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Circuit/System Testing

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IMPORTANT:
  • You must perform the Circuit/System Verification before proceeding with the circuit/system testing.
  • You must perform the Repair Verification after completing the Circuit/System Testing.
  1. Verify the integrity of the entire air induction system by inspecting for the following conditions:
    • A loose or disconnected charge air cooler hose or pipe
    • A restricted or collapsed air intake duct
    • A misaligned or damaged air intake duct
    • A dirty or deteriorating air filter element
    • Any objects blocking the air inlet probe of the MAF/IAT sensor
    • Any contamination or debris on the sensing elements in the probe of the MAF/IAT sensor
    • A cracked or damaged MAF sensor housing
    • Any water intrusion in the induction system
    • Any snow or ice build-up at the air cleaner or MAF Sensor
    • Any snow, ice build-up, or coking at the MAP sensor
    • An intake manifold leak
    • A MAP sensor seal that is missing or damaged
    • An Intake Manifold Resonator with a leaking seal, or a cracked or broken housing
  2. Ignition OFF, disconnect the harness connector at the MAF/IAT sensor.
  3. Ignition OFF for 90 seconds and scan tool disconnected, test for less than 5 ohms between the MAF low reference circuit terminal 2 and ground.
    • If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the ECM.
  4. Ignition OFF and scan tool disconnected for 90 seconds, test for less than 5 ohms between the IAT sensor low reference circuit terminal 4 and ground.
    • If greater than the specified range, test the IAT sensor low reference circuit for an open/high resistance. If the circuit tests normal, replace the ECM.
  5. Ignition ON, verify that a test lamp illuminates between the ignition 1 voltage circuit terminal 3 and ground.
    • If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance.
  6. Ignition ON, test for 4.8-5.2 volts between the signal circuit terminal 1 and ground.
    • If less than the specified range, test the MAF signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the ECM.
    • If greater than the specified range, test the MAF signal circuit for a short to voltage. If the circuit tests normal, replace the ECM.
  7. Engine running at a warm stabilized idle, perform the following:
    1. Command the EGR solenoid to 0 percent with a scan tool.
    2. Observe the Airflow Leak Equivalence Ratio parameter for 10 seconds. The value should be between 87:1 and 1.15:1.
    3. Observe the Airflow Leak Equivalence Ratio parameter while slowly increasing the engine speed until reaching wide open throttle (WOT). After 10 seconds, the value should stabilize and be between 87:1 and 1.15:1.
  8. Remove the Intake Manifold Tube. Refer to Intake Manifold Tube Replacement .
  9. Visually inspect the EGR valve and verify the valve is in the closed position.
    • If the EGR valve is not in the closed position, replace the EGR valve.
  10. Ignition OFF, connect the red lead of the J 38522  to the signal circuit terminal A at the MAF/IAT sensor harness connector. Connect the battery voltage supply to B+, and ground the black lead.
  11. Set the J 38522  signal circuit to 5 volts, the frequency to 5K, and the Duty Cycle to Normal.
  12. Engine idling, observe the scan tool MAP Sensor parameter. The scan tool MAF Sensor parameter should be between 4.950-5.025 Hz.
    • If the MAF Sensor parameter is not within the specified range, replace the ECM.
    • If the MAF Sensor parameter is within the specified range, replace the MAF/IAT sensor.
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