For 1990-2009 cars

### Powertrain Control Module Diagnosis

### Powertain OBD System Check

Important: Understanding the table and using it correctly will reduce diagnostic time, and prevent the unnecessary replacement of parts.

After the visual/physical inspection is complete (refer to Visual/Physical Check in Symptoms ), the Powertrain OBD System Check should be performed. The OBD System Check will provide direction to diagnose the following conditions:

• | PCM inoperative or damaged, no PCM data or SERVICE ENGINE SOON MIL inoperative.

• | PCM DTCs.

• | Fuel System Rich or Lean.

• | Customer Complaint Driveability Symptoms.

The Powertrain OBD System Check is designed as a Master table for driveability and emissions system diagnosis. The OBD System Check should always be used as the starting point for all Powertrain diagnosis.

The Powertrain OBD System Check is an organized approach for identifying a problem. Driver Comments normally fall into one of the following areas:

• | Steady SERVICE ENGINE SOON MIL.

• | Driveability problem.

• | Engine will not start or stalls after start.

### Diagnostic Procedure Use

The diagnostic procedures used in this section are designed to find and repair powertrain related problems. The general approach is to find the appropriate diagnosis for a problem with five basic steps described below.

• | Understand the customers complaint. It is critical that the technician understand what the customers complaint is. Failure to understand this may lead to misdiagnosis, or unnecessary diagnosis. Among other things, the technician must know whether the condition is present at all times, only under certain circumstances, or truly intermittent (random). This will assist the technician in duplicating and diagnosing the problem. Another reason the technician must understand the customers complaint is so the technician may determine whether the complaint requires service or is normal vehicle operation. Trying to diagnose a complaint that is normal will waste time and may result in unnecessary service.

• | Are Diagnostics working properly? Use the Powertrain OBD System Check. This is the starting point for the diagnostic procedure, always begin here.

• | Are DTCs displayed? If a DTC is identified by diagnostics, the Powertrain OBD System Check will direct you to the appropriate table.

• | Is the customer's complaint related to a specific powertrain subsystem? If no related DTCs are set, the next quickest way to locate the problem is to narrow it down to a specific powertrain subsystem. If a specific subsystem can be pinpointed as the cause, it is easier to diagnose.

• | Is the problem powertrain related? Some customer complaints may appear to be powertrain related but are actually caused by other vehicle systems.

### Basic Knowledge Required

You must be familiar with some of the basics to use this section of the Service Manual. They will help you to follow diagnostic procedures in this section.

### Basic Electrical Circuits

You should understand basic electricity and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire and you should be able to identify a shorted or open circuit using a DMM. You should be able to read and understand a wiring diagram.

### Use Of Digital Multimeter (DMM)

You should be familiar with the Digital Multimeter (DMM), particularly essential tool J 39200. You should be able to use the meter to measure voltage (volts), resistance (ohms), current (amps), capacitance (farads), intermittents (min/max) and frequency (Hertz).

### Use Of Circuit Testing Tools

You should only use a test lamp when a diagnostic procedure refers to it's use. You should know how to use fused jumper wires to test components and allow DMM readings without damaging terminals. You should know how to use Connector Test Adapter Kit, J 35616 and use it whenever diagnostic procedures call for front probing any connector.

### PCM Service Precautions

The PCM is designed to withstand normal current draws associated with vehicle operations, however, care must be used to avoid overloading any of these circuits. In testing for opens or shorts do not ground or apply voltage to any of the PCM circuits unless instructed to do so by the diagnostic procedures. These circuits should only be tested using the Digital Multimeter J 39200.

Whenever a PCM removal and replacement is performed, follow the procedures in this section.

### Electrostatic Discharge Damage

The electronic components used in the control systems are often designed in order to carry very low voltage. The electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off, leaving the person highly charged with the opposite polarity. Static charges can cause damage. Use care when handling and testing the electronic components.

### Aftermarket (ADD-ON) Electrical And Vacuum Equipment

Aftermarket (Add-on) Electrical and Vacuum Equipment is defined as any equipment installed on a vehicle after leaving the factory where the vehicle was originally assembled that connects, in any way, to the vehicles electrical or vacuum systems. No allowances have been made in the design of this vehicle for this type of equipment. Therefore, addition of aftermarket equipment must be done with the utmost care for the vehicle.

### Visual/Physical Underhood Inspection

One of the most important checks is a visual/physical underhood inspection. This can often fix a problem. These quick checks take only a few minutes, can save valuable time, and help you correct the problem. For further information, refer to Visual/Physical Check in Symptoms .

All Powertrain diagnosis should begin with a thorough visual inspection. Visual inspection can often lead to repair of a simple problem without use of the tables.

• | Inspect all vacuum hoses for being pinched, cut, disconnected or misrouted. The EVAP Purge Solenoid vacuum hoses can easily be installed incorrectly. Be sure to inspect hoses that are difficult to see such as beneath the upper intake, generator, etc.

• | Check for proper ground connections, ground eyelets connected to ground points, and star washers installed, if applicable.

• | Check the battery positive junction block for loose retainer nuts.

• | Inspect other wiring in the engine compartment for good connections, burned or chaffed spots, pinched wires or harness contact with sharp edges or hot exhaust manifolds.

• | Check for blown or missing fuses and for relays missing or installed in the wrong locations.

### Using Diagnostic Trouble Code (DTC) Tables

When diagnosing this powertrain, you will almost certainly need to use the diagnostic procedures in this or other powertrain sections. The diagnostic procedures are mostly in the form of tables. At the beginning (formerly known as the Facing Page) of each DTC will be a circuit diagram, descriptions and notes about the condition or DTC diagnosed in the table. Reading the diagnostic support information will help you understand the system being tested, the component(s) involved in the testing, how the PCM tests the system (enabling conditions), how the PCM determines that the diagnostic has failed (conditions for setting the DTC), and what the table is trying to accomplish. Below are explanations of the diagnostic support information and tables for DTCs.

### Circuit Diagram

The circuit diagram of the diagnostic support information page will show the circuits and components involved in setting the DTC. This diagram may be used as a reference when circuit checks are required in the table. If more detailed circuit information is required, the Engine Controls Electrical Schematic Diagrams may be referenced.

### Circuit Description

The circuit description explains the sensor and/or circuits involved in setting the DTC. It also gives a brief description of when the DTC is set.

### Conditions for Running the DTC

The running conditions (enabling conditions) are the conditions that must be met before the PCM will test the sensor/system. These conditions are generally set up so that the sensor/system may be reliably checked without a false failure indication.

### Conditions for Setting the DTC

The setting conditions are the conditions that must be met for the DTC to set. A sensor/system is checked only after the running conditions (described above) are met. If the enabling conditions are met, and the PCM detects an abnormal sensor/system condition, the appropriate DTC is set.

### Action Taken When The DTC Sets

The actions taken are the steps the PCM takes after the DTC is set. These actions serve one of three purposes:

• | To inform the driver of the problem.

• | To preserve the driveability of the vehicle.

• | To prevent the failure from causing any damage to the vehicle.

### Conditions For Clearing The MIL / DTC

These are the conditions that must be met to turn OFF the MIL, and/or clear the DTC.

### Diagnostic Aids

Diagnostic Aids provide helpful information when the condition(s) that caused the DTC or driveability problem is not currently present. Sometimes, with the help of snapshot on DTC set data (Freeze Frame or Failure Records) or information from the driver, the problem may still be identified or at least narrowed down to a short list of possible intermittent conditions. When this is true, the Diagnostic Aids may explain what to look for, and the most logical path to lcoate an intermittent condition.

### Test Description

The Test Descriptions are explanations of the reason certain checks are done, and what the check is supposed to uncover. The information is numbered according to the corresponding step in the diagnostic table. When questions of why a certain step is performed, or what results the step should actually produce, observe the Step number next to the check you are performing. Refer to the information under Test Description that has the same number for an explanation.

### Diagnostic Table

Diagnostic tables are an organized and systematic approach to diagnosing a Diagnostic Trouble Code (DTC). The table consists of five separate columns: step number, action, value, yes, and no. The step number indicates which step is being performed. The action column contains all necessary information about how to perform a certain test. The last sentence in each action block will always be a question. The question can only be answered yes or no. The answer to the question will dictate which column you will go to next - yes or no. The yes or no answer to each test will lead to the next logical step within the diagnostic table. Most of the YES and NO boxes will take you to the next logical step within the table. However, some boxes may lead to other system diagnostics, or to the Diagostic Aids when an intermittent condition exists.

Always begin with Step 1 at the top of the table unless there is a notice or caution above it. Never skip steps or jump ahead in the table. Taking short cuts often leads to misdiagnosis. When a problem is found, make the necessary repairs, and then verify the repair.

### Verify Repair

Confident verification of a DTC repair can only be done by matching the test descriptions of the DTC and ensuring that the DTC RUNS and PASSES. To know if a test runs and passes use the scan tool and select DTC Status and note the DTC that needs verification. The status of the diagnostic test can be now observed. For symptom repairs, drive the vehicle and ensure the symptom is gone.

### Checking Terminal Contact

Many tables will have you checking terminal contact before replacing a component. This is done because the checks performed in tables can only check the continuity of a circuit across a wire or in-line connection, not the continuity across the connection at a component. Checking terminal contact will prevent the replacement of good components, prevent comebacks due to intermittent connection problems, and make some repair jobs easier, as in replacing a terminal instead of a component. For this reason it is very important to check terminal contact when instructed to do so.

Checking terminal contact is easy as long as you have a supply of new terminals handy. The Terminal Repair Kit, J 38125, is a good source of terminals for checking terminal contact. It contains a supply of all currently used terminal series and also has the male terminals (12047581) and female terminals (12052922) necessary to build the diagnostic jumper for Ignition Control DTC diagnosis ( for the connector part number refer to the Wiring Systems section of Body and Accessories. To check terminal contact, start by inspecting the male terminals. They should be straight and aligned with other terminals in the row. They should not be twisted, bent or otherwise damaged. The female terminal should be, likewise, inspected for alignment and damage. Finally, take a new male terminal of the same series (e.g. Metripack 150, Weatherpack, etc.) and connect it to the female terminal(s) to be checked. It should not fall out or be easily jarred out of connection. It should require some force to disconnect it. The force required to disconnect it will depend on the size of the terminal being checked. Larger terminals, Metripack 630 series for example, should be very difficult to remove by hand. Smaller terminals, Micropack series for example, should be easier to disconnect by hand but still should not fall out. Replace, do not repair, any damaged terminals. Refer to Engine Electrical and the Terminal Repair Kit, J 38125, for identification of terminal series and repair procedures.

### Diagnosing Intermittents

Diagnosing intermittent conditions can be difficult. The conditions that set the DTC set may not be present. This does not mean that the problem is fixed, it simply means that the problem intermittently occurs. The problem may return in the future. So, if at all possible, the problem should be diagnosed, and repaired. The only way to diagnose an intermittent condition is to gather information from the time when the DTC was set. This can be done in two ways; through snapshot data and driver observations. For further information, refer to Intermittents in Symptoms .