FUEL INJECTION SYSTEMÐ2.5L DIESEL ENGINE
INDEX
page page
GENERAL INFORMATION
INTRODUCTION....................... 43
DESCRIPTION AND OPERATION
AIR CONDITIONING (A/C) CONTROLSÐ
PCM INPUTS........................ 47
AIR CONDITIONING RELAYÐPCM OUTPUT . . 48
BATTERY VOLTAGEÐPCM INPUT.......... 45
BOOST PRESSURE SENSOR............. 45
BRAKE SWITCHÐPCM INPUT............. 47
DATA LINK CONNECTORÐ
PCM INPUT AND OUTPUT.............. 47
DIESEL PCM RELAYÐPCM INPUT......... 48
ENGINE COOLANT GAUGEÐPCM OUTPUT . . 48
ENGINE COOLANT TEMPERATURE SENSORÐ
PCM INPUT......................... 46
ENGINE OIL PRESSURE GAUGEÐ
PCM OUTPUT........................ 48
ENGINE SPEED SENSORÐPCM INPUT..... 46
EXHAUST GAS RECIRCULATION (EGR)
SOLENOIDÐPCM OUTPUT............. 50
FIVE VOLT POWERÐPCM OUTPUT........ 48
FUEL INJECTOR SENSORÐGROUND...... 46
FUEL TIMING SOLENOIDÐPCM OUTPUT.... 48
GLOW PLUG LAMPÐPCM OUTPUT........ 48
GLOW PLUG RELAYÐPCM OUTPUT....... 49
GLOW PLUGS......................... 49
IGNITION CIRCUIT SENSEÐPCM INPUT.... 45
NEEDLE MOVEMENT OR INSTRUMENTED
FIRST INJECTORÐPCM INPUT.......... 45
POWER GROUND...................... 45
POWERTRAIN CONTROL MODULE (PCM) . . . 44
SENSOR RETURNÐPCM INPUT (ANALOG
GROUND)........................... 45SIGNAL GROUNDÐPCM INPUT........... 45
SPEED CONTROLÐPCM INPUTS.......... 48
SPEED CONTROLÐPCM OUTPUTS........ 48
START SIGNALÐPCM INPUT............. 45
TACHOMETERÐPCM OUTPUT............ 49
VEHICLE SPEED SENSORÐPCM INPUT.... 47
VEHICLE THEFT ALARM................. 45
DIAGNOSIS AND TESTING
BOOST PRESSURE SENSOR............. 53
DIAGNOSTIC TROUBLE CODES........... 53
DIESEL DIAGNOSTICS.................. 50
DIESEL PCM RELAY TEST............... 50
ENGINE COOLANT TEMPERATURE
SENSOR TEST....................... 50
ENGINE SPEED SENSOR TEST........... 50
GLOW PLUG RELAY TEST............... 51
GLOW PLUG TEST..................... 51
RELAYSÐOPERATION/TESTING........... 52
VEHICLE SPEED SENSOR TEST........... 53
REMOVAL AND INSTALLATION
A/C CLUTCH RELAY.................... 53
DIESEL PCM RELAY.................... 53
ENGINE COOLANT TEMPERATURE
SENSOR............................ 54
ENGINE SPEED SENSOR................ 53
GLOW PLUG RELAY.................... 55
GLOW PLUGS......................... 54
POWERTRAIN CONTROL MODULE (PCM) . . . 55
VEHICLE SPEED SENSOR............... 55
SPECIFICATIONS
GLOW PLUG CURRENT DRAW............ 56
TORQUE CHARTÐ2.5L DIESEL............ 57
GENERAL INFORMATION
INTRODUCTION
This section will cover components either regulated
or controlled by the Powertrain Control Module
(PCM). The fuel heater relay, fuel heater and fuel
gauge are not operated by the PCM. These compo-
nents are controlled by the ignition (key) switch. All
other fuel system electrical components necessary to
operate the engine are controlled or regulated by the
PCM. Refer to the following PCM description for
more information.
Certain fuel system component failures may cause
a no start, or prevent the engine from running. It is
important to know that the PCM has a featurewhere, if possible, it will ignore the failed sensor, set
a code related to the sensor, and operate the engine
in a ªLimp Homeº mode. When the PCM is operating
in a ªLimp Homeº mode, the Diesel Glow Plug lamp
on the instrument panel will be constantly illumi-
nated, and the engine will most likely have a notice-
able loss of performance. An example of this would be
an Accelerator Pedal Position Sensor failure, and in
that situation, the engine would run at a constant
1100 RPM, regardless of the actual position of the
pedal. This is the most extreme of the three ªLimp
Homeº modes.
In addition to indicating that the glow plugs are
hot enough to start combustion, the Glow Plug Lamp
is also used in the diagnosis of the PCM, and when
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 43
illuminated constantly, it usually indicates a problem
has been detected somewhere within the fuel system.
The DRBIII scan tool is the best method for commu-
nicating with the PCM to diagnose faults within the
system.
DESCRIPTION AND OPERATION
POWERTRAIN CONTROL MODULE (PCM)
The Powertrain Control Module (PCM) is mounted
in the center consule to a bracket located in front of
the Air Bag Module (Fig. 1).
The PCM is a pre±programmed, dual micro±proces-
sor digital computer. It will either directly operate or
partially regulate the:
²Speed Control
²Speed Control LED lamp
²Fuel Timing Solenoid
²Glow Plug Relay
²Glow Plugs
²EGR Solenoid
²Glow Plug Lamp
²Diesel PCM Relay
²Air Conditioning Operation
²Tachometer
²Exhaust Gas Recirculation (EGR) Solenoid
The PCM can adapt its programming to meet
changing operating conditions.
The PCM receives input signals from various
switches and sensors. Based on these inputs, the
PCM regulates various engine and vehicle operationsthrough different system components. These compo-
nents are referred to asPCM Outputs.The sensors
and switches that provide inputs to the PCM are con-
sideredPCM Inputs.
PCM Inputs are:
²Air Conditioning Selection
²Theft Alarm
²Clutch Switch
²Diesel PCM Relay
²ISO-Protocol
²Control Sleeve
²Fuel Temperature
²Boost Pressure Sensor
²Accelerator Pedal Sensor
²EGR
²A/C Pressure
²Engine Coolant Temperature Sensor
²Low Idle Position Switch
²5 Volt Supply
²Vehicle Speed Sensor
²Sensor Return
²Glow Plug
²Engine Speed Sensor (rpm)
²Fuel Injector #1 Sensor
²Starter Signal
²Brake Switch
²Speed Control Switch Position
²Power Ground
²Signal Ground
²Ignition (key) Switch Sense
²Battery Voltage
²SCI Receive (DRB scan tool connection)
PCM Outputs:
After inputs are received by the PCM, certain sen-
sors, switches and components are controlled or reg-
ulated by the PCM. These are consideredPCM
Outputs.These outputs are for:
²A/C Clutch Relay (for A/C clutch operation)
²Speed Control LED
²Data Link Connectors (for DRB scan tool)
²Diesel PCM Relay
²Diesel PCM Sense
²Accelarator Pedal
²5 Volts Supply
²Glow Plug Relay
²Fan Relay
²Fuel Quantity
²Fuel Timing Solenoid
²Fuel Shut-Off Solenoid
²Engine Speed Sensor
²Glow Plug Lamp (malfunction indicator lamp)
²Exhaust Gas Recirculation (EGR) Solenoid
²Glow Plug Relay
²Tachometer
²SCI transmit (DRB scan tool connection)
Fig. 1 PCM Location
14 - 44 FUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINENS/GS
GENERAL INFORMATION (Continued)
AIR CONDITIONING (A/C) CONTROLSÐPCM
INPUTS
The A/C control system information applies to fac-
tory installed air conditioning units.
A/C REQUEST SIGNAL:When either the A/C or
Defrost mode has been selected and the A/C low and
high±pressure switches are closed, an input signal is
sent to the powertrain control module (PCM). The
PCM uses this input to cycle the A/C compressor
through the A/C relay.
If the A/C low or high±pressure switch opens, the
PCM will not receive an A/C request signal. The
PCM will then remove the ground from the A/C relay.
This will deactivate the A/C compressor clutch. Also,
if the engine coolant reaches a temperature outside
normal of its normal range, or it overheats, the PCM
will deactivate the A/C clutch.
BRAKE SWITCHÐPCM INPUT
When the brake light switch is activated, the PCM
receives an input indicating that the brakes are
being applied. After receiving this input, the PCM is
used to control the speed control system. There is a
Primary and a Secondary brake switch. The Second-
ary brake switch is closed until the brake pedal is
pressed.
DATA LINK CONNECTORÐPCM INPUT AND
OUTPUT
The 16±way data link connector (diagnostic scan
tool connector) links the Diagnostic Readout Box(DRB) scan tool with the PCM. The data link connec-
tor is located under the instrument panel near the
bottom of steering column (Fig. 7).
VEHICLE SPEED SENSORÐPCM INPUT
The vehicle speed sensor (Fig. 8) is located in the
extension housing of the transmission. The sensor
input is used by the PCM to determine vehicle speed
and distance traveled.
Fig. 6 Speed Sensor Operation
Fig. 7 Data Link Connector Location
Fig. 8 Vehicle Speed SensorÐTypical
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 47
DESCRIPTION AND OPERATION (Continued)
²The shift lever position must stay until
prompted to shift to overdrive
²The shift lever position must stay in overdrive
after the Shift to Overdrive prompt until the DRBIII
indicates the procedure is complete
²The calculated oil temperature must be above
60É and below 200É
(1) Plug the DRBIII scan tool into the data link
connector. The connector is located under the instru-
ment panel.
(2) Go to the Transmission screen.
(3) Go to the Miscellaneous screen.
(4) Select Quick Learn Procedure. Follow the
instructions of the DRBIII to perform the Quick
Learn Procedure.
PINION FACTOR PROCEDURE
The vehicle speed readings for the speedometer are
taken from the output speed sensor. The TCM must
be calibrated to the different combinations of equip-
ment available. A procedure has been developed
called Pinion Factor. It allows the technician to set
the Transmission Control Module initial setting so
that the speedometer readings will be correct.
Failure to perform this procedure will cause a No
Speedometer Operation condition.
This procedure must be performed if the Transmis-
sion Control Module has been replaced.
To properly read or reset the Pinion Factor, it is
necessary to use a DRBIII scan tool. Perform the fol-
lowing steps with the DRBIII scan tool to read or
reset the Pinion Factor:
(1) Plug the DRBIII scan tool into the data link
connector located under the instrument panel.
(2) Select the Transmission menu.
(3) Select the Miscellaneous menu.
(4) Select Pinion Factor. Then follow the instruc-
tions on the DRBIII scan tool screen.
REMOVAL AND INSTALLATION
GEARSHIFT CABLE
REMOVAL
(1) Remove cable eyelet attachment from transaxle
operating lever pin (Fig. 6).
(2) Using pliers, squeeze ears of cable conduit
attachment at mounting bracket (Fig. 7) and push
through hole to remove (Fig. 8).
(3) Remove the under instrument panel silencer
(Fig. 9). Refer to Group 8E, Instrument Panel And
Gauges for more information.
(4) At the steering column attachment, remove the
cable eyelet attachment from the shift lever pin.(5) Using pliers, squeeze ears of cable attachment
at mounting bracket then push through hole to
remove.
(6) Unseat the dash grommet and remove the
cable from the vehicle.
INSTALLATION
(1) Install cable into steering column attachment
bracket. Verify conduit ears are fully engaged. Verify
cable does not interfere with brake pedal actuation.
(2) Attach cable eyelet fitting onto shift lever pin.
(3) Insert transaxle end of cable through dash
panel hole and fully seat grommet.
(4) Install instrument panel silencer. Verify gear-
shift cable is routed through the slot in the silencer.
CAUTION: Failure to route the cable properly at the
silencer may cause brake pedal interference.
(5) Attach transaxle end of cable to the mounting
bracket on the transaxle. Assure the conduit attach-
ment ears are fully seated.
Fig. 6 Gearshift Cable
Fig. 7 Grommet Clips
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 83
SERVICE PROCEDURES (Continued)
(25) Install transmission jack under transaxle
assembly.
(26) Remove left fender splash shield.
(27) Remove (4) left mount bolts (Fig. 42).(28) Remove lower bellhousing bolts.
(29) Lower transaxle and remove.
INSTALLATION
(1) For installation, reverse removal procedure.
NOTE: Lower control arm pinch bolts must be
installed with the bolt heads to the rear of the ball
joints.
(2) Fill transaxle to the proper level with the spec-
ified lubricant.
(3) While the vehicle is elevated slightly, run the
transaxle through all the forward gears. Apply
brakes and shift into reverse. Run the transaxle
through reverse gear.
Fig. 35 Lower Control Arm Pinch Bolt
Fig. 36 Unseat Control Arm
Fig. 37 Transaxle Drain Plug
Fig. 38 Vehicle Speed Sensor
Fig. 39 Clutch Cable Clip
21 - 14 A±598 MANUAL TRANSAXLENS/GS
REMOVAL AND INSTALLATION (Continued)
probe will drop the temperature 7ÉC (20ÉF) in two
minutes. If the Evaporator Probe is found to be
faulty, check that the sensor is positioned in the
evaporator fins properly. If not, correct and repeat
test. If OK, replace the evaporator probe.
Once the repairs are completed, repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
A/C PERFORMANCE TEST
The air conditioning system is designed to remove
heat and humidity from the air entering the passen-
ger compartment. The evaporator, located in the
heater A/C unit, is cooled to temperatures near the
freezing point. As warm damp air passes over the
fins in the evaporator, moisture in the air condenses
to water, dehumidifying the air. Condensation on the
evaporator fins reduces the evaporators ability to
absorb heat. During periods of high heat and humid-
ity, an air conditioning system will be less effective.
With the instrument control set to RECIRC, only air
from the passenger compartment passes through the
evaporator. As the passenger compartment air dehu-
midifies, A/C performance levels rise.
PERFORMANCE TEST PROCEDURE
Review Safety Precautions and Warnings in this
group before proceeding with this procedure. Air tem-
perature in test room and on vehicle must be 21É C
(70ÉF) minimum for this test.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer and manifold gauge set.
(2) Set control to A/C, RECIRC, and PANEL, tem-
perature lever on full cool and blower on high.
(3) Start engine and hold at 1000 rpm with A/C
clutch engaged.(4) Engine should be warmed up with doors and
windows closed.
(5) Insert a thermometer in the left center A/C
outlet and operate the engine for five minutes. The
A/C clutch may cycle depending on ambient condi-
tions.
(6) With the A/C clutch engaged, compare the dis-
charge air temperature to the A/C Performance Tem-
peratures table.
(7) If the discharge air temperature fails to meet
the specifications in the performance temperature
chart. Refer to the Refrigerant Service Procedures for
further diagnosis.
A/C PRESSURE TRANSDUCER
The work area temperature must not be below
10ÉC (50ÉF) to test the compressor clutch circuit.
Before starting to test the transducer ensure that the
wire connector is clean of corrosion and connected
properly.
(1) With gear selector in park or neutral and park
brake set, start engine and allow to idle.
(2) Install scan tool (DRB):
²Go to main menu
²Select stand alone scan tool (DRB)
²Select refer to the proper year diagnostics
²Select climate control
²Select sensor display
²Select A/C high side volts
For A/C system to operate a voltage between .451
(Low Pressure Cutout) to 4.519 (High Pressure Cut-
out is required. Voltages outside this range indicate a
low or high pressure condition andwill notallow
the compressor to cycle.
Refer to the A/C Pressure Transducer Voltage table
for the appropriate condition(s):
A/C PERFORMANCE TEMPERATURES
AMBIENT TEMPERATURE 21ÉC
(70ÉF)26.5ÉC
(80ÉF)32ÉC
(90ÉF)37ÉC
(100ÉF)43ÉC
(110ÉF)
AIR TEMPERATURE AT LEFT
CENTER PANEL OUTLET1-8ÉC
(34-46ÉF)3-9ÉC
(37-49ÉF)4-10ÉC
(39-50ÉF)6-11ÉC
(43-52ÉF)7-18ÉC
(45-65ÉF)
COMPRESSOR DISCHARGE
PRESSURE AFTER THE FILTER
DRIER1034-1724
kPa
(150-250
PSI)1517-2275
kPa
(220-330
PSI)1999-2620
kPa
(290-380
PSI)2068-2965
kPa
(300-430
PSI)2275-3421
kPa
(330-496
PSI)
EVAPORATOR SUCTION
PRESSURE103-207 kPa
(15-30 PSI)117-221 kPa
(17-32 psi)138-241 kPa
(20-35 PSI)172-269 kPa
(25-39 PSI)207-345 kPa
(30-50 PSI)
24 - 12 HEATING AND AIR CONDITIONINGNS
DIAGNOSIS AND TESTING (Continued)
²No charge
²Compressor not operating
Verify that the test was done with the evaporator
at room temperature. The test consists of starting
the compressor and measuring the time it takes for
the evaporator temperature to fall 7ÉC (20ÉF). If the
compressor has been running, the evaporator is cold
already and will not be capable of falling 7ÉC (20ÉF).
If the test was run with a cold evaporator, turn A/C
off and turn the blower motor switch to high position
for 3 to 5 minutes till the evaporator is to room tem-
perature. Then repeat the Calibration Diagnostic and
Cooldown test.
If refrigerant system is performing properly and
the system will not pass test. Repeat the Calibration
Diagnostic and Cooldown test to determine if the
evaporator temperature FIN sensor has developed an
open or a short circuit. If the HVAC control module
still passes Calibration test, verify Cooldown test
manually with a pocket thermometer. The outlet air
temperature must drop at least 7ÉC (20ÉF) within
two minutes. If the vehicle passes with the manual
thermometer, take HVAC control to level 4 (evapora-
tor probe temperature readout) and repeat the
Cooldown test. Ensure the evaporator is at room tem-
perature before starting test. Check if evaporator
probe will drop the temperature 7ÉC (20ÉF) in two
minutes. If the Evaporator Probe is found to be
faulty, check that the sensor is positioned in the
evaporator fins properly. If not, correct and repeat
test. If OK, replace the evaporator probe.
Once the repairs are completed, repeat the Calibra-
tion Diagnostic and Cooldown test. Repeating the
test is necessary to clear the fault codes.
A/C PERFORMANCE TEST
The air conditioning system is designed to remove
heat and humidity from the air entering the passen-
ger compartment. The evaporator, located in the
heater A/C unit, is cooled to temperatures near the
freezing point. As warm damp air passes over the
fins in the evaporator, moisture in the air condenses
to water, dehumidifying the air. Condensation on the
evaporator fins reduces the evaporators ability to
absorb heat. During periods of high heat and humid-
ity, an air conditioning system will be less effective.
With the instrument control set to RECIRC, only air
from the passenger compartment passes through the
evaporator. As the passenger compartment air dehu-
midifies, A/C performance levels rise.
PERFORMANCE TEST PROCEDURE
Review Safety Precautions and Warnings in this
group before proceeding with this procedure. Air tem-
perature in test room and on vehicle must be 21É C
(70ÉF) minimum for this test.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer and manifold gauge set.
(2) Set control to A/C, RECIRC, and PANEL, tem-
perature lever on full cool and blower on high.
(3) Start engine and hold at 1000 rpm with A/C
clutch engaged.
(4) Engine should be warmed up with doors and
windows closed.
(5) Insert a thermometer in the left center A/C
outlet and operate the engine for five minutes. The
A/C clutch may cycle depending on ambient condi-
tions.
(6) With the A/C clutch engaged, compare the dis-
charge air temperature to the A/C Performance Tem-
peratures chart (Fig. 7).
(7) If the discharge air temperature fails to meet
the specifications in the performance temperature
chart. Refer to the Refrigerant Service Procedures for
further diagnosis.
A/C PRESSURE TRANSDUCER
The work area temperature must not be below
10ÉC (50ÉF) to test the compressor clutch circuit.
Before starting to test the transducer ensure that the
wire connector is clean of corrosion and connected
properly.
(1) With gear selector in park or neutral and park
brake set, start engine and allow to idle.
(2) Install scan tool (DRB):
²Go to main menu
²Select stand alone scan tool (DRB)
²Select refer to the proper year diagnostics
²Select climate control
²Select sensor display
²Select A/C high side volts
For A/C system to operate a voltage between .451
(Low Pressure Cutout) to 4.519 (High Pressure Cut-
out is required. Voltages outside this range indicate a
low or high pressure condition andwill notallow
the compressor to cycle.
The following chart denotes voltages and the
appropriate condition(s):
NS/GSHEATING AND AIR CONDITIONING 24 - 11
DIAGNOSIS AND TESTING (Continued)
cranking. Whenever the Powertrain Control Module
(PCM) sets a Diagnostic Trouble Code (DTC) that
affects vehicle emissions, it illuminates the MIL. If a
problem is detected, the PCM sends a message over
the CCD Bus to the instrument cluster to illuminate
the lamp. The PCM illuminates the MIL only for
DTC's that affect vehicle emissions. The MIL stays
on continuously when the PCM has entered a
Limp-In mode or identified a failed emission compo-
nent or system. The MIL remains on until the DTC
is erased. Refer to the Diagnostic Trouble Code
charts in this group for emission related codes.
Also, the MIL either flashes or illuminates contin-
uously when the PCM detects active engine misfire.
Refer to Misfire Monitoring in this section.
Additionally, the PCM may reset (turn off) the MIL
when one of the following occur:
²PCM does not detect the malfunction for 3 con-
secutive trips (except misfire and fuel system moni-
tors).
²PCM does not detect a malfunction while per-
forming three successive engine misfire or fuel sys-
tem tests. The PCM performs these tests while the
engine is operating within6375 RPM of and within
10 % of the load of the operating condition at which
the malfunction was first detected.
STATE DISPLAY TEST MODE
The switch inputs to the Powertrain Control Mod-
ule (PCM) have two recognized states; HIGH and
LOW. For this reason, the PCM cannot recognize the
difference between a selected switch position versus
an open circuit, a short circuit, or a defective switch.
If the State Display screen shows the change from
HIGH to LOW or LOW to HIGH, assume the entire
switch circuit to the PCM functions properly. From
the state display screen, access either State Display
Inputs and Outputs or State Display Sensors.
STATE DISPLAY INPUTS AND OUTPUTS
Connect the DRB scan tool to the data link connec-
tor and access the State Display screen. Then access
Inputs and Outputs. The following list contains the
PCM system functions accessible through the Inputs
and Outputs screen.
Park/Neutral Switch
Speed Control Resume
Brake Switch
Speed Control On/Off
Speed Control Set
S/C Vent Solenoid
Actual S/C Vent Sol.
S/C Vacuum Solenoid
Actual S/C Vacuum Sol.
S/C Cancel
S/C Last Cutout
S/C Working Status
S/C Denied Status
A/C Clutch Relay
Actual A/C Clutch Relay
EGR Solenoid
Actual EGR Sol.
Automatic Shutdown Relay
Actual Automatic Shutdown Relay
Automatic Shutdown Relay Sense
Radiator Fan Control Module
Actual Radiator Fan Control Module
Duty Cycle EVAP Purge Solenoid
Actual EVAP Purge Sol.
Torque Converter Clutch Solenoid
Power Steering Switch
Closed Loop State
Current CMP Edge
Current CKP State
Current Sync State
Fuel Pump Relay
Actual Fuel Pump Relay
Ignition Sense (A21)
Malfunction Lamp
Limp-in Reason
STATE DISPLAY SENSORS
Connect the DRB scan tool to the vehicle and
access the State Display screen. Then access Sensor
Display. The following list contains the PCM system
functions accessible through the Sensor Display
screen.
Battery Temperature
Engine Coolant Temperature
Engine Coolant Temp Sensor
Throttle Position Volts
Minimum Throttle
Knock Sensor Volts
Battery Voltage
MAP Sensor Reading
Idle Air Control Motor Position
Fig. 1 Data Link (Diagnostic) Connector
25 - 2 EMISSION CONTROL SYSTEMSNS
DESCRIPTION AND OPERATION (Continued)