Chevrolet W-Series Commercial Workshop Repair And Service Manual

TABLE OF CONTENTS 1.0 INTRODUCTION .........................................................1 1.1 SYSTEM COVERAGE ...............................................1 1.2 SIX-STEP TROUBLESHOOTING PROCEDURE ..........................1 2.0 IDENTIFICATION OF SYSTEM .............................................1 3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION ......................1 3.1 GENERAL DESCRIPTION ............................................1 3.2 FUNCTIONAL OPERATION ...........................................2 3.2.1 FUEL CONTROL ............................................2 3.2.2 ON-BOARD DIAGNOSTICS ...................................2 3.2.3 OTHER CONTROLS .........................................5 3.2.4 PCM OPERATING MODES ..................................10 3.2.5 NON-MONITORED CIRCUITS ................................10 3.2.6 SKIS OVERVIEW ..........................................10 3.2.7 SKIM ON-BOARD DIAGNOSTICS .............................10 3.2.8 SKIS OPERATION ..........................................11 3.2.9 PROGRAMMING THE POWERTRAIN CONTROL MODULE ........11 3.2.10 PROGRAMMING THE SENTRY KEY IMMOBILIZER MODULE .....12 3.2.11 PROGRAMMING THE IGNITION KEYS TO THE SENTRY KEY IMMOBILIZER MODULE.....................................12 3.3 DIAGNOSTIC TROUBLE CODES .....................................12 3.3.1 HARD CODE ..............................................12 3.3.2 INTERMITTENT CODE ......................................13 3.3.3 STARTS SINCE SET COUNTER ..............................13 3.3.4 DISTANCE SINCE MI SET ...................................13 3.4 USING THE DRBIIIT ................................................13 3.5 DRBIIIT ERROR MESSAGES AND BLANK SCREEN .....................13 3.5.1 DRBIIIT DOES NOT POWER UP..............................14 3.5.2 DISPLAY IS NOT VISIBLE ...................................14 4.0 DISCLAIMERS, SAFETY, WARNINGS ......................................14 4.1 DISCLAIMERS.....................................................14 4.2 SAFETY ..........................................................14 4.2.1 TECHNICIAN SAFETY INFORMATION .........................14 4.2.2 VEHICLE PREPARATION FOR TESTING.......................14 4.2.3 SERVICING SUB ASSEMBLIES ..............................14 4.2.4 DRBIIIT SAFETY INFORMATION .............................14 4.3 WARNINGS AND CAUTIONS ........................................15 4.3.1 ROAD TEST WARNINGS ....................................15 4.3.2 VEHICLE DAMAGE CAUTIONS ..............................15 5.0 REQUIRED TOOLS AND EQUIPMENT .....................................15 6.0 GLOSSARY OF TERMS..................................................16 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ...........................17 COMMUNICATION *NO RESPONSE FROM PCM (PCI BUS) - NGC ..............................18 *NO RESPONSE FROM PCM (PCM SCI ONLY) - NGC ........................19 i

TABLE OF CONTENTS - Continued *NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE ................22 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE - NGC ...........24 *PCI BUS COMMUNICATION FAILURE .....................................27 DRIVEABILITY - NGC INTERMITTENT CONDITION ..............................................30 P0016-CRANKSHAFT/CAMSHAFT TIMING MISALIGNMENT....................31 P0031-O2 SENSOR 1/1 HEATER CIRCUIT LOW .............................35 P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW .............................35 P0032-O2 SENSOR 1/1 HEATER CIRCUIT HIGH .............................37 P0038-O2 SENSOR 1/2 HEATER CIRCUIT HIGH .............................37 P0033-SURGE VALVE SOLENOID CIRCUIT .................................40 P0068-MANIFOLD PRESSURE/THROTTLE POSITION CORRELATION...........42 P0071-AMBIENT TEMP SENSOR PERFORMANCE ...........................48 P0072-AMBIENT TEMP SENSOR LOW .....................................51 P0073-AMBIENT TEMP SENSOR HIGH .....................................53 P0107-MAP SENSOR LOW ...............................................55 P0108-MAP SENSOR HIGH...............................................58 P0111-INTAKEAIR TEMPERATURE SENSOR PERFORMANCE .................61 P0112-INTAKE AIR TEMPERATURE SENSOR LOW ...........................64 P0113-INTAKE AIR TEMPERATURE SENSOR HIGH ..........................66 P0116-ENGINE COOLANT TEMPERATURE PERFORMANCE...................68 P0117-ENGINE COOLANT TEMPERATURE SENSOR LOW ....................71 P0118-ENGINE COOLANT TEMPERATURE SENSOR HIGH ....................73 P0122-THROTTLE POSITION SENSOR #1 LOW .............................75 P0123-THROTTLE POSITION SENSOR #1 HIGH .............................78 P0125-INSUFFICIENT COOLANT TEMP FOR CLOSED-LOOP FUEL CONTROL . . .81 P0128-THERMOSTAT RATIONALITY .......................................83 P0129-BAROMETRIC PRESSURE OUT-OF-RANGE ..........................88 P0131-O2 SENSOR 1/1 VOLTAGE LOW ....................................92 P0137-O2 SENSOR 1/2 VOLTAGE LOW ....................................92 P0132-O2 SENSOR 1/1 VOLTAGE HIGH ....................................95 P0138-O2 SENSOR 1/2 VOLTAGE HIGH ....................................95 P0133-O2 SENSOR 1/1 SLOW RESPONSE .................................98 P0139-O2 SENSOR 1/2 SLOW RESPONSE .................................98 P0135-O2 SENSOR 1/1 HEATER PERFORMANCE ..........................100 P0141-O2 SENSOR 1/2 HEATER PERFORMANCE ..........................100 P0171-FUEL SYSTEM 1/1 LEAN ..........................................103 P0172-FUEL SYSTEM 1/1 RICH ..........................................108 P0201-FUEL INJECTOR #1 ..............................................112 P0202-FUEL INJECTOR #2 ..............................................112 P0203-FUEL INJECTOR #3 ..............................................112 P0204-FUEL INJECTOR #4 ..............................................112 P0234-OVERBOOST PERFORMANCE .....................................115 P1106-BARO SOLENOID PERFORMANCE .................................115 P1188 TIP SENSOR PERFORMANCE .....................................115 P0243-WASTEGATE SOLENOID CIRCUIT ..................................119 P0300-MULTIPLE CYLINDER MISFIRE ....................................122 P0301-CYLINDER #1 MISFIRE ...........................................122 P0302-CYLINDER #2 MISFIRE ...........................................122 P0303-CYLINDER #3 MISFIRE ...........................................122 P0304-CYLINDER #4 MISFIRE ...........................................122 P0315-NO CRANK SENSOR LEARNED ....................................130 ii

TABLE OF CONTENTS - Continued P0325-KNOCK SENSOR #1 CIRCUIT .....................................132 P0335-CRANKSHAFT POSITION SENSOR CIRCUIT .........................135 P0339-CRANKSHAFT POSITION SENSOR INTERMITTENT ...................140 P0340-CAMSHAFT POSITION SENSOR CIRCUIT ...........................144 P0344-CAMSHAFT POSITION SENSOR INTERMITTENT .....................149 P0420-CATALYTIC 1/1 EFFICIENCY .......................................153 P0440-GENERAL EVAP SYSTEM FAILURE.................................154 P0441-EVAP PURGE SYSTEM PERFORMANCE ............................159 P0442-EVAP SYSTEM MEDIUM LEAK .....................................161 P0455-EVAP SYSTEM LARGE LEAK ......................................161 P0443-EVAP PURGE SOLENOID CIRCUIT .................................166 P0452-NVLD PRESSURE SWITCH SENSE CIRCUIT LOW ....................169 P0453-NVLD PRESSURE SWITCH SENSE CIRCUIT HIGH....................172 P0456-EVAP SYSTEM SMALL LEAK ......................................174 P0461-FUEL LEVEL SENSOR #1 PERFORMANCE ..........................176 P0462-FUEL LEVEL SENSOR #1 LOW ....................................178 P0463-FUEL LEVEL SENSOR #1 HIGH ....................................178 P0480-COOLING FAN 1 CONTROL CIRCUIT ...............................179 P0481-COOLING FAN 2 CONTROL CIRCUIT (NON-TURBO) ..................179 P0481-COOLING FAN 2 CONTROL CIRCUIT (TURBO) .......................181 P0498-NVLD CANISTER VENT VALVE SOLENOID CIRCUIT LOW ..............184 P0499-NVLD CANISTER VENT VALVE SOLENOID CIRCUIT HIGH .............185 P0501-VEHICLE SPEED SENSOR #1 PERFORMANCE (AUTO TRANS) .........187 P0501-VEHICLE SPEED SENSOR #1 PERFORMANCE (MANUAL TRANS) ......188 P0506-IDLE SPEED LOW PERFORMANCE ................................190 P0507-IDLE SPEED HIGH PERFORMANCE ................................190 P0519-IDLE SPEED PERFORMANCE .....................................190 P0508-IAC VALVE SENSE CIRCUIT LOW ..................................192 P0509-IAC VALVE SENSE CIRCUIT HIGH ..................................195 P0513-INVALID SKIM KEY ...............................................197 P0516-BATTERY TEMPERATURE SENSOR LOW ...........................199 P0517-BATTERY TEMPERATURE SENSOR HIGH ...........................201 P0522-OIL PRESSURE SENSOR LOW ....................................203 P0551-POWER STEERING SWITCH PERFORMANCE .......................205 P0562-BATTERY VOLTAGE LOW .........................................207 P0563-BATTERY VOLTAGE HIGH.........................................210 P0572-BRAKE SWITCH #1 CIRCUIT LOW..................................212 P0573-BRAKE SWITCH #1 CIRCUIT HIGH .................................214 P0581-SPEED CONTROL SWITCH #1 HIGH ................................216 P0582-SPEED CONTROL VACUUM SOLENOID CIRCUIT .....................218 P0586-SPEED CONTROL VENT SOLENOID CIRCUIT ........................220 P0594-SPEED CONTROL SERVO POWER CIRCUIT .........................222 P0600-SERIAL COMMUNICATION LINK....................................225 P0601-INTERNAL MEMORY CHECKSUM INVALID...........................225 P0622-GENERATOR FIELD CONTROL CIRCUIT ............................226 P0627-FUEL PUMP RELAY CIRCUIT ......................................228 P0630-VIN NOT PROGRAMMED IN PCM ..................................230 P0632-ODOMETER NOT PROGRAMMED IN PCM ...........................231 P0633-SKIM KEY NOT PROGRAMMED IN PCM.............................232 P0645-A/C CLUTCH RELAY CIRCUIT .....................................233 P0660-MANIFOLD TUNE VALVE SOLENOID CIRCUIT ........................235 P0685-ASD RELAY CONTROL CIRCUIT ...................................238 P0688-ASD RELAY SENSE CIRCUIT LOW .................................240 iii

TABLE OF CONTENTS - Continued P0700-TRANSMISSION CONTROL SYSTEM/READ TRANSMISSION DTCS ON THE DRBIIIT .......................................................243 P0833-CLUTCH RELEASED SWITCH CIRCUIT .............................244 P0850-PARK/NEUTRAL SWITCH PERFORMANCE ..........................246 P1105-TIP SENSOR SOLENOID CIRCUIT ..................................247 P1115-GENERAL TEMP SENSOR PERFORMANCE ..........................249 P1189-TIP SENSOR CIRCUIT LOW .......................................253 P1190-TIP SENSOR CIRCUIT HIGH .......................................256 P1593-SPEED CONTROL SWITCH STUCK .................................259 P1602-PCM NOT PROGRAMMED ........................................262 P1603-PCM INTERNAL DUAL-PORT RAM COMMUNICATION .................263 P1604-PCM INTERNAL DUAL-PORT RAM READ/WRITE INTEGRITY FAILURE . . .263 P1607-PCM INTERNAL SHUTDOWN TIMER RATIONALITY ...................263 P1696-EEPROM MEMORY WRITE DENIED/INVALID .........................264 P1697-EMR (SRI) MILEAGE NOT STORED .................................264 P1854-TIP BARO OUT OF RANGE ........................................266 P2074-MANIFOLD PRESSURE/THROTTLE POSITION CORRELATION - HIGH FLOW/VACUUM LEAK ..................................................270 P2096-DOWN STREAM FUEL SYSTEM 1/2 LEAN ...........................276 P2097-DOWN STREAM FUEL SYSTEM 1/2 RICH ...........................276 P2302-IGNITION COIL #1 SECONDARY CIRCUIT-INSUFFICIENT IONIZATION . . .279 P2305-IGNITION COIL #2 SECONDARY CIRCUIT-INSUFFICIENT IONIZATION . . .279 P2503-CHARGING SYSTEM VOLTAGE LOW ...............................282 U0101-NO TRANSMISSION BUS MESSAGE................................285 U0155-NO CLUSTER BUS MESSAGE .....................................287 U0168-NO SKIM BUS MESSAGES ........................................288 U110C-NO FUEL LEVEL BUS MESSAGE ..................................290 *CHECKING PCM POWER AND GROUND CIRCUITS ........................292 *CHECKING RAD FAN HIGH SPEED OPERATION (TURBO) ..................293 *CHECKING RAD FAN LOW SPEED OPERATION (TURBO) ...................295 *CHECKING RADIATOR FAN RELAY OUTPUT ..............................298 *CHECKING THE A/C RELAY OUTPUT ....................................300 SENTRY KEY IMMOBILIZER ANTENNA FAILURE ....................................................302 COP FAILURE .........................................................302 EEPROM FAILURE .....................................................302 INTERNAL FAULT ......................................................302 RAM FAILURE.........................................................302 SERIAL LINK INTERNAL FAULT ..........................................302 STACK OVERFLOW FAILURE............................................302 PCM STATUS FAILURE .................................................304 SERIAL LINK EXTERNAL FAULT .........................................304 ROLLING CODE FAILURE ...............................................306 VIN MISMATCH ........................................................306 TRANSPONDER COMMUNICATION FAILURE ..............................308 TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE .............308 TRANSPONDER ID MISMATCH ..........................................308 TRANSPONDER RESPONSE MISMATCH ..................................308 STARTING *CHECKING FUEL DELIVERY ............................................311 *CHECKING FUEL PRESSURE LEAK DOWN ...............................314 iv

TABLE OF CONTENTS - Continued *ENGINE CRANKS DOES NOT START ....................................315 *ENGINE CRANKS DOES NOT START - 1.6L ...............................323 *NO CRANK CONDITION................................................330 *NO RESPONSE FROM PCM WITH A NO START CONDITION ................333 *START AND STALL CONDITION .........................................334 VERIFICATION TESTS VERIFICATION TESTS ..................................................337 8.0 COMPONENT LOCATIONS ..............................................345 8.1 CONTROL MODULES AND PDC.....................................345 8.2 CONTROLS AND SOLENOIDS ......................................345 8.3 DATA LINK CONNECTOR ..........................................347 8.4 SENSORS .......................................................347 8.5 FUEL SYSTEM ...................................................349 8.6 SWITCHES/GAUGES ..............................................349 9.0 CONNECTOR PINOUTS ................................................351 A/C COMPRESSOR CLUTCH - BLACK 2 WAY ..............................351 A/C HIGH PRESSURE SWITCH - BLACK 2 WAY ............................351 A/C LOW PRESSURE SWITCH (2.0L LHD) - DK. GREEN 2 WAY ...............351 A/C LOW PRESSURE SWITCH (2.4L TURBO) - DK. GREEN 2 WAY ............351 A/C LOW PRESSURE SWITCH (RHD) - BLACK 2 WAY .......................352 AMBIENT TEMPERATURE SENSOR - BLACK 2 WAY ........................352 BATTERYTEMPERATURE SENSOR - BLACK 2 WAY ........................352 BRAKE LAMP SWITCH - BLACK 6 WAY ...................................352 CAMSHAFT POSITION SENSOR - BLACK 3 WAY ...........................353 CLOCKSPRING - GREEN 7 WAY .........................................353 CLUTCH INTERLOCK/UPSTOP SWITCH (MTX) - BLACK 3 WAY ...............353 CRANKSHAFT POSITION SENSOR - BLACK 3 WAY .........................353 DATALINK CONNECTOR - WHITE 16 WAY ................................354 ENGINE COOLANT TEMP SENSOR (2.0L) - BLACK 2 WAY ...................354 ENGINE COOLANT TEMP SENSOR (2.4L TURBO) - BLACK 2 WAY ............354 ENGINE OILPRESSURE SWITCH - LT. GREEN 2 WAY ......................354 EVAP/PURGE SOLENOID - BLACK 2 WAY .................................355 FUEL INJECTOR NO. 1 - BLACK 2 WAY ...................................355 FUEL INJECTOR NO. 2 - BLACK 2 WAY ...................................355 FUEL INJECTOR NO. 3 - BLACK 2 WAY ...................................355 FUEL INJECTOR NO. 4 - BLACK 2 WAY ...................................355 FUELPUMP MODULE - LT. GRAY 4 WAY ..................................356 FUSES (FB LHD) ......................................................358 FUSES (FB RHD) ......................................................360 GENERATOR (2.0L) - BLACK 2 WAY ......................................360 GENERATOR (2.4LTURBO) - LT. GRAY 2 WAY .............................360 GENERATOR (GENERATOR SIDE) .......................................361 IDLE AIR CONTROL MOTOR (2.0L/2.4L TURBO) - BLACK 2 WAY ..............361 IGNITION COIL - BLACK 3 WAY ..........................................361 INLET AIR TEMPERATURE SENSOR - BLACK 2 WAY........................361 INSTRUMENT CLUSTER - BLACK 26 WAY .................................362 KNOCK SENSOR - BLACK 2 WAY ........................................362 MANIFOLD ABSOLUTE PRESSURE SENSOR (2.0L) - GRAY 3 WAY ............363 v

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Chevrolet W-Series Commercial Workshop Repair And Service Manual

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