ENGINE CONTROL MODULE
DESCRIPTION - ECM
The ECM is bolted to the left side of the engine
behind the fuel filter (Fig. 14). It is a separate com-
ponent and can be serviced. The FPCM is internal to
the fuel injection pump (Fig. 15) and cannot be ser-
viced.
OPERATION - ECM
The main functions of the Engine Control Module
(ECM) and Fuel Injection Pump Control Module
(FPCM) are to electrically control the fuel system.
The Powertrain Control Module (PCM)does not
controlthe fuel system.
The ECM can adapt its programming to meet
changing operating conditions.If the ECM has
been replaced, flashed or re-calibrated, the
ECM must learn the Accelerator Pedal Position
Sensor (APPS) idle voltage. Failure to learn
this voltage may result in unnecessary diagnos-
tic trouble codes. Refer to ECM Removal/Instal-
lation for learning procedures.
The ECM receives input signals from various
switches and sensors. Based on these inputs, the
ECM regulates various engine and vehicle operations
through different system components. These compo-
nents are referred to asECM Outputs.The sensors
and switches that provide inputs to the ECM are
consideredECM Inputs.NOTE: ECM Inputs:
²Accelerator Pedal Position Sensor (APPS) Volts
²APPS Idle Validation Switches #1 and #2
²Battery voltage
²Camshaft Position Sensor (CMP)
²CCD bus (+) circuits
²CCD bus (-) circuits
²Crankshaft Position Sensor (CKP)
²Data link connection for DRB scan tool
²(FPCM) Fuel Injection Pump Control Module
²Engine Coolant Temperature (ECT) sensor
²Ground circuits
²Intake manifold Air Temperature (IAT) sensor
²Manifold Air Pressure Sensor (Boost Pressure
Sensor)
²Oil pressure sensor
²PCM
²Power Take Off (PTO)
²Power ground
²Sensor return
²Signal ground
²Water-In-Fuel (WIF) sensor
Fig. 14 Engine Control Module (ECM) Location
1 - ENGINE CONTROL MODULE (ECM)
2 - HEX HEADED BOLT
3 - 50-WAY CONNECTOR
4 - FUEL TRANSFER PUMP
5 - MOUNTING BOLTS (3)
Fig. 15 Fuel Injection Pump Control Module (FPCM)
Location
1 - FPCM ELECTRICAL CONNECTOR
2 - HIGH-PRESSURE FUEL LINES
3 - FITTINGS
4 - FUEL INJECTION PUMP
5 - FPCM
BR/BEELECTRONIC CONTROL MODULES 8E - 13
NOTE: ECM Outputs:
After inputs are received by the ECM, certain sen-
sors, switches and components are controlled or reg-
ulated by the ECM. These are consideredECM
Outputs.These outputs are for:
²CCD bus (+) circuits
²CCD bus (-) circuits
²CKP and APPS outputs to the PCM
²Data link connection for DRB scan tool
²Five volt sensor supply
²Fuel injection pump
²Fuel injection pump relay
²(FPCM) Fuel Pump Control Module
²Fuel transfer (lift) pump
²Intake manifold air heater relays #1 and #2 con-
trol circuits
²Malfunction indicator lamp (Check engine lamp)
²Oil pressure gauge/warning lamp
²PCM
²Wait-to-start warning lamp
²Water-In-Fuel (WIF) warning lamp
REMOVAL
The ECM is bolted to the engine block behind the
fuel filter (Fig. 16).
(1) Record any Diagnostic Trouble Codes (DTC's)
found in the PCM or ECM.To avoid possible voltage spike damage to either
the Powertrain Control Module (PCM) or ECM, igni-
tion key must be off, and negative battery cables
must be disconnected before unplugging ECM con-
nectors.
(2) Disconnect both negative battery cables at both
batteries.
(3) Remove 50±way electrical connector bolt at
ECM (Fig. 16). Note: Connector bolt is female 4mm
hex head. To remove bolt, use a ball-hex bit or ball-
hex screwdriver such as Snap-Ont4mm SDABM4
(5/32º may also be used). As bolt is being removed,
very carefully remove connector from ECM.
(4) Remove three ECM mounting bolts and remove
ECM from vehicle.
INSTALLATION
Do not apply paint to back of ECM. Poor ground
will result.
(1) Clean ECM mounting points at engine block.
(2) Position ECM to engine block and install 3
mounting bolts. Tighten bolts to 24 N´m (18 ft. lbs.).
(3) Check pin connectors in ECM and 50±way con-
nector for corrosion or damage. Repair as necessary.
(4) Clean pins in 50±way electrical connector with
a quick-dry electrical contact cleaner.
(5) Very carefully install 50±way connector to
ECM. Tighten connector hex bolt.
(6) Install battery cables.
(7)Turn key to ON position. Without starting
engine, slowly press throttle pedal to floor and
then slowly release. This step must be done
(one time) to ensure accelerator pedal position
sensor calibration has been learned by ECM. If
not done, possible DTC's may be set.
(8) Use DRB scan tool to erase any stored compan-
ion DTC's from PCM.
POWERTRAIN CONTROL
MODULE
DESCRIPTION - PCM
The Powertrain Control Module (PCM) is located
in the engine compartment (Fig. 17). The PCM is
referred to as JTEC.
DESCRIPTION - MODES OF OPERATION
As input signals to the Powertrain Control Module
(PCM) change, the PCM adjusts its response to the
output devices. For example, the PCM must calculate
different injector pulse width and ignition timing for
idle than it does for wide open throttle (WOT).
The PCM will operate in two different modes:
Open Loop and Closed Loop.
Fig. 16 Engine Control Module (ECM) Location and
Mounting
1 - ENGINE CONTROL MODULE (ECM)
2 - HEX HEADED BOLT
3 - 50-WAY CONNECTOR
4 - FUEL TRANSFER PUMP
5 - MOUNTING BOLTS (3)
8E - 14 ELECTRONIC CONTROL MODULESBR/BE
ENGINE CONTROL MODULE (Continued)
During Open Loop modes, the PCM receives input
signals and responds only according to preset PCM
programming. Input from the oxygen (O2S) sensors
is not monitored during Open Loop modes.
During Closed Loop modes, the PCM will monitor
the oxygen (O2S) sensors input. This input indicates
to the PCM whether or not the calculated injector
pulse width results in the ideal air-fuel ratio. This
ratio is 14.7 parts air-to-1 part fuel. By monitoring
the exhaust oxygen content through the O2S sensor,
the PCM can fine tune the injector pulse width. This
is done to achieve optimum fuel economy combined
with low emission engine performance.
The fuel injection system has the following modes
of operation:
²Ignition switch ON
²Engine start-up (crank)
²Engine warm-up
²Idle
²Cruise
²Acceleration
²Deceleration
²Wide open throttle (WOT)
²Ignition switch OFF
The ignition switch On, engine start-up (crank),
engine warm-up, acceleration, deceleration and wide
open throttle modes are Open Loop modes. The idle
and cruise modes, (with the engine at operating tem-
perature) are Closed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
This is an Open Loop mode. When the fuel system
is activated by the ignition switch, the following
actions occur:²The PCM pre-positions the idle air control (IAC)
motor.
²The PCM determines atmospheric air pressure
from the MAP sensor input to determine basic fuel
strategy.
²The PCM monitors the engine coolant tempera-
ture sensor input. The PCM modifies fuel strategy
based on this input.
²Intake manifold air temperature sensor input is
monitored.
²Throttle position sensor (TPS) is monitored.
²The auto shutdown (ASD) relay is energized by
the PCM for approximately three seconds.
²The fuel pump is energized through the fuel
pump relay by the PCM. The fuel pump will operate
for approximately three seconds unless the engine is
operating or the starter motor is engaged.
²The O2S sensor heater element is energized via
the ASD relay. The O2S sensor input is not used by
the PCM to calibrate air-fuel ratio during this mode
of operation.
ENGINE START-UP MODE
This is an Open Loop mode. The following actions
occur when the starter motor is engaged.
The PCM receives inputs from:
²Battery voltage
²Engine coolant temperature sensor
²Crankshaft position sensor
²Intake manifold air temperature sensor
²Manifold absolute pressure (MAP) sensor
²Throttle position sensor (TPS)
²Starter motor relay
²Camshaft position sensor signal
The PCM monitors the crankshaft position sensor.
If the PCM does not receive a crankshaft position
sensor signal within 3 seconds of cranking the
engine, it will shut down the fuel injection system.
The fuel pump is activated by the PCM through
the fuel pump relay.
Voltage is applied to the fuel injectors with the
ASD relay via the PCM. The PCM will then control
the injection sequence and injector pulse width by
turning the ground circuit to each individual injector
on and off.
The PCM determines the proper ignition timing
according to input received from the crankshaft posi-
tion sensor.
ENGINE WARM-UP MODE
This is an Open Loop mode. During engine warm-
up, the PCM receives inputs from:
²Battery voltage
²Crankshaft position sensor
²Engine coolant temperature sensor
²Intake manifold air temperature sensor
Fig. 17 PCM Location
1 - PCM MOUNTING BOLTS (3)
2 - POWERTRAIN CONTROL MODULE (PCM)
3 - (3) 32±WAY CONNECTORS
BR/BEELECTRONIC CONTROL MODULES 8E - 15
POWERTRAIN CONTROL MODULE (Continued)
²Power ground
²Sensor return
²Signal ground
²Speed control resume switch
²Speed control set switch
²Speed control on/off switch
²Transmission governor pressure sensor
²Transmission temperature sensor
²Vehicle speed inputs from ABS or RWAL system
NOTE: 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 and A/C clutch
²Auto shutdown (ASD) relay
²CCD bus (+/-) circuits for: speedometer, voltme-
ter, fuel gauge, oil pressure gauge/lamp, engine temp.
gauge and speed control warn. lamp
²Data link connection for DRB scan tool
²Five volt sensor supply
²Generator field driver (-)
²Generator field driver (+)
²Generator lamp (if equipped)
²Malfunction indicator lamp (Check engine lamp)
²Overdrive warning lamp (if equipped)
²Speed control vacuum solenoid
²Speed control vent solenoid
²Tachometer (if equipped)
²Transmission convertor clutch circuit
²Transmission 3±4 shift solenoid
²Transmission relay
²Transmission temperature lamp (if equipped)
²Transmission variable force solenoid (governor
sol.)
OPERATION - 5 VOLT SUPPLIES
Primary 5±volt supply:
²supplies the required 5 volt power source to the
Crankshaft Position (CKP) sensor.
²supplies the required 5 volt power source to the
Camshaft Position (CMP) sensor.
²supplies a reference voltage for the Manifold
Absolute Pressure (MAP) sensor.
²supplies a reference voltage for the Throttle
Position Sensor (TPS) sensor.
Secondary 5±volt supply:
²supplies the required 5 volt power source to the
oil pressure sensor.
²supplies the required 5 volt power source for the
Vehicle Speed Sensor (VSS) (if equipped).
²supplies the 5 volt power source to the transmis-
sion pressure sensor (if equipped with an RE auto-
matic transmission).
OPERATION - IGNITION CIRCUIT SENSE
The ignition circuit sense input tells the PCM the
ignition switch has energized the ignition circuit.
Battery voltage is also supplied to the PCM
through the ignition switch when the ignition is in
the RUN or START position. This is referred to as
the9ignition sense9circuit and is used to9wake up9
the PCM. Voltage on the ignition input can be as low
as 6 volts and the PCM will still function. Voltage is
supplied to this circuit to power the PCM's 8-volt reg-
ulator and to allow the PCM to perform fuel, ignition
and emissions control functions.
REMOVAL
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
The PCM is located in the engine compartment
(Fig. 18).
To avoid possible voltage spike damage to the
PCM, ignition key must be off, and negative battery
cable must be disconnected before unplugging PCM
connectors.
(1) Disconnect negative battery cable(s) at bat-
tery(s).
(2) Remove cover over electrical connectors. Cover
snaps onto PCM.
(3) Carefully unplug the three 32±way connectors
from PCM.
Fig. 18 PCM Location and Mounting
1 - PCM MOUNTING BOLTS (3)
2 - POWERTRAIN CONTROL MODULE (PCM)
3 - (3) 32±WAY CONNECTORS
BR/BEELECTRONIC CONTROL MODULES 8E - 19
POWERTRAIN CONTROL MODULE (Continued)
ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM......................... 1
CHARGING.............................. 27STARTING............................... 32
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION............................1
OPERATION.............................2
DIAGNOSIS AND TESTING..................2
BATTERY SYSTEM......................2
CLEANING...............................5
INSPECTION.............................5
SPECIFICATIONS.........................6
BATTERY
DESCRIPTION............................6
OPERATION.............................7
DIAGNOSIS AND TESTING..................7
BATTERY..............................7
STANDARD PROCEDURE...................8
CHECKING BATTERY ELECTROLYTE
LEVEL................................8
BATTERY CHARGING....................9
BUILT-IN INDICATOR TEST...............11
HYDROMETER TEST....................12
OPEN-CIRCUIT VOLTAGE TEST...........13
LOAD TEST...........................14IGNITION-OFF DRAW TEST...............15
REMOVAL..............................17
INSTALLATION...........................17
BATTERY HOLDDOWN
DESCRIPTION...........................18
OPERATION.............................18
REMOVAL..............................18
INSTALLATION...........................18
BATTERY CABLE
DESCRIPTION...........................19
OPERATION.............................20
DIAGNOSIS AND TESTING.................20
BATTERY CABLES......................20
REMOVAL..............................23
INSTALLATION...........................23
BATTERY TRAY
DESCRIPTION...........................24
OPERATION.............................25
REMOVAL..............................25
INSTALLATION...........................25
BATTERY SYSTEM
DESCRIPTION
A single 12-volt battery system is standard factory-
installed equipment on gasoline engine equipped
models. Models equipped with a diesel engine utilize
two 12-volt batteries connected in parallel. All of the
components of the battery system are located within
the engine compartment of the vehicle. The service
information for the battery system in this vehicle
covers the following related components, which are
covered in further detail elsewhere in this service
manual:²Battery- The storage battery provides a reli-
able means of storing a renewable source of electrical
energy within the vehicle.
²Battery Cable- The battery cables connect the
battery terminal posts to the vehicle electrical sys-
tem.
²Battery Holddown- The battery holddown
hardware secures the battery in the battery tray in
the engine compartment.
²Battery Tray- The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware.
BR/BEENGINE SYSTEMS 8F - 1
place process to identify and correct all sources of
excessive IOD. It is now safe to select the lowest mil-
liampere scale of the multi-meter to check the low-
amperage IOD.
CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.
(6) Observe the multi-meter reading. The low-am-
perage IOD should not exceed thirty-five milliam-
peres (0.035 ampere). If the current draw exceeds
thirty-five milliamperes, isolate each circuit using the
fuse and circuit breaker remove-and-replace process
in Step 5. The multi-meter reading will drop to
within the acceptable limit when the source of the
excessive current draw is disconnected. Repair this
circuit as required; whether a wiring short, incorrect
switch adjustment, or a component failure is at fault.
REMOVAL
(1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
(2) Loosen the battery negative cable terminal
clamp pinch-bolt hex nut.
(3) Disconnect the battery negative cable terminal
clamp from the battery negative terminal post. If
necessary, use a battery terminal puller to remove
the terminal clamp from the battery post (Fig. 16).
(4) Loosen the battery positive cable terminal
clamp pinch-bolt hex nut.
(5) Disconnect the battery positive cable terminal
clamp from the battery positive terminal post. If nec-
essary, use a battery terminal puller to remove the
terminal clamp from the battery post.
(6) Remove the battery hold downs from the bat-
tery. Refer toBattery Hold Downsin this group for
the location of the proper battery hold down removal
procedures.WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
GLASSES SHOULD ALSO BE WORN. IF THE BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
(7) Remove the battery from the battery tray.
INSTALLATION
(1) Clean and inspect the battery. Refer toBat-
tery Systemin this group for the location of the
proper battery system cleaning and inspection proce-
dures.
(2) Position the battery onto the battery tray.
Ensure that the battery positive and negative termi-
nal posts are correctly positioned. The battery cable
terminal clamps must reach the correct battery ter-
minal post without stretching the cables (Fig. 17).
(3) Reinstall the battery hold downs onto the bat-
tery. Refer toBattery Hold Downsin this group for
the location of the proper battery hold down installa-
tion procedures.
CAUTION: Be certain that the battery cable terminal
clamps are connected to the correct battery termi-
nal posts. Reversed battery polarity may damage
electrical components of the vehicle.
Fig. 16 Remove Battery Cable Terminal Clamp -
Typical
1 - BATTERY
2 - BATTERY TERMINAL PULLER
Fig. 17 Battery Cables - Typical
1 - EYELET
2 - NUT
3 - POWER DISTRIBUTION CENTER
4 - POSITIVE CABLE
5 - SCREW
6 - NEGATIVE CABLE
7 - EYELET
8 - CLIP
BR/BEBATTERY SYSTEM 8F - 17
BATTERY (Continued)
(4) Clean the battery cable terminal clamps and
the battery terminal posts. Refer toBattery System
in this group for the location of the proper battery
system cleaning and inspection procedures.
(5) Reconnect the battery positive cable terminal
clamp to the battery positive terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 4 N´m (35
in. lbs.).
(6) Reconnect the battery negative cable terminal
clamp to the battery negative terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 4 N´m (35
in. lbs.).
(7) Apply a thin coating of petroleum jelly or chas-
sis grease to the exposed surfaces of the battery cable
terminal clamps and the battery terminal posts.
BATTERY HOLDDOWN
DESCRIPTION
The battery hold down hardware (Fig. 18) includes
two bolts, two U-nuts and a hold down strap. The bat-
tery hold down bracket consists of a formed steel rod
with a stamped steel angle bracket welded to each end.
The hold down bracket assembly is then plastic-coated
for corrosion protection. Models equipped with the
optional diesel engine have a second battery installed
in a second battery tray on the right side of the engine
compartment. The hold down hardware for the rightside battery is mirror image of the hold down hard-
ware used for the left side battery.
When installing a battery into the battery tray, be
certain that the hold down hardware is properly
installed and that the fasteners are tightened to the
proper specifications. Improper hold down fastener
tightness, whether too loose or too tight, can result in
damage to the battery, the vehicle or both. Refer to
Battery Hold Downsin this group for the location
of the proper battery hold down installation proce-
dures, including the proper hold down fastener tight-
ness specifications.
OPERATION
The battery holddown secures the battery in the
battery tray. This holddown is designed to prevent
battery movement during the most extreme vehicle
operation conditions. Periodic removel and lubrica-
tion of the battery holddown hardware is recomended
to prevent hardware seizure at a later date.
NOTE: Never operate a vehicle without a battery
holddown device properly installed. Damage to the
vehicle, components and battery could result.
REMOVAL
All of the battery hold down hardware except for
the outboard U-nut can be serviced without removal
of the battery or the battery tray. The battery tray
must be removed from the vehicle to service the out-
board U-nut. If the outboard U-nut requires service
replacement, refer toBattery Trayin the index of
this service manual for the location of the proper bat-
tery tray removal and installation procedures.
(1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
(2) Loosen the battery negative cable terminal
clamp pinch-bolt hex nut.
(3) Disconnect the battery negative cable terminal
clamp from the battery negative terminal post. If
necessary, use a battery terminal puller to remove
the terminal clamp from the battery post.
(4) Remove the two battery hold down bolts from
the battery hold down strap (Fig. 19) .
(5) Remove the battery hold down strap from the
top of the battery case.
INSTALLATION
All of the battery hold down hardware except for
the outboard U-nut can be serviced without removal
of the battery or the battery tray. The battery tray
must be removed from the vehicle to service the out-
board U-nut. If the outboard U-nut requires service
replacement, refer toBattery Trayin the index of
this service manual for the location of the proper bat-
tery tray removal and installation procedures.
Fig. 18 Battery Hold Downs - Typical
1 - BATTERY TRAY
2 - U-NUT (2)
3 - BATTERY
4 - BOLT (2)
5 - STRAP
8F - 18 BATTERY SYSTEMBR/BE
BATTERY (Continued)
(1) Clean and inspect the battery hold down hard-
ware. Refer toBatteryin the index of this service
manual for the location of the proper battery hold
down hardware cleaning and inspection procedures.
(2) Position the battery hold down strap across the
top of the battery case.
(3) Install and tighten the two battery hold down
bolts through the holes on each end of the hold down
strap and into the U-nuts on each side of the battery
tray. Tighten the bolts to 4 N´m (35 in. lbs.).
(4) Reconnect the battery negative cable terminal
clamp to the battery negative terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 4 N´m (35
in. lbs.).
BATTERY CABLE
DESCRIPTION
The battery cables (Fig. 20) are large gauge,
stranded copper wires sheathed within a heavy plas-
tic or synthetic rubber insulating jacket. The wire
used in the battery cables combines excellent flexibil-
ity and reliability with high electrical current carry-
ing capacity. Refer toWiring Diagramsin the index
of this service manual for the location of the proper
battery cable wire gauge information.The battery cables cannot be repaired and, if dam-
aged or faulty they must be replaced. Both the bat-
tery positive and negative cables are available for
service replacement only as a unit with the battery
positive cable wire harness or the battery negative
cable wire harness, which may include portions of
the wiring circuits for the generator and other com-
ponents on some models. Refer toWiring Diagrams
in the index of this service manual for the location of
more information on the various wiring circuits
included in the battery cable wire harnesses for the
vehicle being serviced.
GASOLINE ENGINE
Gasoline engine models feature a stamped brass
clamping type female battery terminal crimped onto
one end of the battery cable wire and then solder-
dipped. A square headed pinch-bolt and hex nut are
installed at the open end of the female battery termi-
nal clamp. The battery positive cable also includes a
red molded rubber protective cover for the female
battery terminal clamp. Large eyelet type terminals
are crimped onto the opposite end of the battery
cable wire and then solder-dipped. The battery posi-
tive cable wires have a red insulating jacket to pro-
vide visual identification and feature a larger female
battery terminal clamp to allow connection to the
larger battery positive terminal post. The battery
negative cable wires have a black insulating jacket
and a smaller female battery terminal clamp.
Fig. 19 Left Battery Hold Downs Remove/Install -
Typical for Right Battery
1 - BATTERY TRAY
2 - U-NUT (2)
3 - BATTERY
4 - BOLT (2)
5 - STRAP
Fig. 20 Battery Cables - Typical
1 - EYELET
2 - NUT
3 - POWER DISTRIBUTION CENTER
4 - POSITIVE CABLE
5 - SCREW
6 - NEGATIVE CABLE
7 - EYELET
8 - CLIP
BR/BEBATTERY SYSTEM 8F - 19
BATTERY HOLDDOWN (Continued)