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Diagnostic Test

  1. READ AND RECORD DTCS AND ENVIRONMENTAL DATA - ERASE DTCS AND CHECK FOR DTC TO RETURN 
    1. With the scan tool, read DTCs in all Electronic Control Units (ECUs) and record on the repair order.
    2. For future reference, with the scan tool, run and save a vehicle Scan Report and all related recorded data.
    3. With the scan tool, erase all DTCs.
    4. Turn the ignition off for a minimum of 10.0 seconds.
    5. Turn the ignition on.
    6. Using the When Monitored Conditions above and recorded data, operate the vehicle in the conditions that set the DTC.
    7. With the scan tool, read DTCs.

      Did the DTC return?

      Yes 

      • Go To  2

      No 

  2. CHECKING THE EXHAUST SYSTEM FOR LEAKS 
    1. Perform the CHECKING THE EXHAUST SYSTEM FOR LEAKS test procedure. Refer to CHECKING THE EXHAUST SYSTEM FOR LEAKS .

      Were any exhaust leaks found?

      Yes 

      • Repair or replace the leaking exhaust parts as necessary.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

      No 

      • Go To  3
  3. CHECK THE O2 SENSOR 1/1 (K41) SIGNAL CIRCUIT FOR PROPER VOLTAGE AT THE O2 SENSOR HARNESS CONNECTOR 
    1. Turn the ignition off.
    2. Disconnect the harness connector at the component of the circuit being tested. Note:  The ECU harness connector should still be connected during this test step.
    3. Turn the ignition on.
    4. Set the DVOM to measure DC voltage.
    5. Connect the negative lead of the DVOM to a known good ground.
    6. With the positive lead of the DVOM, measure the voltage of the circuit being tested at the component harness connector.
    7. If it is necessary to probe a terminal at a PCM harness connector, connect the (special tool #10436, Adapter, GPEC Diagnostic) to the appropriate PCM harness connector.
      NOTE:

      Normal operating voltage should be between 4.1 and 5.0 volts.

      CAUTION:

      Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install the GPEC Diagnostic Adaptor to perform the diagnosis.

      Does the circuit have the proper voltage present?

      Yes 

      • Go To  8

      No 

      • Go To  4
  4. CHECK THE O2 SENSOR 1/1 (K41) SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE 
    1. Turn the ignition off.
    2. Disconnect the harness connector at the component of the circuit being tested. Note:  Use the wiring diagram as a guide to follow the path of the circuit.
    3. Turn the ignition on.
    4. Using a DVOM, measure the voltage of the circuit being tested at the component harness connector.
      NOTE:

      The voltage on a 5.0 volt signal or reference circuit should be between approximately 4.8 and 5.2 volts.

      Is the voltage above 5.2 volts?

      Yes 

      • Go To  5

      No 

      • Go To  6
  5. ISOLATE AND CHECK THE O2 SENSOR 1/1 (K41) SIGNAL CIRCUIT FOR A SHORT TO ANOTHER CIRCUIT AT THE PCM HARNESS CONNECTOR 
    1. The ignition must be off when performing a resistance check to find a short between circuits.
    2. Isolate the circuit by disconnecting the Electronic Control Unit (ECU) and every component harness connector containing the circuit being tested. At this time leave all in-line connectors connected. Note:  Use the wiring diagram as a guide to follow the path of the circuit.
    3. Connect one lead of the DVOM to the circuit being tested at the ECU harness connector.
    4. With the other lead of the DVOM probe all other circuits at the ECU harness connector.
    5. If it is necessary to probe a terminal at a PCM harness connector, connect the to the appropriate PCM harness connector.
      NOTE:

      With the circuit isolated there should be no continuity between the circuit being tested and any other circuit.

      Is there continuity between the circuit being tested and any other circuit?

      Yes 

      • Repair the short between the circuits that have continuity. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors to help isolate the location of the short.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

      No 

      • Go To  14
  6. ISOLATE AND CHECK THE O2 SENSOR 1/1 (K41) SIGNAL CIRCUIT FOR A SHORT TO GROUND 
    1. The ignition must be off when checking a circuit for continuity to ground.
    2. Isolate the circuit by disconnecting the Electronic Control Unit (ECU) and every component harness connector containing the circuit being tested. Note:  Use the wiring diagram as a guide to follow the path of the circuit.
    3. Connect the negative lead of the DVOM to a known good ground.
    4. With the positive lead of the DVOM, probe the circuit being tested at the component harness connector and check for continuity between the circuit and ground.
    5. If it is necessary to probe a terminal at a PCM harness connector, connect the to the appropriate PCM harness connector.
      NOTE:

      There should be no continuity between ground and the circuit being tested.

      CAUTION:

      Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install the GPEC Diagnostic Adaptor to perform the diagnosis.

      Is there continuity between ground and the circuit being tested?

      Yes 

      • Repair the circuit for a short to ground. Use the wiring diagram as a guide to trace the circuit and look for any in-line connectors to help isolate the location of the short.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

      No 

      • Go To  7
  7. ISOLATE AND CHECK THE O2 SENSOR 1/1 (K41) SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE 
    1. The ignition must be off when checking the continuity of a circuit.
    2. Isolate the circuit by disconnecting the Electronic Control Unit (ECU) and the component harness connector containing the circuit being tested. Note:  Use the wiring diagram as a guide to follow the path of the circuit.
    3. Before measuring the resistance of any circuit, first measure the resistance between the two leads of the DVOM. Note:  The meter leads can add resistance to the measurement value.
    4. Connect one lead of the DVOM to the circuit being tested at the component harness connector.
    5. Connect the other lead to the circuit being tested at the GPEC Adaptor and measure the resistance of the circuit.
    6. If it is necessary to probe a terminal at a PCM harness connector, connect the to the appropriate PCM harness connector.
      CAUTION:

      Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install the GPEC Diagnostic Adaptor to perform the diagnosis.

      Is the resistance below 3.0 Ohms?

      Yes 

      • Go To  13

      No 

  8. CHECK THE (K902) SENSOR RETURN CIRCUIT FOR PROPER VOLTAGE AT THE O2 SENSOR HARNESS CONNECTOR 
    1. Turn the ignition off.
    2. Disconnect the harness connector at the component of the circuit being tested. Note:  The ECU harness connector should still be connected during this test step.
    3. Turn the ignition on.
    4. Set the DVOM to measure DC voltage.
    5. Connect the negative lead of the DVOM to a known good ground.
    6. With the positive lead of the DVOM, measure the voltage of the circuit being tested at the component harness connector.
    7. If it is necessary to probe a terminal at a PCM harness connector, connect the to the appropriate PCM harness connector.
      NOTE:

      Normal operating voltage should be approximately 2.5 volts.

      CAUTION:

      Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install the GPEC Diagnostic Adaptor to perform the diagnosis.

      Does the circuit have the proper voltage present?

      Yes 

      • Go To  13

      No 

      • Go To  9
  9. CHECK THE (K902) SENSOR RETURN CIRCUIT FOR A SHORT TO VOLTAGE 
    1. Turn the ignition off.
    2. Disconnect the harness connector at the component of the circuit being tested. Note:  Use the wiring diagram as a guide to follow the path of the circuit.
    3. Turn the ignition on.
    4. Using a DVOM, measure the voltage of the circuit being tested at the component harness connector.
      NOTE:

      The voltage on a 5.0 volt signal or reference circuit should be between approximately 4.8 and 5.2 volts.

      Is the voltage above 5.2 volts?

      Yes 

      • Go To  10

      No 

      • Go To  11
  10. ISOLATE AND CHECK THE (K902) SENSOR RETURN CIRCUIT FOR A SHORT TO ANOTHER CIRCUIT AT THE PCM HARNESS CONNECTOR 
    1. The ignition must be off when performing a resistance check to find a short between circuits.
    2. Isolate the circuit by disconnecting the Electronic Control Unit (ECU) and every component harness connector containing the circuit being tested. At this time leave all in-line connectors connected. Note:  Use the wiring diagram as a guide to follow the path of the circuit.
    3. Connect one lead of the DVOM to the circuit being tested at the ECU harness connector.
    4. With the other lead of the DVOM probe all other circuits at the ECU harness connector.
    5. If it is necessary to probe a terminal at a PCM harness connector, connect the to the appropriate PCM harness connector.
      NOTE:

      With the circuit isolated there should be no continuity between the circuit being tested and any other circuit.

      Is there continuity between the circuit being tested and any other circuit?

      Yes 

      • Repair the short between the circuits that have continuity. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors to help isolate the location of the short.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

      No 

      • Go To  14
  11. ISOLATE AND CHECK THE (K902) SENSOR RETURN CIRCUIT FOR A SHORT TO GROUND 
    1. The ignition must be off when checking a circuit for continuity to ground.
    2. Isolate the circuit by disconnecting the Electronic Control Unit (ECU) and every component harness connector containing the circuit being tested. Note:  Use the wiring diagram as a guide to follow the path of the circuit.
    3. Connect the negative lead of the DVOM to a known good ground.
    4. With the positive lead of the DVOM, probe the circuit being tested at the component harness connector and check for continuity between the circuit and ground.
    5. If it is necessary to probe a terminal at a PCM harness connector, connect the to the appropriate PCM harness connector.
      NOTE:

      There should be no continuity between ground and the circuit being tested.

      CAUTION:

      Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install the GPEC Diagnostic Adaptor to perform the diagnosis.

      Is there continuity between ground and the circuit being tested?

      Yes 

      • Repair the circuit for a short to ground. Use the wiring diagram as a guide to trace the circuit and look for any in-line connectors to help isolate the location of the short.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

      No 

      • Go To  12
  12. ISOLATE AND CHECK THE (K902) SENSOR RETURN CIRCUIT FOR AN OPEN/HIGH RESISTANCE 
    1. The ignition must be off when checking the continuity of a circuit.
    2. Isolate the circuit by disconnecting the Electronic Control Unit (ECU) and the component harness connector containing the circuit being tested. Note:  Use the wiring diagram as a guide to follow the path of the circuit.
    3. Before measuring the resistance of any circuit, first measure the resistance between the two leads of the DVOM. Note:  The meter leads can add resistance to the measurement value.
    4. Connect one lead of the DVOM to the circuit being tested at the component harness connector.
    5. Connect the other lead to the circuit being tested at the GPEC Adaptor and measure the resistance of the circuit.
    6. If it is necessary to probe a terminal at a PCM harness connector, connect the to the appropriate PCM harness connector.
      CAUTION:

      Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install the GPEC Diagnostic Adaptor to perform the diagnosis.

      Is the resistance below 3.0 Ohms?

      Yes 

      • Repair the (K902) Sensor Return circuit for an open or high resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

      No 

      • Go To  13
  13. CHECK THE O2 SENSOR 1/1 WIRING AND CONNECTOR 
    NOTE:

    Check for signs of contaminants that may have damaged the O2 Sensor, such as contaminated fuel, unapproved silicone, oil and coolant.

    1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 Sensor 1/1 and the Powertrain Control Module (PCM).
      • Look for any chafed, pierced, pinched, or partially broken wires.
      • Look for broken, bent, pushed out or corroded terminals.
      • Verify that there is good pin to terminal contact in the 1/1 O2 Sensor and Powertrain Control Module connectors.
      • Perform any Service Bulletins that may apply.

      Were any problems found?

      Yes 

      No 

  14. CHECK RELATED PCM AND COMPONENT CONNECTIONS 
    1. Perform any Service Bulletins that apply.
    2. Disconnect all PCM harness connectors.
    3. Disconnect all related in-line harness connections (if equipped).
    4. Disconnect the related component harness connectors.
    5. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
      • Proper connector installation.
      • Damaged connector locks.
      • Corrosion.
      • Other signs of water intrusion.
      • Weather seal damage (if equipped).
      • Bent terminals.
      • Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
      • Terminals that have been pushed back into the connector cavity.
      • Check for spread terminals and verify proper terminal tension.

      Repair any conditions that are found.

    6. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
    7. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
    8. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
    9. With the scan tool, erase DTCs.
    10. Test drive or operate the vehicle in accordance with the when monitored and set conditions.
    11. With the scan tool, read DTCs.

      Did the DTC return?

      Yes 

      No