NOTE: If this vehicle is equipped with an Electronic Throttle Control system, and the APP Sensors, PCM, or
Throttle Body Assembly have been replaced, use the scan tool to perform theETC RELEARN function.
14. If the indicator ball shows a leak present, perform the smoke test indicated in the previous test and identify the
leak and repair. Perform this verification test when the repair is complete.
Didtheindicatorballindicatethealeakispresent?
Ye s>>
Repeat the DTC test to identify the leak and repair.
No>>
Repair is complete.
5.POWERTRAIN VERIFICATION TEST 4
NOTE: 1. After completing the Powertrain Verification Test the Transmission Verification Test must be per-
formed.
NOTE: 2. If the PCM has been replaced and the correct VIN and mileage have notbeen programmed, a DTC
will set in the ABS Module, Airbag Module and the SKIM/SKREEM.
NOTE: 3. If the vehicle is equipped with a Sentry Key Remote Entry, Secret Key data must be updated. Refer
to the Service Information for the PCM, SKIM/SKREEM and the Transponder (ignition key) for programming
information. Using the scan tool, program the Secret Key information intothe PCM using the PCM replaced
function under the WCM menu.
NOTE: 4. If this vehicle is equipped with an Electronic Throttle Control system, and the APP Sensors, PCM,
or Throttle Body Assembly have been replaced, use the scan tool to perform the ETC RELEARN function.
NOTE: 5. When replacing an O2 Sensor, the PCM RAM memory must be cleared, either by disconnecting the
PCM C1 connector or momentarily disconnecting the Battery negative terminal.
6. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when
installing a new O2 sensor. The customermay experience driveability issues if this is not performed.
7. Inspect the vehicle to make sure that all engine components are properlyinstalled and connected. Reassemble
and reconnect components as necessary.
8. Connect the scan tool to the data link connector.
9. Make sure the fuel tank has at least a quarter tank of fuel. Turn off all accessories.
10. If the Catalyst was replaced, with the scan tool go to the MiscellaneousMenu Option
Catalyst Replacedand
press enter.
11. If a Comprehensive Component DTC was repaired, perform steps 12 - 14. Ifa Major OBDII Monitor DTC was
repaired skip those steps and continue verification.
12. After the ignition has been off for at least 10 seconds, restart the vehicle and run 2 minutes.
13. With the scan tool, monitor the appropriate pre-test enabling conditions until all conditions have been met. Once
the conditions have been met, switch screen to the appropriate OBDII monitor, (Audible beeps when the monitor is
running).
14. If the repaired OBDII trouble code has reset or was seen in the monitor while on the road test, the repair is not
complete. Check for any related technical service bulletins or flash updates and return to Engine Electrical Diag-
nostic List.
15. If the conditions cannot be duplicated, erase all DTCs with the Scan tool.
16. If another DTC has set, return to the Engine Electrical Diagnostic Listand follow the path specified for that DTC.
Did the OBDII Monitor run successfully and has the Good Trip Counter changed to one or more?
Ye s>>
Repair is complete.
No>>
Check for any related Technical Service Bulletins and/or refer to the appropriate Diagnostic Procedure.
P0478-HIGH VOLTAGE ON THE ENGINE
BRAKE DRIVER.......................... 1350
P0480-FAN CLUTCH ...................... 1352
P0483-FAN SPEED ....................... 1357
P0500-NO VEHICLE SPEED SENSOR
SIGNAL.................................. 1364
P0513-SKIM INVALID KEY ERROR ......... 1368
P0514-BAT TEMPERATURE SENSOR
RATIONALITY............................ 1370
P0516-LOW VOLTAGE AT THE BAT TEMP
SENSOR................................. 1372
P0517-HIGH VOLTAGE AT THE BAT TEMP
SENSOR................................. 1376
P0521-OIL PRESSURE SWITCH
RATIONALITY............................ 1380
P0524-OIL PRESSURE TOO LOW .......... 1383
P0532-A/C SENDING UNIT VOLTS TOO
LOW..................................... 1385
P0533-A/C SENDING UNIT VOLTS TOO
HIGH.................................... 1391
P0541-LOW VOLTAGE ON THE #1 INTAKE
AIR HEATER RELAY...................... 1396
P0542-HIGH VOLTAGE ON THE #1 INTAKE
AIR HEATER RELAY...................... 1399
P0562-BATTERY VOLTAGE LOW ........... 1402
P0563-BATTERY VOLTAGE HIGH .......... 1406
P0572-LOW VOLTAGE DETECTED AT THE
BRAKE SWITCH.......................... 1409
P0573-HIGH VOLTAGE DETECTED AT THE
BRAKE SWITCH.......................... 1413
P0580-LOW VOLTAGE DETECTED AT THE
SPEED CONTROL SWITCH................ 1416
P0581-HIGH VOLTAGE DETECTED AT THE
SPEED CONTROL SWITCH................ 1420
P0602-CHECKSUM ERROR ............... 1425
P0604-ECM SOFTWARE ERROR .......... 1426
P0606-ECM HARDWARE ERROR .......... 1427
P0607-ECM INTERNAL FAILURE ........... 1428
P0622-GENERATOR FIELD NOT
SWITCHING PROPERLY.................. 1429
P0628-LOW VOLTAGE DETECTED AT THE
FUEL LIFT PUMP......................... 1433
P0629-HIGH VOLTAGE DETECTED AT THE
FUEL LIFT PUMP......................... 1436
P0630-VIN NOT ENTERED ERROR ........ 1439
P0633-SKIM SECRET KEY NOT ENTERED . 1440
P0642-LOW VOLTAGE AT THE #2 SENSOR
SUPPLY CIRCUIT......................... 1441
P0643-HIGH VOLTAGE AT THE #2 SENSOR
SUPPLY CIRCUIT......................... 1445
P0646-LOW VOLTAGE DETECTED AT THE
A/C CLUTCH RELAY...................... 1448
P0647-HIGH VOLTAGE DETECTED AT THE
A/C CLUTCH RELAY...................... 1451
P0652-LOW VOLTAGE AT THE #1 SENSOR
SUPPLY CIRCUIT......................... 1454
P0653-HIGH VOLTAGE AT THE #1 SENSOR
SUPPLY CIRCUIT......................... 1458P0698-ACCELERATOR PEDAL POSITION
SENSOR (APPS) SUPPLY VOLTAGE TOO
LOW..................................... 1461
P0699-ACCELERATOR PEDAL POSITION
SENSOR (APPS) SUPPLY VOLTAGE TOO
HIGH.................................... 1465
P1272-A/C CLUTCH CONTROL CIRCUIT 2
LOW..................................... 1468
P1273-A/C CLUTCH CONTROL CIRCUIT 2
HIGH.................................... 1471
P1274-A/C CLUTCH CONTROL CIRCUIT 2
OPEN.................................... 1475
P1275-A/C CLUTCH CONTROL CIRCUIT 2
OVERCURRENT.......................... 1479
P127C-FUEL PUMP CONTROL CIRCUIT 2
LOW..................................... 1482
P127D-FUEL PUMP CONTROL CIRCUIT 2
HIGH.................................... 1485
P127E-FUEL PUMP CONTROL CIRCUIT 2
OPEN (TIPM)............................. 1489
P0127F-FUEL PUMP CONTROL CIRCUIT 2
OVERCURRENT (TIPM)
................... 1493
P1652-J1850 SHORT TO GROUND ......... 1496
P2121-PPS CONFORMANCE ERROR ...... 1499
P2122-PPS 1 VOLTAGE TOO LOW ......... 1511
P2123-PPS 1 VOLTAGE TOO HIGH ........ 1516
P2127-PPS 2 VOLTAGE TOO LOW ......... 1520
P2128-PPS 2 VOLTAGE TOO HIGH ........ 1525
P2146-BANK 1 (CYLINDERS 1-3) SHORTED
HIGH OR LOW........................... 1529
P2149-BANK 2 (CYLINDERS 4-6) SHORTED
HIGH OR LOW........................... 1537
P2266-WATER IN FUEL (WIF) SENSOR
VOLTAGE TOO LOW...................... 1544
P2269-WATER IN FUEL (WIF) .............. 1547
P2502-CHARGING SYSTEM ERROR ....... 1549
P2503-CHARGING SYSTEM OUTPUT LOW . 1552
P2504-CHARGING SYSTEM OUTPUT HIGH . 1555
P2509-POWERDOWN DATA LOST ERROR . 1559
P2607-LOW VOLTAGE AT THE #2 INTAKE
AIR HEATER RELAY...................... 1563
P2608-HIGH VOLTAGE AT THE #2 INTAKE
AIR HEATER RELAY...................... 1566
P2609-NO VOLTAGE DROP SEEN FROM
INTAKE AIR HEATERS.................... 1569
*CHECKING THE ACCELERATOR PEDAL
SENSOR CALIBRATION................... 1572
*CHECKING THE ECM POWER AND
GROUNDS............................... 1573
* PRESSURE LIMITING VALVE TEST ....... 1574
*ENGINE SURGES ........................ 1575
*ENGINE NO START/HARD START ......... 1578
*FUEL HEATER THERMOSTAT TEST ....... 1581
*IN-TANK FUEL LIFT PUMP FLOW/
DIAGNOSTIC TEST PROCEDURE.......... 1582
*FUEL PUMP RETURN FLOW TEST ........ 1585
*HIGH PRESSURE FUEL PUMP
PERFORMANCE TEST.................... 1586
*INJECTOR RETURN FLOW TEST ......... 1587
POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL)
Diagnostic Test
1.POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL)
1. Clear the DTC before continuing.
2. Check if any of the following conditions exist.
3. The ECM has been disconnected or replaced.
4. The battery power has been disconnected.
5. If the ECM has been replaced, do the following:
6. For ABS and Airbag Systems: Action: Enter correct VIN and Mileage in ECM.Erase ABS and Airbag Module
codes.
NOTE: 7. If the Engine Control Module has been replaced and the correct VIN and mileage have not been
programmed, a DTC will be set in the ABS, Airbag Modules and SKIM module.
8. If the ECM has not been replaced, do the following.
9. Inspect the vehicles to ensure that all engine components are connected. Reassemble and reconnect compo-
nents as necessary.
10. Attempt to start the engine.
11. If the engine is unable to start, look for any Technical Service Bulletins that may relate to this condition. Return
to Symptom list if necessary.
12. If the there are no DTCs present and all components are functional, the repair is complete.
Are any DTC(s) present?
Ye s>>
Repair is not complete, refer to appropriate symptom.
No>>
Repair is complete.
POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL)
Diagnostic Test
1.POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL)
1. Check if any of the following conditions exist.
2. The ECM has been disconnected or replace.
3. The Battery power has been disconnected.
4. If the PCM has been replaced, do the following:
NOTE: 5. If the Engine Control Module has been changed and the correct VIN and mileage have not been
programmed, a DTC will be set in the ABS and Airbag Module.
6. For ABS and Airbag Systems: Enter correct VIN and Mileage in the ECM. Erase ABS and Airbag Module codes.
7. If the ECM has been replaced, do the following.
8. If this verification procedure is being performed after a No Trouble Code repair, do the following.
9. Check to see if the initial symptom still exists. If the initial or another symptom exists, the repair is not complete.
Check all pertinent Technical Service Bulletins and return to the Symptomlist if necessary.
10. If this verification procedure is being performed after a Trouble Coderepair, do the following.
11. Connect the scan tool to the data link connector and erase trouble codes.
12. With the scan tool, reset all memory values.
13. If this test is for an A/C trouble code, ensure it is operating during thefollowing road test.
14. Drive the vehicle for at least five minutes, For some of the drive, go at least 64 km/h (40 MPH). At some point
stop the vehicle and turn the engine off for 10 seconds or more; then restartand continue. Ensure the transmission
shifts through all gears.
15. Upon completion of the road test, turn the engine off and read trouble codeswiththescantool.Ifatroublecode
has been set, return to the Symptom list and follow the path specified.
Is there any DTC(s) present?
Ye s>>
Repair is not complete, refer to appropriate symptom.
No>>
Repair is complete.
POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL)
1.POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL)
1. Check if any of the following conditions exist.
2. The ECM has been disconnected or replace.
3. The Battery power has been disconnected.
4. Inspect the vehicle to ensure that all engine components are properly installed and connected. Reassemble and
reconnect components as necessary.
5. With the DRBIII
,eraseDTCs.
6. If the ECM has been replaced, perform steps 11 through 13, then continue with the verification.
7. If ECM has been changed and correct VIN and mileage have not been programmed, a DTC will be set in ABS
and Air bag modules. In addition, if vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key
data must be updated to enable start.
8. For ABS and Air Bag systems: Enter correct VIN and Mileage in ECM. Erase codes in ABS and Air Bag modules.
9. For SKIM theft alarm: Connect DRBIII
to data link conn. Go to Theft Alarm, SKIM, Misc. and place SKIM in
secured access mode, by using the appropriate PIN code for this vehicle. Select Update the Secret Key data. Data
will be transferred from SKIM to PCM
10. Turn the speed control ON (if equipped, cruise light will be on).
11. Depress and release the SET Switch. If the speed control did not engage,the repair is not complete. Check for
TSBs that pertain to speed control problem and then, if necessary, return to Symptom List.
12. Depress and hold the RESUME/ACCEL Switch. If the vehicle speed did not increase by at least 2 mph, the
repair is not complete. Check for TSBs that pertain to speed control problem and then, if necessary, return to Symp-
tom List.
13. Press and hold the COAST switch. The vehicle speed should decrease. If it did not decrease, the repair is not
complete. Check for TSBs that pertain to speed control problem and then, ifnecessary, return to Symptom List.
14. Using caution, depress and release the brake pedal. If the speed control did not disengage, the repair is not
complete. Check for TSBs that pertain to speed control problem and then, ifnecessary, return to Symptom List.
15. Bring the vehicle speed back up to 35 MPH.
16. Depress the RESUME/ACCEL switch. If the speed control did not resume the previously set speed, the repair
is not complete. Check for TSBs that pertain to speed control problem and then, if necessary, return to Symptom
List.
17. Hold down the SET switch. If the vehicle did not decelerate, the repair is not complete. Check for TSBs that
pertain to speed control problem and then, if necessary, return to SymptomList.
18. Ensure vehicle speed is greater than 35 mph and release the SET Switch. If vehicle did not adjust and set a
new vehicle speed, the repair is not complete. Check for TSBs that pertain to speed control problem and then, if
necessary, return to Symptom List.
19. Depress and release the CANCEL switch. If the speed control did not disengage, the repair is not complete.
Check for TSBs that pertain to speed control problem and then, if necessary, return to Symptom List.
20. Bring the vehicle speed back up above 35 mph and engage speed control.
21. Depress the OFF switch to turn OFF, (Cruise light will be off). If the speed control did not disengage, the repair
is not complete. Check for TSBs that pertain to speed control problem and then, if necessary, return to Symptom
List.
22. If the vehicle successfully passed all of the previous tests, the speedcontrol system is now functioning as
designed. The repair is now complete.
23. NOTE: OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL SET.
24. If the vehicle operator repeatedly presses and releases the SET buttonwith their foot off of the accelerator
(referred to as
lift foot set), the vehicle may accelerate and exceed the desired set speed by up to 5 mph (8km/h).
25. It may also decelerate to less than the desired set speed, before finally achieving the desired set speed.
26. The Speed Control System has an adaptive strategy that compensates forvehicle-to-vehicle variations in speed
control cable lengths.
27. When the speed control is set with the vehicles operators foot off of theaccelerator pedal, the speed control
thinks there is excessive speed control cable slack and adapts accordingly.
28. If the
lift foot setsare continually used, a speed control overshoot/undershoot condition will develop.
29. To
unlearnthe overshoot/undershoot condition, the vehicle operator has to press and release the set button
POWERTRAIN VERIFICATION TEST VER - 5 (DIESEL)
Diagnostic Test
1.POWERTRAIN VERIFICATION TEST VER - 5 (DIESEL)
1. Check if any of the following conditions exist.
2. The ECM has been disconnected or replace.
3. The Battery power has been disconnected.
4. Inspect the vehicle to ensure that all engine components are properly installed and connected. Reassemble and
reconnect components as necessary.
5. If any existing diagnostic trouble codes have not been repaired, go to Symptom List and follow path specified.
6. Connect the scan tool to the data link connector.
7. Ensure the fuel tank has at least a quarter tank of fuel. Turn off all accessories.
8. Perform steps 15 through 17 if the PCM has been replaced. Then proceed with the verification. If the ECM has
not been replaced skip those steps and continue verification.
9. If ECM has been changed and correct VIN and mileage have not been programmed, a DTC will be set in ABS
and Air bag modules. In addition, if vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key
data must be updated to enable start.
10. For ABS and Air Bag systems: Enter correct VIN and Mileage in ECM. Erase codes in ABS and Air Bag mod-
ules.
11. For SKIM theft alarm: Connect scan tool to data link connector to Theft Alarm, SKIM, Misc. and place SKIM in
secured access mode by using appropriate PIN code for this vehicle. SelectUpdate the Secret Key data. Data will
be transferred from SKIM to PCM.
12. If a Comprehensive Component DTC was repaired, perform steps 10-13. Ifa Major OBDII Monitor DTC was
repaired skip those steps and continue verification.
13. After the ignition has been off for at least 10 seconds, restart the vehicle and run 2 minutes.
14. If there are no new DTC’s, the repair was successful and is now complete.Erase DTC’s and disconnect the
scan tool.
15. If the repaired DTC has reset, the repair is not complete. Check for any related TSB’s or flash updates and
return to the Symptom list.
16. If another DTC has set, return to the Symptom List and follow the path specified for that DTC.
17. With the scan tool, monitor the appropriate pre-test enabling conditions until all conditions have been met. Once
the conditions have been met, switch screen to the appropriate OBDII monitor, (Audible beeps when the monitor is
running).
18. If the monitor ran, the repair was successful and is now complete. EraseDTC’s and disconnect the scan tool.
19. If the repaired OBDII trouble code has reset or was seen in the monitor while on the road test, the repair is not
complete. Check for any related technical service bulletins or flash updates and return to Symptom List.
20. If another DTC has set, return to the Symptom List and follow the path specified for that DTC.
Is any DTC(s) present?
Ye s>>
Repair is not complete, refer to appropriate symptom.
No>>
Repair is complete.
When Monitored:
With the ignition on and battery voltage greater than 10.4 volts.
Set Condition:
The circuit voltage to the ECM falls below a calibrated threshold for a certain period of time.
Possible Causes
SENSOR OUT OF SPEC
HARNESS SHORTED (SENSOR SIDE)
(K668) 5-VOLT SUPPLY OPEN
HARNESS SHORTED (ECM SIDE)
INTERMITTENT CONDITION
ECM
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.INLET AIR TEMP SENSOR OUT OF SPEC
Turn the ignition off.
Disconnect the Inlet Air Temp sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the temperature sensor.
Is the resistance between 300 and 90k ohms?
Ye s>>
Go To 2
No>>
Replace the sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 9 - ENGINE- DIAGNOSIS
AND TESTING)
2.INTERMITTENT CONDITION
Reconnect the Inlet Air Temp Sensor harness connector.
Turn the ignition on.
With the scan tool, erase DTCs.
With the scan tool, read DTCs.
Did the DTC return?
Ye s>>
Go To 3
No>>
Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
When Monitored:
With ignition on and battery voltage greater than 10.4 volts.
Set Condition:
The circuit voltage to the ECM is above a calibrated threshold for a certainperiod of time.
Possible Causes
DTC RETURNS
INLET AIR TEMPERATURE SENSOR
(K615) SIGNAL CIRCUIT OPEN
(K690) RETURN CIRCUIT OPEN
(K615) SIGNAL CIRCUIT SHORTED
INTERMITTENT CONDITION
ECM
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.DTC RETURNS
Turn the ignition on.
With the scan tool, erase DTCs.
With the scan tool, read DTCs.
With the scan tool, record all Freeze frame data.
Did the DTC return?
Ye s>>
Go To 2
No>>
Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
2.INLET AIR TEMPERATURE SENSOR
Turn the ignition off.
Disconnect the Inlet Air Temp sensor harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the Inlet Air temp sensor
Is the resistance between 300 and 90k ohms?
Ye s>>
Go To 3
No>>
Replace the Inlet air temperature sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING).