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Powertrain Control Module (PCM) Control Modules

The control module refers to the powertrain control module (PCM). The control module is designed to maintain exhaust emission levels to Federal or California standards while providing excellent driveability and fuel efficiency. Review the components and wiring diagrams in order to determine which systems are controlled by each specific control module. The control module monitors numerous engine and vehicle functions. The control module controls the following operations:

    • Fuel control
    • Ignition control (IC)
    • Knock sensor (KS) system
    • Automatic transmission shift functions
    • Cruise control enable
    • Generator
    • Evaporative emission (EVAP) purge
    • A/C clutch control

Control Module Function

The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the control module include an analog to digital converters, signal buffers, counters, and special drivers. The control module controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7 called one of the following:

    • The quad driver module
    • The output driver modules

The surface mounted quad driver module can independently control up to 4 outputs (control module) terminals. The output driver modules can independently control up to 7 outputs. Not all outputs are always used.

Use of Circuit Testing Tools

Do not use a test lamp in order to diagnose the powertrain electrical systems unless specifically instructed by the diagnostic procedures. Use the J 35616-A Connector Test Adapter Kit whenever the diagnostic procedures call for probing any of the connectors.

Control Module Service Precautions

The control module is designed to withstand the normal current draws that are associated with the vehicle operations. Avoid overloading any circuit. When testing for opens or shorts, do not ground any of the control module circuits unless instructed. When testing for opens or shorts, do not apply voltage to any of the control module circuits unless instructed. Only test these circuits with DMM J 39200 , while the control module connectors remain connected to the control module.

Aftermarket (Add-On) Electrical And Vacuum Equipment

The aftermarket (add-on) electrical and vacuum equipment is defined as any equipment that is installed on a vehicle after leaving the factory that connects to the electrical or vacuum systems of the vehicle. No allowances have been made in the vehicle design for this type of equipment.

Notice: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems.

Notice: Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle.

The add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include any equipment which is not connected to the electrical system of the vehicle such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain problem is to remove all of the aftermarket electrical connections from the vehicle. After this is done, if the problem still exists, diagnose the problem in the normal manner.

Electrostatic Discharge Damage

Notice: In order to prevent possible Electrostatic Discharge damage to the PCM, Do Not touch the connector pins or the soldered components on the circuit board.

The electronic components used in the control systems are often designed in order to carry very low voltage. The electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off, leaving the person highly charged with the opposite polarity. Static charges can cause damage. Use care when handling and testing the electronic components.

Engine Controls Information

The driveability and emissions information describes the function and operation of the control module. The emphasis is placed on the diagnosis and repair of problems related to the system.

Engine components, wiring diagrams, and diagnostic tables:

    • The component locations
    • The wiring diagrams
    • The control module terminal end view and terminal definitions
    • The On-Board Diagnostic (OBD) System Check
    • The diagnostic trouble code (DTC) tables

The Component System includes the following items:

    • The component and circuit description
    • The On-vehicle service for each sub-system
    • The functional checks with the diagnostic tables
    • How to use electrical systems diagnostic information

The DTCs also contain the diagnostic support information containing the circuit diagrams, the circuit or the system information, and helpful diagnostic information.

Maintenance Schedule

Refer to the General Motors Maintenance Schedule in General Information of the appropriate service manual for the maintenance that the owner or technician should perform in order to retain emission control performance.

Visual and Physical Underhood Inspection

Perform a careful visual and physical underhood inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a problem without further steps. Use the following guidelines when performing a visual and physical inspection:

    • Inspect all of the vacuum hoses for the following conditions:
       - Correct routing
       - Pinches
       - Cuts
       - Disconnects
    • Inspect the hoses that are difficult to see beneath the air cleaner, the A/C compressor, the generator, etc.
    • Inspect all of the wires in the engine compartment for the following items:
       - Proper connections
       - Burned or chafed spots
       - Pinched wires
       - Contact with sharp edges
       - Contact with hot exhaust manifolds

This visual and physical inspection is very important. Perform the inspection carefully and thoroughly.

Basic Knowledge Of Tools Required

Notice: Lack of basic knowledge of this powertrain when performing diagnostic procedures could result in incorrect diagnostic performance or damage to powertrain components. Do not attempt to diagnose a powertrain problem without this basic knowledge.

A basic understanding of hand tools is necessary in order to effectively use this information.

System Status and Drive Cycle For Satisfying the Federal Inspection/Maintenance (I/M 240) Regulations

The system status selection is included in the scan tool System Info menu.

Several states require that the I/M 240 (OBD ll system) pass on-board tests for the major diagnostics prior to having a vehicle emission inspection. This is also a requirement to renew license plates in some areas.

Using a scan tool, the technician can observe the system status, complete or not complete, in order to verify that the vehicle meets the criteria which complies with local area requirements. Using the system status display, any of the following systems or a combination of the systems may be monitored for I/M readiness:

    • The catalyst
    • The HO2S
    • The HO2S heater

Important: The system status display indicates only whether or not the test has been completed. The system status display does not necessarily mean that the test has passed. If a Failed Last Test indication is present for a DTC associated with one of the above systems, that test is failed. Diagnosis and repair is necessary in order to meet the I/M 240 requirement. Verify that the vehicle passes all of the diagnostic tests associated with the displayed system status prior to returning the vehicle to the customer. Refer to the Typical OBD II Drive Cycle table to use as a guide to complete the I/M 240 system status tests. More than one drive cycle may be needed.

Following a DTC info clear, the system status will clear only for the systems affected by any DTCs stored. Following a battery disconnect or a control module replacement, all of the system status information will clear.

Typical OBD II Drive Cycle

Diagnostic Time Schedule for I/M Readiness

Vehicle Drive Status

What is Monitored?

Cold Start, coolant temperature less than 50°C (122°F)

--

Idle 2.5 minutes in Drive (Auto) Neutral (Man), A/C and rear defogger ON

HO2S Heater, Misfire, Secondary Air, Fuel Trim, EVAP Purge

A/C off, accelerate to 90 km/h (55 mph), 1/2 throttle.

Misfire, Fuel Trim, Purge

3 minutes of Steady State - Cruise at 90 km/h (55 mph)

Misfire, EGR, Secondary Air, Fuel Trim, HO2S, EVAP Purge

Clutch engaged (Man), no braking, decelerate to 32 km/h (20 mph)

EGR, Fuel Trim, EVAP Purge

Accelerate to 90-97 km/h (55-60 mph), 3/4 throttle

Misfire, Fuel Trim, EVAP Purge

5 minutes of Steady State Cruise at 90-97 km/h (55-60 mph)

Catalyst Monitor, Misfire, EGR, Fuel Trim, HO2S, EVAP Purge

Decelerate, no breaking. End of Drive Cycle

EGR, EVAP Purge

Total time of OBD II Drive Cycle 12 minutes

--

Primary System Based Diagnostics

There are primary system-based diagnostics which evaluate the system operation and their effect on vehicle emissions. The primary system-based diagnostics are listed below, with a brief description of the diagnostic functionality.

Oxygen Sensor Diagnosis

Diagnose the fuel control oxygen sensors (O2S) for the following conditions:

    • A slow response
    • Response time, time to switch R/L or L/R
    • An inactive signal, output steady at bias voltage--approximately 450 mV
    • A signal fixed high
    • A signal fixed low

Diagnose the catalyst monitor heated oxygen sensors (HO2S) for the following functions:

    • Heater performance, time to activity on cold start
    • Signal fixed low during steady state conditions or power enrichment--hard acceleration when a rich mixture should be indicated
    • Signal fixed high during steady state conditions or decel fuel mode, deceleration when a lean mixture should be indicated
    • Inactive sensor, output steady at approximately 438 mV

Fuel Control Oxygen Sensors (O2S)


Object Number: 18519  Size: SH

The main function of the fuel control heated oxygen sensor is to provide the control module with exhaust stream information in order to allow proper fueling and to maintain emissions within the mandated levels. After the sensor reaches the operating temperature, the sensor generates a voltage inversely proportional to the amount of oxygen present in the exhaust gases.

The control module uses the signal voltage from the fuel control heated oxygen sensors in a Closed Loop in order to adjust the fuel injector pulse width. While in Closed Loop, the control module can adjust fuel delivery in order to maintain an air-to-fuel ratio which allows the best combination of emission control and driveability.

If the oxygen sensor pigtail wiring, connector or terminals are damaged, replace the entire oxygen sensor assembly. Do not attempt to repair the wiring, the connector, or the terminals. In order for the sensor to function properly, the sensor must have a clean air reference provided. This clean air reference is obtained by way of the oxygen sensor wires. Any attempt to repair the wires, the connectors or the terminals could result in the obstruction of the air reference. Any attempt to repair the wires, the connectors or the terminals could degrade the oxygen sensor performance.

HO2S Heater


Object Number: 10975  Size: SH

The oxygen sensor heaters are required by catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine.

Catalyst Monitor Heated Oxygen Sensors (HO2S)

In order to control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), the system uses a three-way catalytic converter. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen.

The control module has the ability to monitor this process using the heated oxygen sensors (HO2S). The HO2S produces an output signal which indicates the oxygen storage capacity of the catalyst, this in turn indicates the catalyst's ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the O2S signal will be far more active than that produced by the HO2S.

Catalyst Monitor Diagnostic Operation

The OBD II catalyst monitor diagnostic measures oxygen storage capacity. In order to do this, the heated sensors are installed before and after the three-way catalyst (TWC). The voltage variations between the sensors allow the control module to determine the catalyst emission performance.

As a catalyst becomes less effective in promoting chemical reactions, the capacity of the catalyst to store and release oxygen generally degrades. The OBD II catalyst monitor diagnostic is based on a correlation between conversion efficiency and oxygen storage capacity.

A good catalyst, which operates at approximately 95 percent hydrocarbon conversion efficiency, shows a relatively flat output voltage on the post-catalyst heated oxygen sensor (HO2S). A degraded catalyst, which may operate at approximately 65 percent hydrocarbon conversion, shows a greatly increased activity in output voltage from the post catalyst HO2S.

The post-catalyst HO2S 2 is used to measure the oxygen storage and release capacity of the catalyst. A high oxygen storage capacity indicates a good catalyst. Low oxygen storage capacity indicates a failing catalyst. The TWC, the HO2S 2, and the HO2S 3 must be at operating temperature in order to achieve correct oxygen sensor voltages like those shown in the post-catalyst HO2S 3 outputs graphic.

The catalyst monitor diagnostic is sensitive to the following conditions:

    • Exhaust leaks
    • HO2S contamination
    • Alternate fuels

Exhaust system leaks can lead to the following results:

    • Prevent a degraded catalyst from failing the diagnostic
    • Cause a false failure for a normally functioning catalyst
    • Prevent the diagnostic from running

Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants prevents the TWC diagnostic from functioning properly.

Three-Way Catalyst Oxygen Storage Capacity


Object Number: 14442  Size: SH

The control module must monitor the three-way catalyst (TWC) system for efficiency. In order to accomplish this, the control module monitors the pre-catalyst and post-catalyst oxygen sensors. When the TWC is operating properly, the post-catalyst (2) oxygen sensor will have significantly less activity than the pre-catalyst (1) oxygen sensor. The TWC stores the oxygen as needed during the normal reduction and oxidation process. The TWC releases oxygen as needed during the normal reduction and oxidation process. The control module calculates the oxygen storage capacity using the difference between the pre-catalyst and post-catalyst oxygen sensor voltage levels.


Object Number: 14446  Size: SH

Whenever the voltage levels of the post-catalyst (2) oxygen sensor nears the voltage levels that of the pre-catalyst (1) oxygen sensor, the efficiency of the catalyst is degraded.

Stepped or staged testing levels allow the control module to statistically filter the test information. This prevents falsely passing or falsely failing the oxygen storage capacity test. The calculations performed by the On-Board Diagnostic System are very complex. For this reason, do not use post catalyst oxygen sensor activity in order to determine the oxygen storage capacity unless you are directed to do this by the service information.

Three stages are used in order to monitor catalyst efficiency. Failure of the first stage indicates that the catalyst requires further testing in order to determine catalyst efficiency. Failure of the second stage indicates that the catalyst may be degraded. The third stage then looks more closely at the inputs from the pre and post O2S before determining if the catalyst is indeed degraded. This further statistical processing is done in order to increase the accuracy of the oxygen storage capacity type monitoring. Failing the first (stage 0) or the second (stage 1) test DOES NOT indicate a failed catalyst. The catalyst may be marginal or the fuel sulfur content could be very high.

Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an aftermarket catalyst does not contain the same amount of cerium as the original part, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC.

Fuel Tank Pressure Sensor


Object Number: 12758  Size: LF
(1)EVAP Purge Solenoid Ignition Feed
(2)Intake Manifold
(3)Fuel Tank Pressure Sensor
(4)Fuel Tank Pressure Sensor Ground Circuit
(5)Fuel Tank Pressure Sensor Signal Circuit
(6)Fuel Tank Pressure Sensor 5 Volt Reference Circuit
(7)Fuel Filler Neck
(8)Rollover Valve
(9)Fuel Tank
(10)EVAP Vent Valve Filter
(11)EVAP Vent Valve
(12)EVAP Vent Valve Control Circuit
(13)EVAP Valve Ignition Feed
(14)EVAP Canister
(15)EVAP Purge Solenoid
(16)EVAP Purge Solenoid Control Circuit

The EVAP system uses a Fuel Tank Pressure Sensor (located on top of the fuel tank sender unit.) in order to detect when the EVAP system is purging. The Fuel Tank Pressure Sensor detects the flow from the engine through the EVAP Canister Purge Solenoid Valve. When the EVAP system is not purging, the fuel tank pressure sensor will detect no change in fuel tank vacuum. When the EVAP System is purging, the Fuel Tank Pressure Sensor will detect a vacuum in the fuel tank. A change in Fuel Tank Pressure will be displayed on the scan tool.

If any of the following EVAP malfunctions are present:

    • Leak
    • Plug
    • Malfunctioning Fuel Tank Pressure Sensor

One of the following DTCs will set:

    • P0440
    • P0442
    • P0446
    • P1441

If any of these DTCs are set, go to the DTC table for diagnosis.

Misfire Monitor Diagnostic Operation

The misfire monitor diagnostic is based on the crankshaft rotational variations, or reference period. The control module determines the crankshaft rotational velocity using the crankshaft position (CKP) sensor and the camshaft position (CMP) sensor. When a cylinder misfires, the crankshaft slows down momentarily. By monitoring the crankshaft and camshaft position sensor signals, the control module can calculate when a misfire occurs.

For a non-catalyst damaging misfire, the diagnostic is required to monitor a misfire present for between 1000-3200 engine revolutions.

For a catalyst damage misfire, the diagnostic responds to the misfire within 200 engine revolutions.

Rough roads may cause a false misfire detection. A rough road applies torque to the drive wheels and the drive train. This torque can intermittently decrease the crankshaft rotational velocity. The control module detects this as a false misfire.

On the automatic transmission equipped vehicles, the torque converter clutch (TCC) will disable whenever a misfire is detected. Disabling the TCC isolates the engine from the rest of the drive line and minimizes the effect of the drive wheel inputs on the crankshaft rotation.

When the TCC has disabled as a result of misfire detection, the TCC will re-enable after approximately 3200 engine revolutions if no misfire is detected. The TCC remains disabled whenever the misfire is detected, with or without a DTC set. This allows the misfire diagnostic to re-evaluate the system.

During a transmission high temperature condition, the misfire diagnostic will disable and the TCC will operate normally. This avoids further increasing the temperature of the transmission.

Misfire Counters


Object Number: 17379  Size: LF

Whenever a cylinder misfires, the misfire diagnostic counts the misfires. Then the misfire diagnostic notes the crankshaft position at the time the misfire occurred. These misfire counters are basically a file on each engine cylinder.

A current and a history misfire counter is maintained for each cylinder. The misfire current counters indicate the number of firing events out of the last 200 cylinder firing events which were misfires. The misfire current counters display real time data without a misfire DTC stored. The misfire history counters indicate the total number of cylinder firing events which were misfires. The misfire history counters display 0 until the misfire diagnostic has failed and a DTC P0300 is set. Once the misfire DTC sets, the misfire history counters will be updated every 200 cylinder firing events.

The misfire counters graphic illustrates how these misfire counters are maintained. If the misfire diagnostic reports a failure, the diagnostic executive reviews all of the misfire counters before reporting a DTC. This way, the diagnostic executive reports the most current information.

When crankshaft rotation is erratic, the control module detects a misfire condition. Because of this erratic condition, the data that is collected by the diagnostic can sometimes incorrectly identify which cylinder is misfiring. The misfire counters graphic shows there are misfires counted from more than one cylinder. Cylinder #1 has the majority of counted misfires. In this case, the misfire counters would identify cylinder #1 as the misfiring cylinder. The misfires in the other counters were just background noise caused by the erratic rotation of the crankshaft. If the number of accumulated is sufficient for the diagnostic to identify a true misfire, the diagnostic will set DTC P0300.

Use Techline™ equipment to monitor misfire counter data on OB  ll compliant vehicles. Knowing which specific cylinders misfired can lead to the root cause, even when dealing with a multiple cylinder misfire. Using the information in the misfire counters, identify which cylinders are misfiring. If the counters indicate cylinders numbers 1 and 4 misfired, look for a circuit or component common to both cylinders number 1 and 4, such as an open ignition coil in an electronic ignition system.

The misfire counter information is located in the specific eng. menu, misfire data sub-menu of the data list.

The misfire diagnostic may indicate a fault due to a temporary fault not necessarily caused by a vehicle emission system malfunction. Possible malfunctions include the following conditions:

    • Contaminated fuel
    • Running out of fuel
    • Fuel fouled spark plugs
    • Basic engine fault

Fuel Trim System Monitor Diagnostic Operation

This system monitors the averages of short and long term FT values. If these fuel trim values stay at their limits for a calibrated period of time, a malfunction is indicated. The fuel trim diagnostic compares the averages of short term FT values and long term FT values to rich and lean thresholds. If either value is within the thresholds, a pass is recorded. If either value is outside their thresholds, a rich or lean diagnostic trouble code (DTC) will set.

In order to meet OBD ll requirements, the control module uses weighted fuel trim cells in order to determine the need to set a fuel trim DTC. A fuel trim DTC can only be set if fuel trim counts in the weighted fuel trim cells exceed specifications. This means that the vehicle could have a fuel trim problem which is causing a concern under certain conditions (i.e. engine idle high due to a small vacuum leak or rough due to a large vacuum leak) while the vehicle operates fine at other times. No fuel trim DTC would set (although an engine idle speed DTC or O2S DTC may set). Remember, use a scan tool in order to observe fuel trim counts while the problem is occurring.

Remember, a fuel trim DTC may be triggered by a list of vehicle faults. Make use of all information available, including other DTCs stored, rich or lean condition, etc., when diagnosing a fuel trim fault.

Comprehensive Component Monitor Diagnostic

The comprehensive component monitoring diagnostics are required to monitor emissions-related input and output powertrain components. The CARB OBD II comprehensive component monitoring list of components Intended to illuminate the malfunction indicator lamp (MIL) is a list of components, features or functions that could fall under this requirement.

Input Components

The control module monitors the input components for circuit continuity and out-of-range values. This includes performance checking. Performance checking refers to indicating a fault when the signal from a sensor does not seem reasonable, for example, a throttle position (TP) sensor that indicates high TP at low engine loads or MAP voltage. The input components may include but are not limited to the following sensors:

    • The vehicle speed sensor (VSS)
    • The crankshaft position (CKP) sensor
    • The knock sensor (KS)
    • The throttle position (TP) sensor
    • The engine coolant temperature (ECT) sensor
    • The camshaft position (CMP) sensor
    • The manifold absolute pressure (MAP) sensor
    • The mass air flow (MAF)

In addition to the circuit continuity and rationality check, the ECT sensor is monitored for the ability to achieve a steady state temperature in order to enable a closed loop fuel control.

Output Components

The output components respond to control module commands. Components where functional monitoring is not feasible will be monitored for circuit continuity and out-of-range values if applicable.

Output components to be monitored include, but are not limited to the following circuits:

    • The idle air control (IAC) motor
    • The control module controlled EVAP canister purge valve
    • The electronic transmission controls
    • The A/C relay
    • The cooling fan relay
    • The VSS output
    • The MIL control
    • The cruise control inhibit

California Air Resources Board (CARB) OBD II Comprehensive Component Monitoring List of Components Intended to Illuminate MIL

Important: Not all vehicles have these components:

    • Transmission range (TR) mode pressure switch
    • Transmission turbine speed sensor (HI/LO)
    • Transmission vehicle speed sensor (HI/LO)
    • Ignition sensor (cam sync, diag)
    • Ignition sensor hi resolution (7x)
    • Knock sensor (KS)
    • Engine coolant temperature (ECT) sensor
    • Intake air temperature (IAT) sensor
    • Throttle position (TP) sensor A, B
    • Manifold absolute pressure (MAP) sensor
    • Mass air flow (MAF) sensor
    • Automatic transmission temperature sensor
    • Transmission torque converter clutch (TCC) control solenoid
    • Transmission TCC enable solenoid
    •  Transmission shift solenoid A
    • Transmission shift solenoid B
    • Transmission 3/2 shift solenoid
    • Ignition control (IC) system
    • Idle air control (IAC) coil
    • Evaporative emission purge vacuum switch
    • Evaporative emission canister purge (EVAP canister purge)

Wiring Harness Service

The control module harness electrically connects the control module to the various solenoids, switches, and sensors in the vehicle engine room and passenger compartment.

Replace the wire harnesses with the proper part number replacement. When splicing signal wires into a harness, use the wiring that has high temperature insulation.

Consider the low amperage and voltage levels utilized in the Powertrain control systems. Make the best possible bond at all splices. Use rosin-core solder in these areas.

Molded-on connectors require complete replacement of the connector. Splice a new connector into the harness. Replacement connectors and terminals are listed in Group 8.965 in the Standard Parts Catalog.

For wiring repair, refer to Wiring Repairs in Wiring Systems.

Connectors and Terminals

In order to prevent shorting between opposite terminals, use care when probing a connector and when replacing terminals. Damage to the components could result.

Always use jumper wires between connectors for circuit checking.

Never probe through the Weather-Pack seals.

Use the Tachometer Adapter J 35812, or the equivalent, which provides a convenient connection to the tachometer lead. The J 35616-A Connector Test Adapter Kit , or the equivalent, contains an assortment of flexible connectors used in order to probe the terminals during the diagnosis. The fuse remover and the BT-8616 test tool, or the equivalent, is used for removing a fuse and to adapt the fuse holder to a meter for diagnosis.

Open circuits are often difficult to locate by sight because oxidation or terminal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor or in the wiring harness may temporarily correct the open circuit. Oxidized or loose connections may cause intermittent problems.

Be certain the type of connector and terminal before making any connector or terminal repair. Weather-Pack and Com-Pack III terminals look similar, but are serviced differently.

Powertrain Control Module (PCM) Serial Data Communication

Class 2 Serial Data

U.S. Federal regulations require that all automobile manufacturers establish a common communications system. This vehicle utilizes the Class 2 communications system. Each bit of information can have one of two lengths, long or short. This allows the vehicle wiring to be reduced by the transmission and reception of the multiple signals over a single wire. The messages which are carried on Class 2 data streams are also prioritized. In other words, if two messages attempt to establish communications on the data line at the same time, only the message with the higher priority will continue. The device with the lower priority message must wait. The most significant result of this regulation is that the regulation provides the scan tool manufacturers with the capability of accessing the data from any make or model vehicle sold in the United States.

The Diagnostic Executive

The Diagnostic Executive is a unique segment of the software which is designed to coordinate and prioritize the diagnostic procedures as well as define the protocol for recording and displaying their results. The Diagnostic Executive has the following main responsibilities:

    • Monitoring the diagnostic test enabling conditions
    • Requesting the malfunction indicator lamp (MIL)
    • Illuminating the MIL
    • Recording pending, current, and history DTCs
    • Storing and Erasing Freeze Frame Data
    • Monitoring and recording test status information

On-Board Diagnostic Tests

A diagnostic test is a series of steps which has a beginning and an end. The result of which is a pass or fail reported to the diagnostic executive. When a diagnostic test reports a pass result, the diagnostic executive records the following data:

    • The diagnostic test has completed since the last ignition cycle.
    • The diagnostic test has passed during the current ignition cycle.
    • The fault identified by the diagnostic test is not currently active.

When a diagnostic test reports a fail result, the diagnostic executive records the following data:

    • The diagnostic test has completed since the last ignition.
    • The fault identified by the diagnostic test is currently active.
    • The fault has been active during this ignition cycle.
    • The operating conditions at the time of the failure.

Trip

The ability for a diagnostic test to run depends largely upon whether or not a trip has been completed. A trip for a particular diagnostic is defined as a key ON and key OFF cycle in which all the enabling criteria for a given diagnostic have been met allowing the diagnostic to run. The requirements for trips vary as they may involve items of an unrelated nature, such as driving style, length of trip, ambient temperature, etc. Some diagnostic tests run only once per trip (e.g., catalyst monitor) while others run continuously (e.g., misfire and fuel system monitors). If the proper enabling conditions are not met during that ignition cycle, the tests may not be complete or the test may not have run.

Warm-Up Cycle

A warm-up cycle consists of an engine start-up and vehicle operation such that the coolant temperature has risen more than 4°C (40°F) from the start-up temperature and reached a minimum engine coolant temperature of 71°C (160°F). If this condition is not met during the ignition cycle, the diagnostic may not run.

Diagnostic Information

The diagnostic tables and the functional checks are designed in order to locate a poor circuit or a malfunctioning component through a process of logical decisions. The tables are prepared with the assumption that the vehicle functioned correctly at the time of assembly and that there are no multiple faults present.

There is a continuous self-diagnosis on certain control functions. This diagnostic capability is complemented by the diagnostic procedures which are contained in this manual. The language of communicating the source of the malfunction is a system of diagnostic trouble codes. When a malfunction is detected by the control module, a diagnostic trouble code will set and the malfunction indicator lamp (MIL) will illuminate on some applications.

Malfunction Indicator Lamp (MIL)

The malfunction indicator lamp (MIL) is on the instrument panel. The MIL has the following functions:

    • The MIL informs the driver that a fault that affects the emission levels of the vehicle has occurred. The owner should take the vehicle in for service as soon as possible.
    • As a bulb and system check, the MIL comes ON with the key ON and the engine not running. When the engine is started, the MIL turns OFF if no DTCs are set.

When the MIL remains ON while the engine is running, or when a malfunction is suspected due to a driveability or emissions problem, perform an On-Board Diagnostic (OBD) System Check. The procedures for these checks are given in engine controls. These checks expose faults which the technician may not detect if other diagnostics are performed first.

MIL Requests and History Codes

The diagnostic executive must acknowledge when all the emissions related diagnostic tests have reported a pass or fail condition since the last ignition cycle. Each diagnostic test is separated into 4 types:

    • Type A is emissions related and turns ON the MIL the first time the diagnostic executive reports a fault.
    • Type B is emissions related and turns ON the MIL if the fault is active for 2 consecutive driving cycles.
    • Type C is non-emissions related and does not turn ON the MIL but will turn on the service light.
    • Type X is non-emissions related and does not turn ON the MIL or the service light.

When a type A diagnostic test reports a failure, the diagnostic executive immediately requests to have the MIL turn ON for that diagnostic test. When a type B diagnostic test reports a failure during 2 consecutive trips, the diagnostic executive turns on the MIL for that diagnostic test. The diagnostic executive has the option of turning the MIL OFF when the diagnostic test which caused the MIL to illuminate the passes for 3 consecutive trips. In the case of misfire or fuel trim malfunctions, there are additional requirements as follows:

    • The load conditions must be within 10 percent of the vehicle load present when the diagnostic executive reported the failure.
    • The engine speed conditions must be within 375 RPM of the engine speed present when the diagnostic executive reported the failure.
    • The engine coolant temperature must have been in the same range present when the diagnostic executive reported the failure.

When the diagnostic executive requests the service light to be turned ON or a type C diagnostic fault is reported, a history DTC is also recorded for the diagnostic test. The provision for clearing a history DTC for any diagnostic tests requires 40 subsequent warm-up cycles during which no diagnostic tests have reported a fail, a battery disconnect, or a scan tool clear info command.

Special Cases Of Type A Diagnostic Tests

Unique to the misfire diagnostic, the diagnostic executive has the capability of alerting the driver of potentially damaging levels of misfire. If a misfire condition exists that could potentially damage the catalytic converter, the diagnostic executive will command the MIL to flash at a rate of once per second during the times that the catalyst damaging misfire condition is present.

Special Cases Of Type B Diagnostic Tests

Misfire and fuel trim malfunctions are special cases of type B diagnostics. Each time a fuel trim malfunction is detected, the engine load, the engine speed, and the engine coolant temperatures are recorded.

When the ignition is turned OFF, the last reported set of conditions remain stored. During subsequent ignition cycles, the stored conditions are used as a reference for similar conditions. If a fuel trim malfunction occurs during 2 consecutive trips, the diagnostic executive treats the failure as a normal type B diagnostic. The diagnostic executive does not use the stored conditions. However, if a fuel trim malfunction occurs on 2 non-consecutive trips, the stored conditions are compared with the current conditions. The MIL will then illuminate under the following conditions:

    • When the engine load conditions are within 10 percent of the previous test that failed.
    • The engine speed is within 375 RPM of the previous test that failed.
    • The engine coolant temperature is in the same range as the previous test that failed.

Storing And Erasing Freeze Frame Data

Government regulations require that the engine operating conditions are to be captured whenever the MIL is illuminated. The data that is captured is called Freeze Frame data. The Freeze Frame data is very similar to a single record of operating conditions. Whenever the MIL is illuminated, the corresponding record of operating conditions is recorded to the Freeze Frame buffer.

Each time a diagnostic test reports a failure, the current engine operating conditions are recorded in the failure records buffer. A subsequent failure will update the recorded operating conditions. The following operating conditions for the diagnostic test which failed typically include the following parameters:

    • The air fuel ratio
    • The air flow rate
    • The fuel trim
    • The engine speed
    • The engine load
    • The engine coolant temperature
    • The vehicle speed
    • The throttle position (TP) angle
    • The manifold absolute pressure/barometric pressure (MAP/BARO)
    • The injector base pulse width
    • The loop status

Freeze Frame data can only be overwritten with the data associated with a misfire or a fuel trim malfunction. The data from these faults take precedence over data that is associated with any other fault. The Freeze Frame data will not be erased unless the associated history DTC is cleared.

Intermittent Malfunction Indicator Lamp

In the case of an intermittent fault, the malfunction indicator lamp (MIL) may illuminate and then after 3 trips turn OFF. However, the corresponding diagnostic trouble code will store in the memory. When unexpected diagnostic trouble codes appear, check for an intermittent malfunction.

Data Link Connector (DLC)

The provision for communicating with the control module is a data link connector (DLC). The DLC is usually located under the instrument panel. The DLC is used in order to connect to a scan tool. Some common uses of the scan tool are listed below:

    • Identifying stored diagnostic trouble codes (DTCs).
    • Clearing the DTCs
    • Performing the output control tests.
    • Reading the serial data.

Control Module Learning Ability

The control module has a learning ability which allows the control module to make corrections for minor variations in the fuel system in order to improve driveability. Whenever the battery cable is disconnected, the learning process resets.

The driver may note a change in vehicle performance. In order to allow the PCM to re-learn to drive the vehicle at part throttle with moderate acceleration. The vehicle may also operate at idle conditions until the normal performance returns.

Reprogramming (Flashing) The Control Module

Some vehicles allow the reprogramming of the control module without removal from the vehicle. This provides a flexible and a cost-effective method of making changes in software and calibrations.

Refer to the latest Techline information on reprogramming or flashing procedures.

Verifying Vehicle Repair

Verification of the vehicle repair will be more comprehensive for vehicles with OBD II system diagnostics. Following a repair, the technician should perform the following steps:

  1. Review the fail records and the Freeze Fame data for the DTC which was diagnosed. Record the fail records or Freeze Fame data. The Freeze Frame data will only store for an A or B type diagnostic.
  2. Clear the DTCs.
  3. Operate the vehicle within the conditions noted in the fail records or the Freeze Frame data.
  4. Monitor the DTC status information for the specific DTC which has been diagnosed until the diagnostic test associated with that DTC runs.

Following these steps are very important in verifying repairs on the OBD II systems. Failure to follow these steps could result in an unnecessary repair.

Reading Diagnostic Trouble Codes

Use a diagnostic scan tool in order to read the diagnostic trouble codes. Failure to follow this step could result in unnecessary repairs.

Clearing Diagnostic Trouble Codes

In order to clear Diagnostic Trouble Codes (DTCs), use the diagnostic scan tool clear DTCs or clear info function. When clearing DTCs follow the instructions supplied by the tool manufacturer. When a scan tool is not available, disconnecting one of the following sources for at least thirty (30) seconds can also clear the DTCs:

Notice: Turn off the ignition key when disconnecting or reconnecting battery power in order to prevent system damage.

    • The power source to the control module. Examples include the following:
       - Fuse
       - Pigtail at battery Control Module connectors etc.
    • The negative battery cable

Disconnecting the negative battery cable may result in the loss of other on-board memory data, such as preset radio tuning.

DTC Modes

The OBD II vehicles have three options available in the scan tool DTC mode in order to display the enhanced information available. A description of the new modes, the DTC Info and the Specific DTC, follows. After selecting the DTC, the following menu appears:

    • The DTC Info
    • The Specific DTC
    • The Freeze Frame
    • The Failure Records
    • The Clear Info

The following is a brief description of each of the sub menus in the DTC Info and the Specific DTC. The order in which they appear here is alphabetical and not necessarily the way they will appear on the scan tool.

DTC Info Mode

Use the DTC Info mode in order to search for a specific type of stored DTC information. There are seven choices. The electronic service information may instruct the technician to test for DTCs in a certain manner. Always follow the published service procedures.

In order to get a complete description of any status, press the Enter key before pressing the desired F-key. For example, pressing enter, then an F key will display a definition of the abbreviated scan tool status.

DTC Status

This selection displays any DTCs that have not run during the current ignition cycle or have reported a test failure during this ignition up to a maximum of 33 DTCs. The DTC tests which run and pass removes that DTC number from the scan tool screen.

Fail This Ign. (Fail This Ignition)

This selection displays all of the DTCs that have failed during the present ignition cycle.

History

This selection displays only the DTCs that are stored to the history memory of the control module. The history memory will not display the Type B DTCs that have not requested the MIL. The history memory will display all of the type A and B DTCs that have requested the MIL and have failed within the last 40 warm-up cycles. In addition, the history memory will display all of the type C DTCs that have failed within the last 40 warm-up cycles.

Last Test Fail

This selection displays only the DTCs which have failed during the last time that the test ran. The last test may have ran during a previous ignition cycle if the a type A or B DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail.

MIL Request

This selection displays only the DTCs that are requesting the MIL. Type C DTCs cannot be displayed by using this option. This selection will report type B DTCs only after the MIL has been requested.

Not Run SCC (Not Run Since Code Clear)

This option displays up to 33 DTCs that have not run since the DTCs were last cleared. Since any displayed DTCs have not run, their condition, passing or failing, is unknown.

Test Fail SCC (Test Failed Since Code Clear)

This selection displays all of the active and history DTCs that have reported a test failure since the last time the DTCs were cleared. The DTCs that last failed over 40 warm-up cycles (before this option is selected) will not be displayed.

Specific DTC Mode

This mode is used in order to check the status of the individual diagnostic tests by the DTC number. This selection can be accessed if a DTC has passed or failed. Many OBD II DTC mode descriptions are possible because of the extensive amount of information that the Diagnostic Executive monitors regarding each test. Some of the many possible descriptions follow with a brief explanation.

This selection only allows the entry of the DTC numbers that are supported by the vehicle that is being tested. If an attempt is made to enter the DTC numbers for tests which the diagnostic executive does not recognize, the requested information will not be displayed correctly and the scan tool may display an error message. The same applies to using the DTC trigger option in the snapshot mode. If an invalid DTC is entered, the scan tool will not trigger.

Failed Last Test

For type A and B DTCs, this message will display during the subsequent ignition cycles until the test passes or the DTCs are cleared. For type C DTCs, this message clears whenever the ignition is cycled.

Failed Since Clear

This message displayed indicates that the diagnostic test failed at least once within the last 40 warm-up cycles since the last time the control module cleared the DTCs.

Failed This Ign. (Failed This Ignition)

This message displayed indicates that the diagnostic test has failed at least once during the current ignition cycle. This message will clear when the DTCs are cleared or the ignition is cycled.

History DTC

This message displayed indicates that the DTC has stored to memory as a valid fault. A DTC displayed as a history fault does not necessarily mean that the fault is no longer present. The history description means that all of the conditions necessary for reporting a fault have met.

MIL Requested

This message displayed indicates that the DTC is currently causing the MIL to turn ON. Remember that only type A and B DTCs can request the MIL. The MIL request cannot determine if the DTC fault conditions are currently being experienced. This is because the diagnostic executive requires up to 3 trips during which the diagnostic test passes to turn OFF the MIL.

Not Run Since Cl (Not Run Since Cleared)

This message displayed indicates that the selected diagnostic test has not run since the last time the DTCs were cleared. Therefore, the diagnostic test status, passing or failing, is unknown. After the DTCs are cleared, this message continues to be displayed until the diagnostic test runs.

Not Run This Ign. (Not Run This Ignition)

This message displayed indicates that the selected diagnostic test has not run this ignition cycle.

Test Ran and Passed

This message displayed indicates that the selected diagnostic test has the following items:

    • Passed the last test
    • Ran and passed during this ignition cycle
    • Ran and passed since the DTCs were last cleared
    • This test has not failed since the DTCs were last cleared.

Whenever the indicated status of the vehicle is Test Ran and Passed after a repair verification, the vehicle is ready to be released to the customer.

If the indicated status of the vehicle is Failed This Ign after a repair verification, then the repair is incomplete. A further diagnosis is required.

Prior to repairing a vehicle, use the status information in order to evaluate the state of the diagnostic test and to help identify an intermittent problem. The technician can conclude that although the MIL is illuminated, the fault condition that caused the code to set is not present. An intermittent condition must be the cause.

Powertrain Control Module (PCM) General Description

Powertrain Control Module (PCM)


Object Number: 13732  Size: SH

The Powertrain Control Module (PCM), located under the instrument panel, is the control center of the fuel injection system. It constantly looks at the information from various sensors, and controls the systems that affect emission or engine performance. The PCM also performs the diagnostic function of the system. It can recognize operational problems, alert the driver through the Malfunction Indicator Lamp (MIL), and store a DTC or DTC's which identify the problem areas to aid the technician in making repairs. See Introduction inPowertrain Control Module (Control Modules) for more information on using the diagnostic functions of the PCM.

The PCM used on the OBD II LD9 (2.4L) engine is referred to as PCM-6SU. For service, this PCM only consists of two parts: a controller (the PCM without a KS module) and Knock Sensor (KS) module.

EEPROM

This assembly contains the functions of the electrically erasable programmable read only memory (EEPROM) and is a permanent part of the PCM. The EEPROM contains the calibrations needed for a specific vehicle applications and is serviced only through a re-programming procedure.

PCM Function

The powertrain control module (PCM) supplies either 5 or 12 volts to power various sensors or switches. This is done through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low. Therefore, a 10 megohm input impedance digital voltmeter is required to assure accurate voltage readings.

The powertrain control module (PCM) controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7, called either a surface mounted quad driver module (QDM), which can independently control up to 4 outputs, PCM terminals, or output driver modules (ODM)s, which can independently control up to 7 outputs. Not all outputs are always used.

PCM Re-Programming

Refer to the latest Techline information on re-programming procedures.

Password Learn Procedure

In order for a theft deterrent vehicle to run, a password is communicated between the Instrument Panel Cluster (IPC) and the PCM. If a PCM is replaced, the new PCM needs to learn the correct password of the vehicle. When the new PCM is installed, the EEPROM calibration is flashed into the new PCM and the vehicle will learn the new password upon initial ignition ON. If the IPC is replaced, the PCM needs to learn the new password from the IPC. The password learn procedure is as follows:

  1. Attempt to start vehicle, then leave the ignition ON. The THEFT SYSTEM telltale will flash for 10 minutes.
  2. When the THEFT SYSTEM telltale stops flashing, start the vehicle. Once the vehicle is running, the password is learned.