor Low or no output from
High Temperature signal line becomes High Vacuum sensor with engine
Indication grounded for 3 seconds. running.
Code 15 - Coolant Sensor Sets if the sensor, Code 35 - IAC IAC error
Low Temperature connections, or wires
Indication open for 3 seconds. Code 42 - EST ECM has seen an open
or grounded EST or
Bypass circuit.
Code 2 1 - T P S TP S 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
1200 RPM. long or the system has
failed a functional
Code 22 - T P S A shorted to ground or check.
Signal Voltage Low open signal circuit will
set code in 3 seconds. Code 44 Sets if oxygen sensor
Lean Exhaust Indication voltage remains below
Code 23 - M A T Sets if the sensor, .2 volts for about 20
Low Temperature connections, or wires seconds.
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
N o Vehicle Speed during a road load decel. .7 volts for about 1
Indication minute.
Code 25 - M A T Code 51 Faultv M E M -C A L ,

Sets i f the sensor or
High Temperature PROM, or ECM
signal line becomes
Indication grounded for 3 seconds.
Code 52 Fuel C A L P A K
missing or faulty.
Code 53 System overvoltage.

Indicates a basic
generator problem.
Code 32 - EGR Vacuum switch shorted
to ground on start up Code 54 - Fuel Pump Sets when the fuel
Low voltage pump voltage is less
OR
than 2 volts when
Switch not closed after
reference pulses are
the ECM has
being received.
commanded EGR for a
specified period of time.
Code 55 Faulty ECM
OR
EGR solenoid circuit
open for a specified
5-27-87
period of time 7S3337-6E
Figure 15 - 3 - ECM Code System

15-8 COMPUTER COMMAND CONTROL (NON- "SCAN")
"A/OA/-SCAATDIAGNOSTICS
CODE 13
OXYGEN SENSOR CIRCUIT
(OPEN CIRCUIT)
ALL ENGINES
FIELD SERVICE MODE:

ENGINE RUNNING, DIAGNOSTIC TERMINAL GROUNDED.
'OPEN LOOP": "SERVICE ENGINE SOON" LIGHT FLASHES AT A RATE OF 2 TIMES PER SECOND.
"CLOSED LOOP": "SERVICE ENGINE SOON" LIGHT FLASHES AT A RATE OF 1 TIME PER SECOND.
6-20-87
CLEAR CODES AND CONFIRM "CLOSED LOOP " OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
8S4350-6E
COMPUTER COMMAND CONTROL (NON- "SCAN") 15-9
'NON-SCAN" DIAGNOSTICS
CODE 14
ALL ENGINES
6-19-87
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. * 8S4351-6E
7N O N - S C A N " DIAGNOSTICS
CODE 15
ALL ENGINES
6-19-87
CLEAR CODES AND CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. * 8S 4352-6E
'NON-SCAN" DIAGNOSTICS CODE 21

(TPS) CIRCUIT
ALL ENGINES
6-19-87
8S4353-6E
'N O N - S C A N " DIAGNOSTICS

CODE 22
ALL ENGINES
CLEAR CODES AND CONFIRM "CLOSED LOOP'' OPERATION AND NO "SERVICE ENGINE SOON"LIGHT. 6-20-87
8S 4354-6E
CODE 23
MANIFOLD AIR TEMPERATURE (MAT)
SENSOR CIRCUIT
2.5L ENGINE

DISCONNECT M AT SENSOR.
IGNITION " O N ', ENGINE STOPPED.
CHECK VOLTAGE BETWEEN M AT SENSOR HARNESS
TERMINALS USING A DIGITAL VOLTMETER
(J-29125) OR EQUIVALENT.
4 VOLTS OR OVER BELOW 4 VOLTS
CHECK RESISTANCE ACROSS M AT SENSOR

TERMINALS. SHOULD BE LESS THAN 25,000
CHECK VOLTAGE BETWEEN HARNESS
CONNECTOR SIGNAL CKT AND
OHMS, SEE TABLE FOR APPROXIMATE GROUND.
TEMPERATURE TO RESISTANCE VALUES.
OK NOT OK 4 VOLTS OR OVER BELOW 4 VOLTS
CHECK FOR SIGNAL CKT BEING REPLACE FAULTY SENSOR GROUND OPEN SIGNAL CKT,
SHORTED TO VOLTAGE. IF NOT SENSOR CKT. FAULTY CONNECTION(S) FAULTY CONNECTION
SHORTED TO VOLTAGE .CODE OR FAULTY ECM. OR FAULTY ECM.
23 IS INTERMITTENT. IF
ADDITIONAL CODES WERE
STORED, SEE APPLICABLE
CHART. IF NO CODES REFER TO MAT SENSOR
ECM INTERMITTENT CODES OR TEMPERATURE TO RESISTANCE VALUES
PERFORMANCE IN SECTION "2 ".
(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
6-22-87
8S 4602-6E

CODE 24
VEHICLE SPEED SENSOR (VSS) CIRCUIT
ALL ENGINES
CLEAR CODES AND CONFIRM CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
6-22-87
8S 4603-6E

CODE 25
MANIFOLD AIR TEMPERATURE (MAT)
SENSOR CIRCUIT
2.5L ENGINE
a

DISCONNECT MAT SENSOR.
CHECK VOLTAGE BETWEEN M AT SENSOR HARNESS
CONNECTOR TERMINALS USING A DIGITAL
VOLTMETER (J-29125) OR EQUIVALENT.
4 VOLTS OR OVER BE L O W 4 V O L T S
i CHECK RESISTANCE ACROSS MAT SENSOR

TERMINALS. SHOULD BE MORE THAN 185 OHMS.
CK T 4 7 2 S H O R T E D T O
G R O U N D OR
SEE TABLE FOR APPROX. TEMPERATURE TO
CKT 4 7 2 S H O R T E D TO
RESISTANCE VALUES.
S E N S O R G R O U N D C IR C U IT
OR F A U LTY ECM.
OK NOT OK
INTERMITTENT FAULT IN SENSOR CIRCUIT OR REPLACE SENSOR

CONNECTOR. IF ADDITIONAL CODES WERE
STORED, SEE APPLICABLE CHART. IF NO CODES ,
REFER TO ECM INTERMITTENT CODES OR M A T SENSOR
PERFORMANCE IN SECTION "2 ". T E M P E R A T U R E T O R ES IS TA N C E V A L U E S
(A P P R O X IM A TE )
F C OHMS
210 100 185
160 70 450
100 38 1,600
70 20 3 ,4 0 0
40 4 7 ,500
20 -7 13,500
0 -18 25,000
-40 -40 100,700
8S 4604-6E
BEFORE USING THIS CHART, CHECK V A C U U M SOURCE TO EGR

SOLENOID, ALSO CHECK HOSES FOR LEAKS OR RESTRICTIONS.
CODE 32
SHOULD BE AT LEAST (7") HG VACUUM AT 2000 RPM.
EGR SYSTEM CHECK
2.5L&5.0L
DISCONNECT EGR SOLENOID VACUUM LINE FROM THROTTLE BODY.
4.3L (EXCEPT ST)
GROUND DIAGNOSTIC TERMINAL 5.7L (UNDER 8500 GVW)
INSTALL A HAND HELD VACUUM PUMP WITH GAGE TO THROTTLE BODY
SIDE OF EGR SOLENOID.
APPLY VACUUM AND OBSERVE EGR VALVE DIAPHRAGM.
VALVE SHOULD MOVE.
DOES IT?
YES NO
ZLZ

UNGROUND DIAGNOSTIC TERMINAL.
VACUUM SHOULD BLEED OFF AND
CONNECT VACUUM PUMP TO EGR VALVE SIDE OF
HARNESS.
VALVE SHOULD CLOSE. APPLY VACUUM AND OBSERVE VALVE.
DOES IT? VALVE SHOULD MOVE.
DOES IT?
YES NO
HZ X

IGNITION "OFF"
CONNECT A VACUUM
DISCONNECT
SOLENOID
YES NO
I
PUMP TO EGR VALVE. ELECTRICAL FAULTY VACUUM HOSE
USING A MIRROR, CONNECTOR. TO EGR VALVE OR FAULTY
OBSERVE EGR DOES VACUUM VALVE
DIAPHRAGM WHILE BLEED OFF?
APPLYING VACUUM.
DIAPHRAGM SHOULD DISCONNECT EGR ELECTRICAL CONNECTOR.
YES NO CONNECT TEST LIGHT BETWEEN HARNESS
MOVE FREELY AND
IE HZ CONNECTOR TERMINALS.
HOLD VACUUM FOR AT
LEAST 20 SECONDS. CKT 435 REPLACE IGNITION "O N " ENGINE "OFF"
DOES IT? SHORTED TO SOLE TEST LIGHT SHOULD LIGHT.
GROUND OR NOID. DOES IT?
FAULTY ECM
YES NO
H
YES NO FAULTY CONNECT TEST LIGHT
ZEZ in SOLENOID BETWEEN HARNESS
APPLY VACUUM TO EGR VALVE. REPLACE EGR CONNECTION TERMINAL "A" AND
START ENGINE AND VALVE. OR FAULTY GROUND
IMMEDIATELY OBSERVE SOLENOID.
VACUUM GAGE ON VACUUM
PUMP. NOUGHT LIGHT
VALVE IS GOOD IF DIAPHRAGM I7 Z
HAS MOVED TO SEATED
REPAIR OPEN REPAIR OPEN CKT 435.
POSITION (VALVE CLOSED) AND
CKT 439. IF NOT OPEN, IT IS A
VACUUM DROPPED WHILE
FAULTY ECM. * *
STARTING ENGINE.
VACUUM DROPPED NO VACUUM DROP

X I
BE SURE VACUUM HOSE REMOVE EGR VALVE.
CHECK PASSAGES * * BEFORE REPLACING ECM, REFER TO ECM QDR CHECK
BETWEEN SOLENOID AND EGR
FOR BEING PLUGGED. PROCEDURE.
VALVE IS OK. (NO LEAKS OR
IF NOT PLUGGED, REPLACE ANY RELAY OR SOLENOID IF THE COIL RESISTANCE
RESTRICTIONS) IF NO PROBLEM
REPLACE VALVE. MEASURES LESS THAN 20 OHMS.
IS FOUND, THE EGR CIRCUIT IS
OK.
7S3870-6E
IF ANY OTHER CODES ARE STORED. DIAGNOSE THEM FIRST.

CODE 32
O
DISCONNECT EGR SOLENOID VACUUM HOSE (MANIFOLD
SIDE).
EGR SYSTEM FAILURE
CHECK PORTED VACUUM SOURCE TO SOLENOID ( IF NOT 2.8L & 7.4L
OK .REPAIR).
CHECK VACUUM HOSE BETWEEN SOLENOID AND VALVE
4.3L (ST)
FOR RESTRICTIONS. 5.7L (OVER 8500 GVW)
INSTALL A HAND HELD VACUUM PUMP WITH GAGE ON
MANIFOLD SIDE OF EGR SOLENOID.
IGNITION "O N " ENGINE STOPPED .
DIAGNOSTIC TERMINAL GROUNDED .
APPLY VA C UUM .
OSBSERVE EGR VALVE .
VALVE SHOULD MOVE . DOES IT?
NO YES
H Z 1
INSTALL A VACUUM GAGE IN START AND IDLE ENGINE.
VACUUM LINE AT VALVE. LIFT UP ON EGR VALVE AND OBSERVE IDLE.
REPEAT TEST.
DOES GAGE INDICATE VACUUM. 1
1
1 ... IDLE ROUGHENS NO CHANGE
NO YES
HZ z n RECONNECT EGR SO LENOID. REMOVE EGR VALVE .
DISCONNECT SOLENOID REPLACE
(H. CONNECT VACUUM GAGE TO CHECK PASSAGES FOR
CONNECTOR. EGR VALVE VACUUM HOSE AT EGR VALVE . BEING PLUGGED. IF
PROBE HARNESS ENGINE AT NORMAL OPERATING NOT PLUGGED
CONNECTOR TERMINAL TEMP. REPLACE EGR VALVE .
"A" WITH A TEST LIGHT IN DRIVE (AUTOMATIC TRANS.).
TO GROUND. HOLD BRAKES AND ACCELERATE
MOMENTARILY UP TO ABOUT
1800 RPM.
OBSERVE GAGE.
LIGHT "O N" LIGHT "OFF"
SHOULD HAVE OVER 2" VACUUM
X I BUT LESS THAN 10".
CONNECT A TEST LIGHT REPAIR OPEN
BETWEEN HARNESS IN CKT 439
CONNECTOR TERMINALS
"A " & "D ". OK NOT OK
LIGHT "O N" LIGHT "OFF"

NO TROUBLE OVER 10" NO VACUUM OR
' I --------- 1 .... FOUND. SEE ECM VACUUM LESS THAN 2"
CONNECT TEST LIGHT REPAIR OPEN INTERMITTENT
BETWEEN HARNESS IN GROUND CODES OR ......
CONNECTOR TERMINALS CKT PERFORMANCE IN REPLACE IF THERE ARE NO
"A " & "B". SECTION "2". EGR FILTER RESTRICTIONS IN
GROUND DIAGNOSTIC VACUUM LINES,
TERMINAL. PERFORM P/N
SWITCH CHECK
1_ IN SECTION "3 ".
LIGHT "O N " LIGHT "OFF'
I ~ ~ ~ T ~
REPLACE SOLENOID OPEN CKT 435 OR

FAULTY ECM. SEE
DIAGNOSTIC AIDS
FOR CODE 32 IN
SECTION "3".
6-25-87
CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 8S4624-6E
CODE 33
MAP SENSOR
ALL ENGINES
IF ENGINE IDLE IS ROUGH, UNSTABLE, OR INCORRECT, CORRECT BEFORE USING CHART. SEE DRIVEABILITYSYMPTOMS
IN SECTION "2".
IGNITION "ON" ENGINE STOPPED VOLTAGES

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
L O W A LT IT U D E = H IG H PRESSURE = H IG H VOLTAGE
6-22-87
8S 4605-6E
'A/OA/-SCAW"DIAGNOSTICS
CODE 34
MAP SENSOR
ALL ENGINES

IGNITION "OFF", CLEAR CODES.
DIAGNOSTIC TERMINAL NOT GROUNDED.
START ENGINE AND RUN FOR 1 MINUTE OR UNTIL "SERVICE ENGINE SOON" LIGHT COMES ON.
GROUND DIAGNOSTIC TERMINAL AND NOTE CODE.
CODE 34 NO CODE 34

IGNITION "OFF",CLEAR CODES.
DISCONNECT M AP SENSOR AND JUMPER HARNESS
PROBLEM IS INTERMITTENT. IF NO
OTHER CODES WERE STORED, SEE
ECM INTERMITTENT CODES OR
CONNECTOR TERMINAL "B" TO "C".
DIAGNOSTIC TERMINAL NOT GROUNDED. PERFORMANCE IN SECTION "2 ".
START ENGINE AND RUN FOR 1 MINUTE.
OR UNTIL "SERVICE ENGINE SOON" LIGHT COMES ON.
CODE 34 CODE 33
REMOVE JUMPER FROM TERMINAL "B" TO "C". REPLACE SENSOR

CHECK VOLTAGE BETWEEN HARNESS CONNECTOR
TERMINAL "A " AND "C USING DIGITAL
VOLTMETER (J-34029-A) OR EQUIVALENT.
4 TO 6 VOLTS BELOW 4 TO 6 VOLTS

-----r -------- -
OPEN IN MAP SIGNAL CKT 432 OPEN IN 5V REFERENCE CKT416

OR OR
SHORT TO GROUND IN CKT 432 SHORT TO GROUND IN CKT 416
OR OR
FAULTY ECM CONNECTOR CKT 455/469 SHORTED TO CKT 416
OR OR
FAULTY ECM. FAULTY ECM CONNECTOR
OR
FAULTY ECM.
8S 4606-6E
NON-SCAN" DIAGNOSTICS
CODE 35
2.5L ENGINE
A/C "OFF" DURING ENTIRE CHECK.
ENGINE AT NORMAL OPERATING TEMPERATURE
AND TRANSMISSION IN DRIVE (A/T) OR NEUTRAL
(M/T).
RECORD ENGINE SPEED, IF IDLE IS ERRATIC OR
UNSTABLE, REFER TO CODE 35 ON FACING PAGE,
IN SECTION "3".


IN FIRST STEP.
IDLE ENGINE FOR 1 MINUTE IN DRIVE (A/T) OR
NEUTRAL (M /T).
NOTE ENGINE SPEED.

RECORDED IN FIRST STEP.
1 . ............ . . . . ... .
SEE CODE 35 ON FACING PAGE

IGNITION "OFF".
"DIAGNOSTIC AIDS" IN SECTION 3".

GROUND DIAGNOSTIC TEST TERMINAL.
NO LIGHTS, ONE OR
MORE CIRCUITS.
LIGHT STEADY
OR FLASHING ALL
CIRCUITS
CHECK FOR OPEN OR SHORT TO

VALVE, OR PLUGGED
PASSAGE. IF LIGHT
REFER TO CODE 35 AND
CHECK RESISTANCE ACROSS IAC COILS. SHOULD BE REPAIR WIRING AND TEST, STEP 4 ON FACING
MORE THAN 20 OHMS BETWEEN IAC TERMINALS RECHECK. PAGE, IN SECTION "3 "
OPPOSITE HARNESS CONNECTOR TERMS. "A " TO "B*
AND "C" TO "D ".
OK
NOT OK
FAULTY ECM
1
CONNECTION OR ECM.
IDLE NOT OK
REPLACE ECM
7-14-87
CLEAR CODES , CONFIRM "CLOSED LOOP" OPERATION, NO "SERVICE ENGINE SOON" LIGHT. 8S4607-6E
'A/OA/-SCAATDIAGNOSTICS
CODE 42

CLEAR CODES.
IDLE ENGINE FOR 1 MINUTE OR UNTIL "SERVICE
ENGINE SOON" LIGHT COMES ON.
ELECTRONIC SPARK
TIMING (EST) CIRCUIT

IGNITION "O N". ENGINE STOPPED.
GROUND DIAGNOSTIC TERMINAL AND NOTE CODES.
ALL ENGINES
CODE 42 NO CODE 42
IGNITION "OFF". CODE 42 INTERMITTENT. IF NO

DISCONNECT ECM CONNECTORS. ADDITIONAL CODES WERE STORED
IGNITION "ON". REFER TO ECM INTERMITTENT
OHMMETER SELECTOR SWITCH IN THE 1000 TO 2000 CODES OR PERFORMANCE IN
OHMS RANGE. SECTION '"2".
PROBE ECM HARNESS CONNECTOR CKT 423 WITH AN
OHMMETER TO GROUND.
IT SHOULD READ LESS THAN 500 OHMS.
DOES IT?
YES NO
m m
PROBE ECM HARNESS CONNECTOR CKT 424 WITH OPEN CKT 423. FAULTY CONNECTION
A TEST LIGHT TO 12 VOLTS AND NOTE LIGHT. OR FAULTY IGNITION MODULE.
LIGHT "OFF" LIGHT "O N'

~ r ~ .. ixzzz:
WITH O H M METER STILL CONNECTED TO ECM HARNESS
CKT 423 AND GROUND. AGAIN PROBE ECM HARNESS
DISCONNECT IGNITION MODULE 4-W AY
CONNECTOR.
CKT 424 WITH THE TEST LIGHT CONNECTED TO 12
VOLTS. ( AS TEST LIGHT CONTACTS CKT 424, 1
RESISTANCE SHOULD SWITCH FROM UNDER 500 TO LIGHT "O N" LIGHT "OFF"
OVER 5,000 O H M S ,) I ........ .. r r ............
DOES IT?
CKT 424 SHORTED FAULTY IGNITION
TO GROUND. MODULE.
YES
NO
r
m
DISCONNECT DIST. 4-W AY CONNECTOR . NOTE OHM

METER THAT IS STILL CONNECTED TO CKT 423 AND
RECONNECT ECM AND IDLE ENGINE
FOR ONE MINUTE OR UNTIL "SERVICE
ENGINE SOON" LIGHT COMESON.
GROUND. RESISTANCE SHOULD HAVE GONE HIGH (OPEN
CIRCUIT). DOES IT? 1.
LIGHT "O N ' LIGHT "OFF'
I
YES NO CODE 42 CODE 42 INTERMITTENT.
m I I
CKT 424 OPEN. FAULTY CKT423 FAULTY ECM NO TROUBLE FOUND. CHECK
CONNECTIONS OR FAULTY SHORTED TO HARNESS AND CONNECTORS FOR AN
IGNITION MODULE. GROUND. INTERMITTENT OPEN OR SHORT TO
GROUND IN CKT 423 AND 424.
6-22-87
8S4608-6E
CODE 43
ELECTRONIC SPARK CONTROL (ESC)
CIRCUIT
2.8L, 4.3L&V8 ENGINES

IGNITION "O F F", CLEAR CODES.
IDLE ENGINE FOR 1 MINUTE OR UNTIL "SERVICE ENGINE
SOON" LIGHT COMES ON.
CODE 43 NO CODE 43
~l

ENGINE IDLING.
BACK PROBE ECM TERMINAL B-7 WITH A VOLTMETER
TO GROUND AND NOTE VOLTAGE.

DIAGNOSTIC TERMINAL
UNGROUNDED.
CONNECT TACHOMETER.
ENGINE RUNNING AT ABOUT 1500
RPM.
TRANS. IN P/N AND AT N O R M .
OVER 6 VOLTS OPERATING TEM P.
UNDER 6 VOLTS
TAP ENGINE BLOCK IN AREA OF
I KNOCK SENSOR AND CHECK FOR
RPM DROP.

RECHECK VOLTAGE AT ECM TERM. B7
IT IS FAULTY
CONNECTION AT ECM
TERMINAL B-7 OR
ECM.
UNDER 6 VOLTS OVER 6 VOLTS RPM DROPS NO RPM DROP

IGNITION "OFF"
DISCONNECT ECM A-B CONNECTOR.
IGNITION "O N"
REPLACE ESC
MODULE .
PROBLEM IS
INTERMITTENT. IF
NOOTHERCODES
SEE "ECM
SYSTEM CHECK
IN SECTION "9".
WERE STORED, SEE
RECHECK VOLTAGE ECM INTERMITr NT
CODES OR
PERFORMANCE IN
SECTION "2".
UNDER 6 VOLTS
OVER 6 VOLTS

DISCONNECT ESC MODULE . CHECK VOLTAGE
FROM ESC CONNECTOR TERM. B TO GROUND.
SHOULD READ BATTERY VOLTAGE
REPLACE ECM
OK NO TOK
CHECK FOR OPEN OR SHORT TO GROUND IN CKT 485. REPAIR OPEN IN.
IF NOT OPEN OR SHORTED TO GROUND, IT IS FAULTY CKT 439.
ESC CONNECTION OR ESC MODULE .
6-22-87
8S 4609-6E
CODE 44
(LEAN EXHAUST INDICATED)
ALL ENGINES
FIELD SERVICE MODE :

ENGINE RUNNING , DIAGNOSTIC TERMINAL GROUNDED .
"OPEN LOOP" , " SERVICE ENGINE SOON " LIGHT FLASHES AT A RATE OF 2 TIMES PER SECOND .
"CLOSED LOOP" , " SERVICE ENGINE SOON " LIGHT FLASHES AT A RATE OF 1 TIME PER SECOND
6-22-87
8S 4610-6E
CODE 45
(RICH EXHAUST INDICATED)
ALL ENGINES
FIELD SERVICE MODE;

-ENGINE RUNNING, DIAGNOSTIC TERMINAL GROUNDED.
- "OPEN LOOP", "SERVICE ENGINE SOON" LIGHT FLASHES AT A RATE OF 2.5 TIMES PER SECOND.
- "CLOSED LOOP", "SERVICE ENGINE SOON" LIGHT FLASHES AT A RATE OF 1 TIME PER SECOND.
8S4611-6E
CODE 51 CODE 51
CODE 52
CODE 53 FAULTY MEM-CAL
CODE 55 (2.5L ENGINE)
OR
PROM PROBLEM
CHECK THAT ALL PINS ARE FULLY INSERTED IN THE SOCKET. IF OK. REPLACE
PROM, CLEAR MEMORY. AND RECHECK. IF CODE 51 REAPPEARS, REPLACE ECM.
CODE 52
FUEL CALPAK MISSING
CHECK FOR MISSING CALPAK AND THAT ALL PIN ARE FULLY INSERTED IN THE
SOCKET - IF OK, REPLACE ECM.
CODE 53
SYSTEM OVER VOLTAGE
(2.5L ENGINE)
THIS CODE INDICATES THERE IS A BASIC GENERATOR PROBLEM .
CODE 53 WILL SET IF VOLTAGE AT ECM TERMINAL B1 IS GREATER THAN 17.1 VOLTS FOR 2 SECONDS .
CHECK AND REPAIR CHARGING SYSTEM.
CODE 55
ALL ENGINES
EXCEPT 2.5L ENGINE
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. _ Q,
INDEX
SECTION PAGE SECTION PAGE SECTION PAGE

A Code System ......................................................3-8 EGR On-Vehicle Service............................. 9-3
Code 1 3 ................................................................3-36 EGR System Check.......................................9-3
Abbreviation.............................................14-1 Code 1 4 ................................................................3-38 EGR Vacuum Control.................................. 9-3
Acceleration Mode. . ............................... 4-3 Code 1 5 ................................................................ 3-40 EGR Vacuum Solenoid.............................. 9-10
Accelerator Control Cable .......................4-40 Code 2 1 ................................................................ 3-42 EGR Valves.................................................. 9-2
Accelerator Pedal......................................4-41 Code 2 2 ................................................................ 3-44 Elapsed Timer Module ........................... 3-6
A/C Control Code 2 3 ................................................................3-46 Electronic Control Module
General Description............................. 3-7 Code 2 4 ................................................................ 3-48 General Description.............................. 3-3
Diagnosis............................................... 3-14 Code 2 5 ................................................................ 3-50 Diagnosis................................................ 3-9
Service . . . . ...........................................3-100 Code 32 - 2.5L, 4 3L, 5.0L, & 5.7L Service.................................................... 3-94
Action Symbol Usage...............................ii (Under 8500 GVW ) .................................... 3-52 Electronic Spark Control............................ 7-1
Air Cleaner................................................. 12-1 Code 32 - 2.8L, 4 3L (ST) 7.4L & 5.7L Electronic Spark Timing........................... 6-1
Air Cleaner Element..................................12-3 (Over 8500 G V W )......................................... 3-54 Emissions.................................................... 1-2
Air Conditioning Electrical System Code 3 3 ................................................................ 3-56 Emissions, Above Normal (Odors)............2-3
Diagnosis............................................. 4-76 Code 3 4 ................................................................ 3-58 Engine Crank But Will Not Run................ 3-20
AIR Control Valve...................................... 8-6 Code 3 5 ................................................................ 3-60 EST Performance Check............................ 6-3
Air Filter Element Replacement..............12-3 Code 4 2 ................................................................ 3-62 Evaporative Emission Control.................. 5-1
AIR Filter Fan.............................................8-3 Code 4 3 ................................................................ 3-64 Exhaust Gas Recirculation......................... 9-1
AIR Hoses and Pipes..................................8-3 Code 4 4 ................................................................ 3-66 Exhaust System ......................................... 3-14
Air Injection Reaction............................... 8-1 Code 4 5 ................................................................ 3-68 Restricted System.................................. 3-73
Air Management System .........................8-1 Code 5 4 ................................................................ 3-70
Diagnosis...............................................8-2 F
Codes 51, 52, 53, 55 ......................................... 3-72
Air Pump Diagnosis..................................8-2 Cold Start Program M o d ifie r ....................... 3-6 Field Service Mode...................................... 3-8
AIR System - 2.8L...................................... 8-1 Compact Three S e rvice.................................... 3-94
Filter Crankcase Ventilation .....................1 1-2
AIR System -4.3L &V8 ............................. 8-1 Component Locations .................................... 1-4
Forward........................................................ i
ALDL Connector........................................ 3-2 Component Systems .......................................1-4
Fourth Gear Switch...................................... 1 0-4
Automatic Transmission...........................10-1 Fuel Control System.................................... 4-1
Computer Command C o n tr o l....................... 3-1
Auxiliary Fuel Tank Control .................... 4-34 Connector and Terminal S e rv ic e .................. 3-92 Fuel Cutoff Mode........................................ 4-3
Connector Test A d ap ter Kit ..........................13-5
Fuel Filter Replacement............................. 4-32
B Coolant Sensor Fuel Filters....................................................4-7
Fuel Hoses and Vapor Pipes .......................4-7
Backfire......................................................2-2 General D e s c rip tio n .................................... 3-4
Service......................................................4-34
Basic Electrical Circuits............................. 1-2 Diagnosis........................................................ 3-12
Battery Voltage Correction Mode........... 4.3 Service............................................................. 3-111
Fuel Injector................................................. 4-4
Fuel Lines Repair.........................................4-34
Before Starting ........................................ 2-1 Crankcase Vent Filter ....................................11-2
Fuel Line Wrench........................................ 13-7
Bulb Check................................................. 3-7 Crank S ignal........................................................ 3-7
Crank Signal Diagnosis....................................3-14
Fuel Meter Assy. - TBI 700 ........................... 4-26
Fuel Meter Body -TBI 220 ........................... 4-21
c Cut Out, Misses ................................................ 2-6
Fuel Module................................................. 4-31
CALPAK D Fuel Pressure Gage...................................... 13-7
General Description........................... . 3.4 Fuel Pump Diagnosis..................................3-10
Diagnosis...............................................3-10 Deceleration M ode ......................................... 4-3 Fuel Pump Operation..................................4-7
Service................................................... 3-109 Detonation ........................................................ 2-5 Fuel Pump Relay...........................................4-7
Caution..................................................... jj Diagnostic M o d e .............................................. 3-8 Replacement...........................................4-29
Chart A-1: Diagnostic Tools.................................................13-1 Fuel Pump Replacement............................. 4-29
No Service Engine Soon" Light . . . . 3.16 Dieseling, R u n -O n ........................................... 2-2 Fuel Pump Tests...........................................4-12
Chart A-2: Digital V o ltm eter (D VM ) ...............................13-5 Fuel System Cleaning..................................4-35
No ALDL Data or W o n 't Flash Code 12 or Distributor Reference Signal .......................3 7 Fuel System Pressure Relief .......................4-12
"Service Engine Soon" Light on Steady 3-18 Downshift C o n tro l........................................... 10-1 Fuel System Pressure Test........................... 3-34
Chart A-3: Downshift Control Relay .............................. 10-1 Fuel Tank......................................................4-7
Engine Crank But W o n 't Run - 2.5L . . 3-20 Draining the Fuel T a n k ....................................4-35 Fuel Tank Draining...................................... 4-35
Engine Crank But W o n 't Run
D r iv e a b ility .......................................................1 -2 Fuel Tank Filler Neck ..................................4-35
-Except 2 .5 L .............................................. 3-22
Driveability S ym ptom s..................................2-1 Fuel Tank Leak Test....................................4-40
Fuel Tank Purging...................................... 4-35
Chart A-4: E Fuel Tank Replacement........................... .. 4-35
Injector Circuit Diagnosis - 2.5 L ............. 3-24 Fuel Tank Selector Valve ........................... 4-34
Injector Circuit Diagnosis - except 2.5L 3-26 EAC V a l v e ........................................................ 8-2
Fuel Tank Selector Valve Replacement . . 4-34
Chart A-5: E -C ell.................................................................. 3-6
Fuel Pump Relay Circuit - S T M ................3-28 E-Cell R e p la c e m e n t.......................................3-116
G
Fuel Pump Relay Circuit - CKRVGP. . . . 3-30 ECM Code System ............................................3-8
General Information .................................. 1-1
Chart A-6: ECM T erm in a ls-2.5 L .................................... 3-105
Glossary of Terms.........................................14-1
Fuel System Pressure T e s t ....................... 3-34 ECM Terminal - 2.8 L .......................................3-106
Check Valve D ia g n o s is ..................................8-3 ECM Terminal - 4.3L & V 8 .............................3-107
H
Circuit T e s te r ................................................... 13-6 ECT V a lv e ...........................................................8-2
Clear Flood M o d e ............................................4-2 EGR C o n tro l......................................................9-1 Hall Effect Switch........................................6-2
Clearing Trouble C o d e s .............................. 3-9 EGR D ia g n o s is .................................................9-3 Hard Start....................................................2-4
Closed Loop S y s te m .......................................4-2 EGR Filter R e p la c e m e n t............................... 9-10 Hesitation.................................................... 2-6
INDEX
SECTION PAGE SECTION PAGE SECTION PAGE

I Oxygen Sensor Stumble....................................................2-6
General Description................................ 3-5 Surges and/or Chuggle...........................2-4
IAC Valve Flange - TBI 220 .................... .4-27 Diagnosis..................................................3-12 Switches
IAC Valve Flange - TBI 700 .................... .4-27 Service......................................................3-112 Brake ................................................. 10-1
Idle Air Control Valve............................. 4-4 Oxygen Sensor Wrench ............................. 13-6 Fourth Gear.........................................10-4
Idle Air Control Wrench..........................13-6 Manual Clutch Start........................... 10-1
Idle Speed................................................3-10 P Oil Pressure.........................................4-9
Ignition Module......................................6-2 Park/Neutral Switch Park/Neutral .......................................3-7
Ignition System Diagnosis.......................6-2 General Description................................ 3-7 Power Steering .................................. 3-7
Ignition Timing...................................... 6-3 Diagnosis..................................................3-14 System Check........................................... 3-7
Incorrect Idle............................................2-3 Service......................................................3-116
Information Sensors ............................. 3-3 Parts.............................................................iv T
Injector Circuit Diagnosis - 2.5L..............3-24 PCV Valve .................................................... 11-2 Table of Contents .................................. iii
Injector Circuit Diagnosis -except 2.5L . 3-26 Poor Fuel Economy...................................... 2-1 Tachometer............................................. 13-5
Injector Test Light ...................................13-6 Port EGR Valve............................................. 9-2 TBI Model 220 ......................................... 4-3
In-Line Filter ...........................................4-32 Positive Crankcase Ventilation ................ 11 -1 TBI Model 700 ......................................... 4-3
In-Tank Filter...........................................4-32 Power Steering Pressure Switch TCC Brake Switch.................................... 10-1
Intermittent Codes...................................2-2 General Description................................ 3.7 TCC Electrical Diagnosis
Diagnosis..................................................3-14 2 5L and 2.8L.......................................10-2
K Service......................................................3-116 4 3L and V8 .........................................10-4
Pressure Regulator .................................... 4-4 TCC Pulse Switch .................................... 10-1
Knock Sensor PROM TCC Solenoid...........................................10-1
General Description........................... 3-7 General Description................................ 3-4 TCC System ............................................. 10-1
Diagnosis............................................. 3-64 Diagnosis..................................................3-10 Terminal Service .................................... 3-92
Service................................................. 3-116 Service......................................................3-109 Test Light ............................................... 13-5
Pump, Fuel....................................................4-7 Thermae Vacuum Diaphragm Motor. . . . 12-4
L Thermae Wax Pellet Actuator ...............12-4
Lack of Power ..........................................2-5 R Thermostatic Air Cleaner........................12-1
Light, Manual Transmission Shift......... .10-1 THM400 ................................................. 10-1
Relays THM 700 ..................................................10-1
Light, Service Engine Soon.................... ..3-3 A/C Clutch Control - 2.5L.........................3-14 Throttle Position Sensor
A/C Clutch Control - 2.8L......................... 3-14 General Description........................... .3-5
M Downshift Control.................................. 10-1 Diagnosis..............................................3-12
Maintenance Schedule........................... ..1-2 Fuel Pump............................................... 4-7 Service................................................. .3-115
Manual Transmission Shift Light ......... ..10-1 Restricted Exhaust System .........................3-73 Throttle Position Switch Adjustment . . . 3-13
MAP Sensor Rough, Idle ..................................................2-3 TPS Output Check-TBI 220 ....................3-13
General Description........................... ..3-5 Run Mode....................................................4-2 Transmission Converter Clutch................10-1
Diagnosis............................................. ..3-12 Transmission Gear Position Signal .........3-7
Service....................................................3-111 s
MAT Sensor Sag......... ................................................. 2-6 u
General Description........................... ..3-6 "Scan" Tool................................................. 13-1
Diagnosis............................................. ..3-13 "Scan" Tool Positions............................. 13-2 Unstable Idle...........................................2-3
Service....................................................3-116 Sensors
MEM-CAL Coolant....................................................3-4 V
General Description........................... ..3-4 Knock ......................................................3-7
Diagnosis............................................. ..3-10 MAP ........................................................ 3-5 Vacuum Pump.........................................13-5
Service...................................................3-94 MAT ........................................................ 3-6 Vapor Pipes............................................. 4-7
Metri-Pack Service....................................3-93 Oxygen....................................................3-5 Vehicle Emission Control
Metri-Pack Terminal TPS .......................................................... 3-5 Information Label ............................. 1-2
Terminal Remover............................. .13-6 VSS.......................................................... 3-6 Vehicle Speed Sensor
Micro-Pack Service...................................3-93 Serial Data Line...........................................3-8 General Description........................... 3-6
Minimum Air Rate Adjustment Wrench . 13-7 Service Engine Soon Light .........................3-3 Diagnosis............................................. 3-13
Minimum Air Rate - TBI 220 .................... 4-17 Shift Light, Manual Transmission..............10-1 Service..................................................3-116
Minimum Air Rate - TBI 700 .................... 4-17 Solenoids Voltmeter, Digital ..................................13-5
Downshift............................................... 10-1
N EAC.......................................................... 8 1 w
EGR.......................................................... 9 4
Negative Backpressure EGR Valve ......... 9-2 TCC.......................................................... 10-1 Weather Pack Terminal Service ............3-93
Normal (Open) Mode................................13-1 Spark Knock................................................. 2-5 Terminal Remover..............................13-6
Spark Tester ............................................... 13-7 Wiring Harness
0 Special Tools............................................... 13-1 General Description........................... 3-3
Specifications............................................... 13-8 Service..................................................3-92
Oil Pressure Switch.................................... 4-9 Speed Sensor-VSS Buffer Amplifier......... 10-1 Wiring Diagram - 2.5 L ........................... 3-95
Replacement.........................................4-31 Stalling........................................................ 2-3 Wiring Diagram - 2.8 L ........................... 3-98
Open Loop System.................................... 4-2 Starting Mode.............................................4-2 Wiring Diagram-4.3L&V8...................3-101

1988 GMC Light Duty Truck Fuel and Emissions Including Driveability

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1988 GMC Light Duty Truck Fuel and Emissions Including Driveability

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1988 Light Duty Truck

Fuel and Emissions

Gas Engines Only)

X-8832 10-30 Series R-V-G-P Light Duty Truck Service Manual

GMC TRUCK DIVISION

ACTION SYMBOL USAGE

The general narrative w riting style has been replaced in

Remove or Disconnect Inspect

-4- Install or Connect 1 Measure

Disassemble [jp] Tighten

IJJI Clean 1^1 Adjust

THROTTLE BODY INJECTION FUEL CONTROL

All information, illustrations, and specifications

VISUAL/PHYSICAL UNDERHOOD INSPECTION SECTION DESCRIPTION

One of the most important checks that must Section "2"

BASIC ELECTRIC CIRCUITS Th is is an e le c t r o n ic a ll y co n tr o lle d e x h a u s t

"A L W A Y S REFER TO THE VEHICLE EM ISS IO N CONTROL INFOR M ATIO N LABEL

EXHAUST EMISSION SYSTEM

CERT YEAR C H EC K SUM

D IV IS IO N DISPLA C EM ENT VEHICLE CLASS AND STA N D A R D S

Figure 1-1 Vehicle Emission Control In fo rm atio n Label

Section "7" Section "12"

The P C V system passes crankcase vapors into the

Figure 1-2 - C om ponent Locations 2.5L (M Series)

'S / T ' series r p o :L N 8 engine c o d e : E 2 . 5 L L4

COMPUTER COMMAND Q ECM INFORMATION : : EMISSION COMPONENTS

Figure 1-3 - Com ponent Locations 2.5L (ST Series)

' S / T ' series r p o :LL2 e n g i n e c o d e :R 2 . 8L V 6

COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

Figure 1-4 - C om ponent Locations 2.8L (ST Series)

'S/T' SERIES r p o :LB4 ENGINE CODE:Z 4 .3 L V 6

COMPUTER COMMAND O e c m in f o r m a t io n '"! EMISSION COMPONENTS

Figure 1-5 - C om ponent Locations 4.3L (ST Series)

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

COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

Figure 1-6 - C om ponent Locations - 4.3L (CK Series)

' G ' SERIES r p o :LB4 ENGINE CODE:Z 4 .3 L V 6

COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

14 Transmission dow nshift relay (THM -400 only) 4-15-87

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

'M ' series rpo:LB 4 engine c o d e : Z 4.3L V6

COMPUTER COMMAND O ECM INFORMATION r EMISSION COMPONENTS

Figure 1-8 - Com ponent Locations 4.3L (M Series)

'R/V' series rpo:LB4 en g in e c o d e :Z 4.3L V6

COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

Figure 1-9 - Com ponent Locations 4.3L (RV Series)

'C /K ' series r p o :L 0 3 /L 0 5 engine co d e :H /K 5 .0 / 5 . 7 L V 8

COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

Figure 1-10 - C om ponent Locations - 5.0L/5.7L (CK Series)

'G 's e rie s r p o :L 0 3 /L 0 5 engine co d e :H /K 5 . 0 /5 . 7 L V 8

Figure 1-11 - C om ponent Locations 5.0L/5.7L (G Series)

'R/V' SERIES rpo :L03/L05 engine code: H/K 5.0/5.7L V8

COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

Figure 1-12 - Com ponent Locations 5.0L/5.7L (RV Series)

'P' SERIES r p o :L05 ENGINE CODElK 5.7L V8

COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

Figure 1-13 - C om ponent Locations 5.7L (P Series)

' C / K & R / V ' series rp o:L19 e n g in e c o d e :N 7 .4 L V 8

COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

Figure 1-14 - C om ponent Locations - 7.4L (CK & RV Series)

' G ' series rp o:L19 e n g in e c o d e :N 7 .4 L V 8

COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

Figure 1-15 - C om ponent Locations 7.4L (G Series)

POOR FUEL ECONOMY