VEHICLE MANAGEMENT, AND (CONTROL& INTRODUCTION dla “This manvals intended to provde he technician wih the information necessary to diagnose anc ‘pair the V-MAG (Vehicle Management and Conta) System on the CHCL, MH. AW, RB an AD ‘models. Although every etort has been made to ensure that al information i as accurate as possibo, due to our product upgrades. some information may not be appicable to al particular ‘chassis. Not allchasss are equaly equiped, and care shoud be taken to determine exactly wich ‘equipment is onthe vehicle. Please pay paricuaratenton tothe Notes. Cautions, and Warnings which are placed throughout ‘he manual, These are intended to cal attention o pectic procedures which must be folowed. A listing of these messages is included on the folowing page for No par of tis manual may be reproduced, stored in a retrieval system, or transmitted in any bem ‘wthout he pier witten permission of Mack Trucks Ine ‘This manual supercodes the V-MAC manusl dated May 1991, Information specie to al chassis ‘manutactxrod botore dune 1992 is now covered in ths version ofthe manual lease take th time to fariaize yours withthe contents of hs manual betore attempting to work (2 vehicle. Make sure you completely understand ine instuctons for performing atest bore beginning the test procedte. Oo not altomp to save time by skipping steps or using procecires (ter than those listed in hs manual Frat Peiting Auge 1998 Seven Pog Febuary 2009 8201 VEHICLE MANAGEMENT AND CONTROL iINTRODUCTION EXPLANATION OF SIGNAL WORDS ATTENTION CCorecty performed service procedures a critical for technician safely and consequent sae, rekable operation of the vent, Cawtonary “Signal Words” (Oanger-Warring-Cauton) may appear in various locations throughout this manual. Information accented by one ofthese signal words must be observed tO minimize the risk of personal injury to sarice personnal, or the posit of mproper service methods which ‘may damage the vehicle or rend it unsafe. Addonal Noles and Service Finis are uiized (9 emphasize areas of procedural importance and prove suggesions for ease of repair. ‘The {oloring defnions indicate the use of hese signal words as hey appear trough the manda DEW Dirocts attention to unsate practices andlor existing hazards which will result in personal injury or death If proper precautions are not taken, [AWARNING Directs attention to unsafe practices which could result in personal injury oF ath if proper precautions are not taken. [A CAUTION] Directs attention to unsafe practices which could result in damage to equipment and possible subsequent personal injury or death it proper ‘Precautions are not taker i VEHICLE MANAGEMENT AND CONTROL 8-201& INTRODUCTION a NOTE ‘An operating procedure, practice, condition, et. which is essential to emphasize. ‘SERVICE HINT. A helpful cuggestion which wil make the servicing being performed a ite easier ‘andlor faster. ‘Aso not that particular sence operations may require the use of spocialtoos designed for purposes. These special tools should be Used in the manner described, whenever specid in the instuctons. ‘Anyone using a service procedure or tol not racommened inthis manual mus fist sais inset thoroughly that reer ris safely nor vehicle satay will be jeopardizes by the service motheahe selects. Indviduls coving In any manner trom the instuctons provided assume all sks of Consequential personal jury oF damage fo equipment involved e201 VEHICLE MANAGEMENT AND CONTROL& TABLE OF CONTENTS & ‘V-MAG System Overview Page 1 system Diagnostics Page 11 Diagnostic Toots Page 12 Mack Bink Code Identification Table Page 15 SAEIATA Standard Terminology Page 16 ro-Link 2000 Page 18 Diagnostic Computer Page 19 Diagnostic Test Procedures Page 20 SAE Message Descriptions Page 23 Multiple Active Codes Page 20 Engine Ol Pressure Sensor (0-1 oF 1-2 Codes) .... Page 29 Low Oi Pressure With Driver Alarm (0 Code) Page 43 Incorrect Ol Pressure Vs. Gauge (0 Code) Page 40 Coolant Level Sensor (0-7 Coss) Page 48 Low Coolant Level (Wo Code) Page 55 (Covlant Temperature Sensor (2-1 oF 2-2 Codes) .... Page 59 Intake Manifold Ar Temperature Sensor (2-9 oF 2-4 Codes) .... Page 71 Butlered APM Line (Tachometer Signal) (21 Code) Page 83 Buttered RPM Line (Tachometer Signa) (Wo Code) Page 88 PMITDO (Engine Positon) Sensor (9-2 Case) Page 90 Injection Pump RPM (Engine Speed) Sensor (2-3 Code) Page 95 Injocton Pump RPM (Engine Speec) Sensor (Wo Code) Page 105, “Timing Event Marker (TEM) (9-4 Cose) Page 108, Timing Actuator (9-8 Cove) Page 111 MPH (Road Speed) Sensor (€1, 4-2 07 43 Codes) Page 124 Rack Postion Sonsor(APS) (4-4 or 4-5 Codes) .... Page 132 “Thvote Postion Sensor(TPS) (5-1 Cose) Page 140, ‘Thvotte Postion Sensor(TPS) (6-2 Cove) Page 146 Fuel Conte! Actuator (6-3 and 5-4 Code) .... Page 153 Fuel Request Line : (6-1 Coss) Page 164 Data Line input (6-2 Code) Page 170 'SAEIATA J1708 Serial Line (6-3 Cote) Page 176 wv ‘VEHICLE MANAGEMENT AND CONTROL 8-201& TABLE OF CONTENTS & Butlered MPH, (Speedometer Signa) (Wo Code) Page 181 lecronte Mallurction Lamp inoperative (No Code) Page 185, evar Alarm (No Code) Page 191 Dynatard Verbal Complaint (No Code) Page 195, Switch Cieut Diegnostcs (7-2 or 7-4 Codes) ..... Page 204 Service Brake Swich, Parking Brake Switch, Ciuich Switch Adjustment Speed Conttol ONOFF, SetResume Switches, PTO Select Sch Shutdown Overrce Switch, Torque Limt Switch Page 204 ‘Sitch Cirout Schematios Page 203, ‘No Active Codes (Or Intermittent Problems) (No Codes) Page 220, Resetng Low Idle Speed age 230 ‘system Connecters Page 232 ‘Connector Repair Page 249 Seting Injection ining Page 258 Y-MAG Service Tools Page 261 ‘Torque Spectcafons Page 262 Engine Parameter Valin Page 248 ‘Speedometer Dipwiich Settings Page 268 V-MAG Najor Functions Page 267 wiring Identication Page 270 Wire Use Charts (CH Model) Page 271 Wire Use Charts (RB.AD RW Models) Page 274 Wire Use Chars (MH Moga) Page 278 Glossary Pago 281 Vehicles Manulacured Betore September 1200 Page 283 Injection Pump Cantrol Rod Guide Adjustment Page 285 Electical Diagrans A Roar 1 Book 5-201 VEHICLE MANAGEMENT AND CONTROL vde TABLE OF CONTENTS & NOTE PAGE VEHICLE MANAGEMENT AND CONTROL 2& V-MAC SYSTEM OVERVIEW a& ‘The Vehicle Nanagement and Control System (V-MAC) isan electronic engine conto! system consis ofthe following components: VEMAC moduo Fuel ction Contot Module (FC) ECONOVANCE® Fuel Injection Timing Advance Mechanism Injection Pume/Actuator Assembly which Incudes: Rack Postion Sensor Fuel Fack Actuator Fuel Shutot Solenoid (ELAB) eM Sensor “To enabie V-IAC to pattorm Its engine management and contol functions, the following sansors proves information To the system, FPM/TDC (ENGINE POSITION) Sensor [MPH (Road Speed) Sensor Timing Evont Marker (TEM) ‘Trvote Poston Sonsor (TPS) Intake Manflé ArTomperature Sensor Engine ll Pressure Sensor Coolant Level Sensor CCoctant Temperature Sensor “The following swiches are also monitored to provide information relating to diver actions. Speed Contre ON'OFF Switch Speed Contre SET/ DECEL Switch ‘Speed Cone! RESUMEIACCEL Switch Service Brake Switch Parking Brake Switch Ceusen Switch Engine Brake Switch PTO Switen ‘Shutdown Ovarigo Switch “Torque Limiting Switch ‘A-complete description of the system components and thir functions and locations onthe ‘yetiee Is cocaine in the following sectons. } comin aon ir ten e201 VEHICLE MANAGEMENT AND CONTROL. Page 1V-MAC SYSTEM OVERVIEW & ‘The V-MAC Module and the Fuel Injection Control Module are. mounted on & panel lundomestn tho éashboars erect in ton! of the passenger seat ‘Location Of V-MAG And Fuel Injecton ‘Control (FIC) Mecules ‘The V-MAC Module (1) isa microprocessor based controler which provides contol cuput for timing and speed contol. I also does the agnostic faut logging and password processing for botn the V-MAC module and the fel injection contel module ‘The Fue injection Control Module (FC) (2) contains two microprocessors that are usod forhigh speed contol tasks such as fel rack postioning and pm puse reading. This Subsystem supp the basic contra of th ‘quay of fuel being injected ino the engine. 'V-MAC Module And Fue injection Cont! (FIC) Module Page2 VEHICLE MANAGEMENT AND CONTROL e201V-MAC SYSTEM OVERVIEW @> ‘The Fuel Injection Pump is sina to current production pumps using mechanical {overnes, andi located on the Fgh sido of the engine. On bis pump. the mechanical fgoverner is replaced by an actuator ‘ssombly “The Fuel Rack Actuator, (1) located on the {ar of the pump uses a proportional solenoid to provide postening force which works ‘against a rtum sing. An increase in current flow moves the pump rack to a higher tue livery poston, With a decrease in current ow, the rotum sping moves the rack to a lower fuel detvery postion. When electric powers removes rom to actuator, hereturn fing effects the shut. The actualor incorporates 2 rack posiion sencor that Fuel Rack Actuator supplies. rack fostion information, via an ‘ect signal, 1 the controler to allow for contol under all operating condos. ‘Noo loostod ttn tho aotuater housing ie an tengine speed (APM) sensor. The APM sensor Is a magni pickup which generates votage ses to the controller as the teeth on the Speed wheel othe injection pump pass bythe tp ofthe sensor Hf the fel inectan conto! made detects a ‘ack poston err, (the actual rack postion ders fom the desired postion) the Fuel Shutoff Solencid (ELAB) (shown by arto) ‘huts off he fowot fel othe igection pump. “Turing th key suitch OFF willalso cause his solonaié to shut the fow of fue. Fuel Shutoff Solenoid (ELA) e201 VEHICLE MANAGEMENT AND CONTROL Page 3V-MAC SYSTEM OVERVIEW @ “AS aunning change in 1882 modes, be Fuel ‘Shuto Solenoid (ELAS) i liinated rom the ‘uo! pump, and a Shut Relays added othe lectieal Equipment Panel. Tris Shuotl Flay wil remove power trom the Rack ‘Actuator and teeters shut of the ue supply. “te. ECONOVANCE® Ting Advance Mochanim sovos es 2 pat of ea Miecton ute aro ested baboon onde hina ck are to recion pump. Ting is changed by tag te Fiethon puny tamshatrasve ote enone isc apogee command Som fe" aucronc cowl, The seleo hs a Macros ecco tea oy soote tric ovel eng tie on oat! ecto pump oy one usc Sher) at eet conoleg by Sotre nyo scuner te Eooeranen a Sontel ve, not cones te eachca Esconee Ted ar coos ote VMAG mos hoa 5 peptone te tof few tthe ‘Econovance Timing Advance (Current production. Page 4 VEHICLE MANAGEMENT AND CONTROL. e201& V-MAC SYSTEM OVERVIEW & ‘The ECONOVANCE Control Valve consists of two components ina single assombl. which Is mounted on the top of the ECONOVANCE mechanism. The components are: Preportonal sole ‘This electric solenoid Is an analog device vuhich can be moved smoothly to any postion Ins range of tavel by vary tho oloctic Current to t. The electric current is supplied ‘and contoled by the V-MAC modu. Hydraulc spool ve “The proportional solenas is used to sot this valve at he positon needed to contra the fow ‘of engine oo the econovanc. Since this Is 2 spool valo, is not affected by the oll pressize being controled. Sensors ‘The V-MAC mania raoniuns intrmation via octal signals from many sensors and ‘swiches which ae: RPMVTDG (ENGINE POSITION) sensor ‘Tiss @ speed sensor based on the principle ‘of magnetic induction to generate an slecrc pulse when a part made of a magnetic ‘material passes close tos tip. senses the passage of any ol the six notches macrined in fhe foward acd of the engin. fyuhol These notches provide si puses for each revoluton a the engine crarkshaf, spaced to ‘cur ata fixed relationship to top dead center ‘of each piston. Engine RPM is used as the Primary parameter for determining the desod timing, This sensor also. provides. tho Crarkshat positon information needed for Comparison” with he timing event mark Informaton to calculate the curent (actual) lection timing, 8-201 VEHICLE MANAGEMENT AND CONTROL Page 5 PM/TDC Sensor& @ _V-MAC SYSTEM OVERVIEW MPH (Road Speed) sensor ‘The MPH Sensor (1) is another speed sonsor based on te principe of magnetic induction to gonerato an electric pulse. It senses the passage of @ series of tech of a whoo! ‘mounted on the transmission output shat. Vericie speed isthe primary parameter used for crise control or toad speed Imiting modes. Timing Event Marker (TEM) ‘The timing event marker. located in the ‘outside rear of the injocton pump. is sar to the speed ensore desorbed above. It ‘senses the passage ofthe ting bump on tho injection pump speed sensor, which is ‘adjusted {© occur at port closure of the umber 6 plunger dung lnyeclon pump ccalraton. This same bump is used to cient the inecton pump camshaft as the pump I assombied to the engine, and to set tho lial Injection ting. ‘Tening Event Marker (TEM) Sensor Page 6 VEHICLE MANAGEMENT AND CONTROL e201@ _v-macsystemoverview a Coolant Temperature Sensor “The coolant temperature sensor (1), usually located in the raar of the water manta, allows evaluaion of operating condions ‘causing high cocant temperatures: radiator blockage, thermesta fale, heavy lad, tigh ambiont temperatures, ete. This sensor is ‘also used for cols start erhancomant by the {uel injection contol modulo. Intake Manifold Air Temperature Sensor The intake manioié slr temperature sensor (2) locate inthe itako mantis used for Aaccurata aiitus "rato calcuston. This temperature Inlamation i$ aio used fot {engine timing corso, o prevent the formation ‘of white smoke ding engine warm-up and to Provont mist under light lead conations. Coolant Temperature Sensor And intake Maniold Ar Temperature Sensors Engine Oll Pressure Sensor ‘Tha engine ol pressure sensor, located ontop ofthe ol iter assombly, monitors the engine fll pressure to wan of lubrcalen system ‘aie Engine Ol Pressure Sensor 8-201 VEHICLE MANAGEMENT AND CONTROL Pago 7V-MAC SYSTEM OVERVIEW @ CCoolant Level Sensor ‘The coolant level sensor, located onthe roar ofthe racator near tho boom of tho Uoper Codlant tank, monitors tho vel of coolant in the radiator to wan of low coolant lov ‘Coolant Level Sensor ‘Trotte Position Sensor (TPS) ‘The thotie postion sensor replaces the rmachanical Snkage for fuel corr with an lectic sensor. ‘The “crve by wre” pedals Gesigned fo provide a system that “fois” similar to the standard type of pedal and mechanical “nkage. but with reduced Senativty 10 chasels motion for improved Contr. This sensor provides diver ue urement input to the V-MAC. system trough the fue jection corr module. Trrotle Postion Sensor pages. VEHICLE MANAGEMENT AND CONTROL e201@ _v-macsystemovervew @ Cab and Dashboard Switches Speed Control Switchos “These swiches provide the Input trom the liver to set the modes or the. command speeds forthe speed contaltuncions. These Switches, which are located on the ashboard, “include: a Speed Control ONOFF Switch, and one switch which combines "tre SETIDEGEL, "and RESUMEIACCEL functions. Speed contol functions are exclaned inthe Speed Control section ofthe Operators Gude ‘The folowing switches provide operating Information 1 V-MAC: Service Brake Switch, located ining win ‘Speed Control Switches te brake system: Parking Brake Switch, located nine in the parang brake orout ‘Clutch Switch cated uncer the dashboard above the clutch pedal; PTO Switch and Engine Brake Switch, located on the ashboard. Tre diver activates. these: ‘swiches by appl/ng the brakes, asengaging the clutch, or engaging the PTO or engine brake. ‘Tho Shut-Dowr Override Switch, located (on the dashboard, alows a short prod of ‘operation after th engine has been shutdown due to @ problem detected by V-MAC. This enables the drier to move the vehicle if necessary The Torque Liniting Switch, (not on al vehicles) located in the wansmision, senses when the transmissions in a vary low gear 80 that engine torque can be reduced to protect dtiveine components, 8-201 VEHICLE MANAGEMENT AND CONTROL Pages@ — v-Macsystemoverview a ‘The serial communication port is a six pia ‘connector used for system diagnostics and feprogramming. This por, which conforms to the SAE J1708 Serial Communication Link Standard, i located undor the dashboard to the let of the steering colure, ‘Sala! Communications Port CCommunicatons betwoon the V-MAC modle and the fuel injecton control module are Apcomplshed trough tbe use of a serial Communication ine. and deciated conal lines The dedicated tnes alow fastr ‘communication than the seria ine. One of these ins isthe foe request ine, The main Uso of tis line Is for speed conto: V-MAC ‘aleuates the fel quantity needed to maintain the dested speed and passes the infomation to te tu! injeton control macule on tis ine. ‘A conliming message must be sent onthe etal nk to weep this information current. Tho fuel Injection contol module wil assume a {allure of the speed convol ft te proper contimation Is not received parodeally ‘nother dedicated conralIne passes fl ‘quantly data from the fue injocton contol module tothe V-MAC module tage 10 VEHICLE MANAGEMENT AND CONTROL eat@ _v-macsystempiacnostics > The V-MAC modulo contains a varity of standard intgraied software packages which alow for detecton, logging and retioval of agnostic information about the V-MAC. system, The dajnostic sofware isan inogeal part of the V=NAC system software wtich Contrualy perferms the task of plausbilly testing and valsty checking on all system Inputs. The purpase ofthe ciagnostic software 's to ald in troubleshooting tho V-MAC system \ahie proving more safety by constant checking ofthe narcware. ‘The clagnostc sotware performs the task of montring all the inputs and. detecting the ‘cases ware the input Is out ot the allowable range orn an invalid state. Upon the detection of an unusual cendtion, the V-MAC sotware begins @ timer to alow the stato of ths inpu/seasor to sete back tothe normal state, Iti condition does nat clear within ho setting tine of Uist sera, Wen a fault will be ‘aseumed. The ‘aut recognition periods have been selected according tothe safety factor of the sensor, These time periods have been spectiod 10 ct detect false tauts, while ‘maintaining engheivenicle safety. ‘ter a falure is detected, the agnostic ‘software performs the flloning functions. 1. The electronic malfunction lamp located on the dashboard, vil go ON. This ight wilremain (ONor active taut, and go OFF when there are no longer any active fauts present in the systom. 2. fault message wil be sent in a standard focmat on the SAE/ATA serial ie to alert other vices of hs tlure. A similar message wil ‘be transmited when the falure is cleared, 3. Tho normally transmited data_on the SSABIATA sofal tine for tis sensor will bo tepiaced wih a "Bad Data” Indicator. This ‘signals the other devices on the serial ine 0 lgnoce the cata for bis senso. 4 The V-MAC module updates the fault tate ints iteral memary. This faut able contains an occurrence count of he number of mes the faire has occured. This occurence countis limited to 15. The stored codes remain in memory unti cleared by an off-bowd agnostic compute. 5, A detaut or customer programmable value vill be assumed for circu falures. This vals provides a means of allowing the fenginalvehile to operate even though the \V-HAC module does nat have any information from that partelar excuit. [AL the fares in the V-MAG system are recoverable, This moans that i the unusual state of an Input changes to normal for & Continuous period of imo, then the faut will 26 cleared and the faut lamp wil go OFF. However, the faut occurence count vill 2° keptin order to allow for later owbleshootngot ths inactve fare, ‘The V-MAG eiagnostc sotware is closely tod to the SAE/ATA sorial ine. This provides an feasy means of troubleshooting the systam since @ complete fault history can be retioved from the SAEIATA so‘al ine wih an of-board agnostic tool Pro-Link 8000, Diagnostic PC) 8-201 ‘VEHICLE MANAGEMENT AND CONTROL Page 11& V-MAC SYSTEM DIAGNOSTICS & For SABIATA standard terminology, $00 the SAEIATA descriptive worcing ist. ‘SERVICE HINT When @ problem occurs In the SAEIATA 19708 soil lina, the Pro-Link 9000 and the alagnostc PC may not be able to read the information trom the vehicle. The fault lamp will be on, and the ash ‘itches wil have to be used to read the Dink codes. The Pro-Link wil give @ ‘message “No Data Rocoved. To utize tho diagnostic capabities of the V-MAC systom, several dagnaste tools are valle, These to's ar listed below. 1 Pro-Link 9000 Pro-Link 9000 Diagnostic Tool Page 12 VEHICLE MANAGEMENT AND CONTROL “The Pro-Link 6000 sa hand held device which connects to the serial communication port located under he dashboard to the let ofthe stoating column, This unt splays at active faults, all occurrences of Iacive faut, ana lows monitoring ot selected system Parameters. This unt also alows stored fault ‘00088 to be cleared, resoting of te IW idle ‘peed, and customer data repcagcamming 2 Diagnostic Computer (any EM-PC ‘compatbe computer) ‘Typical Laptop Computer ‘Tne Diagnostic Computers the mast advanced of the clagnostic tools avaiable for troubleshooting the V-MAC system. In addon to pertoming all te functions ofthe Pro-Link 9000, tis unt wi alow for enhanced agnostics of the systom, and also reprogramming of Mack proprietary data 3. Digital Mutimeter ‘The Digital Mutimotr is usod to make the required measurements in the diagnose testing procedures. These tests wil include measuring volage and resistance, and chocks for short circuits and open cxcuts. e201@ _v-macsystempiacnostics @& For consistent, successful resuts in tho agnostic tests, an understanding of the folowing terms essential Voltage (vals) is the electric potent or potentalaiference expressed in vot. Resistance (chins) isthe onpostion afer by component tc the passage through It of a steady elect curent, expressed in ohms CCurront (amp) isthe term forthe strength of the flow of elactcy, expressed in amps. Short Circult (short) is a conection of Comparatively low resistance accidentally or Intentonaly made between points on a out between which e resistance Is narmally much roar. (open Circuit (open Is any stuston where the normaly clsed a continous fow of electicy has boon interapted. For example: a broken wie in the wiring names. Since there are many various types of digital rmutimeters avaiable, specific instuctons aro not given her. Famess connector © goad ground 1 te votage is betwen 4.75 and 5.25 vot orn Faress Connector Test 2 (chang for svayvotage on me sor eo) fa a vw ian T]] ince ae mere nano.s va preset. poceeste a) tess an 0.5 vs preset, proaes 0 tet 5 essa vatsoe est 3 (crecking the vote erence PLS) cron Test 3 “0 Ine igh a ow prooees test 6 1 the sotage atest 1 was loss than 478 vot, Page 30 VEHICLE MANAGEMENT AND CONTROL 8-201Test 4 (cneting ne hanes for say vote) 1. Tum the onion Hay OFF 2. Daconnac he tarnss fom Ne V-WAC mos. 3. Tum the gin Hay ON tne (pm 9) et the WAMAC connector ent Me Test § (Chetry for a stot, sgl to urd in neenass) fn (om ©) on te sensor ond ofthe harness foe red round 1 thro conta, preses 1 tet 10 ENGINE OIL PRESSURE SENSOR DIAGNOSTIC BLINK CODES OR 1-2 Bee iS 988@ OSS8Blg 1S 288G) 10eQG0|\'|e0eee| e359 (|eeeog Sa VEHICLE MANAGEMENT AND CONTROL ages:ENGINE OIL PRESSURE SENSOR DIAGNOSTIC BLINK CODES 1-1 OR 1-2 ‘Cenreior Test 6 (Crock for way votage in valape ‘eteronce PLSIH in) SESS) rr wror 22980|Q|@2aae|| > omer vnc mn comen BOOGO| |. weno vey on IQPOO| | |OO@OS| 4 Wessire he vatage tom he vatage reference PuSte) tne. (pin 2) on he V-MAC. moa ‘Sonnac 0 goed rong Menauiog wotge vibe voagele ashen Svs, proceed tet 3. Whe vetage a greaer man 5 vats, locate and report shor 0 power, Relece the presse Taree Comenar Test 7 (Checking for continuity he harness) : $. Comact jumper between he vlogs eterence ss PLLS(e Ine (pn) andthe ol prostre signing ton Chatto senor ena tte herness >| 4. Check for camtnuty between the vorage: felrence PLUS) In (pn 2) an the l prossre isin} onthe V-MAG mule and fe cont 8 unser senor 8 an pe ¢ 1 ther ie contrat, prose to ton 16 1 ne NO cont, nete an reps the open bnna otagereerencaPLUS() ne ViNAG Wemese Connector ©2886) 1S G8ae| 2e80e8|9/e0e00|| lSeaee) 1 OHO] | (OOS) regen crt nvr page 32 VEHICLE MANAGEMENT AND CONTROL e201ENGINE OIL PRESSURE SENSOR DIAGNOSTIC BLINK CODES 1-1 OR 1-2 Tost 9 (Cresta for pi 0 in shor in he terest) tignline pin} andallchar ps onttsharess “Test 10 (checting for contrat ogrouns en ne 1. Tenth ky OFF anathen cacanect he Y-MAC Signal na (93) mine VAC modus connector Har ie conty, este an Yepe the srr 10 ®ee8eeq SG8Se! 2288S) 1S 9@89| O®@ O@C@HO] 1 |O9O9@! SOSA! Cheztng entry borin oR Vana Comer D2aee| SG88G| 22889) 9/8 0eee) SOR © GQeel 8350 J ©ooo@ Ul ‘Sreceng contin em gn Segre e201 VEHICLE MANAGEMENT AND CONTROL Page 33ENGINE OIL PRESSURE SENSOR DIAGNOSTIC BLINK CODES 1-1 OR 1-2 Soe vow nd itn as user San 0@ DOO: 1|99090, Tost 11 (Checking tan open inte apna! nen {e VelkC radia canracar endo hahaa 1 moe is sontnty. remove the hmper ans nar NO contr, loons an rath open Test 13 (Croceng fo pn 9 pt shot) tn9 ¥-MAC mgua ora pinto Ba sort ereura 1 era NO tpn stot, resins the V-MAC Page 34 VEHICLE MANAGEMENT AND CONTROL 8-201ENGINE OIL PRESSURE SENSOR & Ce) DIAGNOSTIC BLINK CODES 1-1 OR 1-2 Test 14 (chestng lr short to ground in ne sotege clarence PLUS) Se, LUSCH nena) te V-MAC Mosse {mere is coninty lest an eps the srr to ‘pound int tape eerance PS (6 ne Inne Tost 19 (Crosing for pn to pin shen the V.Mtkc mecule exes beteoon te ol pressure sigan (pn 3) an ay Trness Gonnestar |) @eee| |G O8886) 2888S|Q/@0ee0) OZSSS| SG G@S8| TOGO) [] |OOOOG! Ccrsking continty 0 in 2 V-MAG MODULE rs 8-201 VEHICLE MANAGEMENT AND CONTROL page 35& DIAGNOSTIC BLINK CODES 1-1 OR 1-2 VAWAG Farmase Comes ENGINE OIL PRESSURE SENSOR rest) loeE [d@a@e| \28esee| OGQaeG ©0} ol@2ee9) cecking coninty oa vn Pago 38 Farnese Comecir “>| (eckng wotago on pin & VEHICLE MANAGEMENT AND CONTROL ference St es) ‘ise view 2. Tum te kay i Tost 21 (checking fr © pn opin stort the ‘loa ine (pn 3) end a oar pine a tha VMAS peseal 1. Check er canny tata the of pressure Test 22 (cnecking for votage on the votage 3. aad the vatage on the votage reference St) re (pn) atthe senaor end of the e201ENGINE OIL PRESSURE SENSOR OR 1-2 DIAGNOSTIC BLINK CODES Tost 29 (Crecxeo for # pn to ln stor ne ames) 1. heck for cantly ewoen the votage reference RUS(} he pin) ath V-HAC mole tna ofthe hana al ofr se 1 eras NOT apoter pla wih contr, sroceed PLUS( bn in the harose ear Tost 39 checting for votage on the wouage relrorce MINUS(= ne) tat) tne pin) one rns a he WMA epson the ol pressure sensor. ©eSe6] [eo0es) 2e98e|g|e0800 \oQeee HDG) (| |OOOS! ‘Crking corttyetenen pa an oer pine VAG Horass Connector OSS8e| [SSeeeq O2S8G)Q/eeeee) GOS OG) @OSGO| OTF OOO} |] |CO@©OG| essueg vaso on pin 12 8-201 VEHICLE MANAGEMENT AND CONTROL Page 37ENGINE OIL PRESSURE SENSOR te DIAGNOSTIC BLINK CODES 1-1 OR 1-2 V-Mac MODULE VEWAG Farnese Come" H288G| [@9eeq 2 2GSS|9/22e8e) 0 ©0009) Tost 43 (cheering far @repaable start at he Vaya mace sce for short betwen theo pressure sor ne (pt 3) and at acacen pa Test 44 (Croce for votage he harness on he vatepe reference MASI) Ie) 1. Tm te lnton hay OFF. 2. Tum the onion kay ON HDS (-) te fan 12) on te 1 ors are gs han 0.5 oes, replace he V-MC {he stent on he vtgereterence HIUS() Ina a Page 38 VEHICLE MANAGEMENT AND CONTROL e201& ENGINE OIL PRESSURE SENSOR DIAGNOSTIC BLINK CODES 1-1 OR 1-2 Test 45 (Crecny contnuty 1 oun 1. Ten the gin tay OF. NUS Ie (gn A) onthe sensor end rune Test 59 (Chosng fara open & shot at ne VAMC macula cemnetor) 1. Vunty inspect the V-MAC module. comet, toe (on 2} vottgeceterance MAG meoaue connector Ccrecking coninuty ona & \V-MAG MODULE e201 VEHICLE MANAGEMENT AND CONTROL Page 39ENGINE OIL PRESSURE SENSOR DIAGNOSTIC BLINK CODES 1-1 OR 1-2 Terese Conracor Test 90 (Checking for an open the V-MAC re) ie 1 Samm eben PLUS() ine (an) ane — (Gn) ate eo ao ote ae Ty]. he tay on rte aot aut changes rom pratt on (code a4 1) fo peter gh (ends 1-2) proceed 0 test tea unoer Sea IF ne sine faut does NOT change, replace the CConect jumper between pi Band pin Tare Comoaa? Tost 91 (Creching far an open in te votege reference 18) ne pn 12) the arbse eat side vie "he VAMC module) L,| tomar arma sonsor 2. Tan ay OF, dart KE Bly) >! Erbil 2. ce ory am te rma sp Ing (pn 3) tome wotoge rfornce MINUS) tre user Sea {pn 12} onthe WAC moa ono the arose tar NO contr, locate ar vepat the open ‘nb sotage relorenoe MMUSC). tne the pe | 8686] [seees) 22892|,|e0009) i Oo @ 0) ‘SERVICE HINT. —| = It ls go00 practice to bo suo the test 2 feadsin your etc tet ht ore n good rec coninybatwaen ‘conan (not bant or camaged In ary aera way Page 40 VEHICLE MANAGEMENT AND CONTROL e201ENGINE OIL PRESSURE SENSOR DIAGNOSTIC BLINK CODES Test 180 (creaing for comactr) 1. Visuy rape the sonor connector (oth 1) fore rpaiaie open ary of hep. 1 rei NOT a para tt 2 Fin the gray 8616-2 matt ed rom he BSE V-MAC per Wire Ka. Agno raotert, jana wit ono ofr rctanguar female pr re sensor eonracter. any pus th eta the Sensor connector pr. Ropeat hs proces fr he remainng we feria, bing cart aig he Tana win the recungu pine (on © ia turned 80 ogres rom ps A and). ‘rain pia, bang caf alone lod wih he ‘ectangu pe (pn C8 tres 80 dress rom pire And 8) If any of 9p te sono fo 088, eptc8 Ife pain te ceanectr are NOT lone, rocees to tet 380 Test 182 (crecing for a repavabieosen athe V-MAC module ernete) lor. both se, a the womb elrerce MUS () tre (p12) 1 bares 2 ropetable pen rape the V-MAC Irnerla NOT arpa au, rpice ne V-MAC ‘module an the ermectorH necessary OR 1-2 & es Se view van @ > ‘atoer Sea ®e8eeq SOB 2288S/Q/908 OG} SO@ OPC) [] |OO® '@G 8G GO OG e201 VEHICLE MANAGEMENT AND CONTROL. Page 41ENGINE OIL PRESSURE SENSOR DIAGNOSTIC BLINK CODES 1-1 OR 1-2 “Test 360 (Crectn for bad comet nthe sane Dtreiee replace he ol resi sent Page 42 VEHICLE MANAGEMENT AND CONTROL. 8201LOW OIL PRESSURE WITH DRIVER ALARM NO DIAGNOSTIC BLINK CODE DIAGNOSTIC PROCEDURE FLOW CHART [A CAUTION -m ancl Engine Shutdown lamp turn ON, Indicating low oll pressure. ‘STOP THE ENGINE IMIMEDIATELY!! Tost 1 (creckng fo o ve) 1. Check the ot eal en the psn est 2 (Locking missing ot tings) tor misting i ftnge, Look artsy around the ub a 9p, tea far e-201 VEHICLE MANAGEMENT AND CONTROL page ss,LOW OIL PRESSURE WITH DRIVER ALARM NO DIAGNOSTIC BLINK CODE Test (checking oral pressure wile cron) 1. Tum me tay OF. 2 Conngct a guage tate krown ob accurate 1a the lets gallery cro pees wih 9 hose 3: Disconest mo revere poly dios om the elects! equipment pana 10 gouge dae NOT roger ot passe win 30socond of raing, nee prob wih hl p> Test 8 (crooning mo proteue sera) 1 Tan the ey OFF 2. Riot the reverse olrty od, 8 Tum tha Key ON, tat nd ae the engin. tne pressue on th page does rt reach o xc pater 15 soconce ting, STOPTHE ENG! Tel presaie senor wort propery thee ata rachael probrn aun into ol pram, such ab 8 ‘Tost 17 (creating elevation) Wisc age wn nem fan ively was uo tothe Nah wth. Tere emo barony for an ovo 1 te gouge and V-MAC aldo et agree win ts new range, proces 1 tet 36, page «¢ VEHICLE MANAGEMENT AND CONTROL e201LOW OIL PRESSURE WITH DRIVER ALARM NO DIAGNOSTIC BLINK CODE Test 36 (cect! checks) Proce ote Enns Ol Pressure Bagront, Bink Cases 1-1 ar 1-2, the gnostic takes you trough WEL 16, ptorm the towing bear proceing to tat 50 fount 5 ihn sit soa esac Coneuy sn, theres f rake ord 003 our motor, ee} ening he ea VEHICLE MANAGEMENT AND CONTROL raooasINCORRECT OIL PRESSURE VS. GAUGE NO DIAGNOSTIC BLINK CODE ® DIAGNOSTIC PROCEDURE FLOW CHART NOTE \When pectomming your electrical tests, tis important to wiggle wires and connectors to find Intamitent connection problems. sorte ar tm acme atin ot ene ecdy VAC an aed ontedagonic Test 1 (chockng mo prossuo ose) 1. Connet oaup8 iat is Kno tobe Roce toe ol rasa Gry orc pede wth a howe, es ogrenwitin3 par hens pooam waneNO DIAGNOSTIC BLINK CODE INCORRECT OIL PRESSURE VS. GAUGE & Test 3 (cresting suvaton) 0 nd V-MAC ogra within 36 ro 1 the gtupe and V-MAC si do rot a6 win is new ange, pooeed 0 test 7. Tost (eects check) Prooeesto te Engine Pressure Dgrosts Bn Cade 1-1 or 1-2. Whe aprotic takes you aught Beton tho waar reerence MUS | terminals ate harness, bukhead comector, ard V-MAC connector, es wal aa for evcance of damaged 1 Oks scala eter anne Cominty sel. tho resstarce ie (pn 8) onthe sac and of te nasa a 8000 grou ran cia eves (aha, hetero) enng ns oh tanthare serene the roastance is eas than 20 ots, proceed ott SO ol he Engine Ol resure agri e201 VEHICLE MANAGEMENT AND CONTROL age 47ts COOLANT LEVEL SENSOR ) DIAGNOSTIC BLINK CODE 1-7 Or @rO > OrO -e® © -® © DIAGNOSTIC PROCEDURE FLOW CHART [AWARNING checking coolant in a hot engine. Walt for the engine to coo! prior the first stop but do NOT depress. After the pressure has completely dssipated, press the cap dawnward and continue turning to remove. NOTE len performing your electica tests, It Is Important to wiggle wites and connects to ‘ind intermittent connection problems Page 48 VEHICLE MANAGEMENT AND CONTROL e201COOLANT LEVEL SENSOR DIAGNOSTIC BLINK CODE 1 - 7. Tost 1 (creck he coosnt lvl ‘View Of Radiator And Coolant Level ‘Sensor eran lll « Ga VEHICLE MANAGEMENT AND CONTROL PacesCOOLANT LEVEL SENSOR DIAGNOSTIC BLINK CODE 1-7 Tost 4 (crocing fr contnty on te tensa) tor cmtinuty Between th sane Body 1 ores contrat, proceed to 88. wif 5 4 tore NO cots, eae gots Checking coin of sensor Test 5 (Chacking the votge onthe menos) (ffs | nee rege so - VEHICLE MANAGEMENT AND CONTROL a2COOLANT LEVEL SENSOR & ee DIAGNOSTIC BLINK CODE 1-7 Test 8 (Creting te vie onthe herae) 1. Turn te ont bay OFF. 3. Tum he ignition key OX (pn) atthe MC mois ence thehamess 08 If me vetage ie eater han to volo, proceed o test 18 Test 10 (creckag fa « bad connecter) 1. Clesn ne consactorbtwsan heharmats anne tut gs any, cleting te connecter nes rnty coreces the proiem.fetun te ‘eptace he oot av! probe. [220080] feseea) |®2886|g|e0e00 looe@p| 1 |OOOO@) Cece he terminals e201 VEHICLE MANAGEMENT AND CONTROL Page 61‘V-MAG Hemoee Conactor ©2886) D28ae OG BRB l©Ooc@o] 0 SH8S6 OOOOG| Ccreckng contnay on pa essen vag onthe tases Page 52 LANT LEVEL SENSOR DIAGNOSTIC BLINK CODE 1-7 VEHICLE MANAGEMENT AND CONTROL & Tost 11 (cnckng fr contrat athe harness) 1. Ta eign bay OFF. Sippy Ine at ho sraar era tte harass fo 8 13 900s una 127818 NO coniny. repar or ropace the Tost 16 icrecting me votage onthe coolant veh 2. aggre te votop rom th costar evel ode ioe sersr and otha harass to 2 goad pound ‘ot 0 nit 96 ets, ote and rps the e201& Tost 17 (Cnocieg for contnty) 2, Check for cortnty Setwean the cotta robe ine (pe tba V-MAE mooie or of he NO coninuty, proceed to oe 36. Tost 22 (Chaka for 0 988 V-MAC module) 2. Reconnect the V-MAC mods 4 Tum me ignition koy On, 2-201 COOLANT LEVEL SENSOR DIAGNOSTIC BLINK CODE 1 - 7 VEHICLE MANAGEMENT AND CONTROL (80889 Ccecking corny between [©e8e6] eoeea) 22e0982|p|e000¢) joeeee 2888 OOOO} [] |OOOOG) zea @ (ck he connect or Page 69COOLANT LEVEL SENSOR DIAGNOSTIC BLINK CODE 1-7 “Test 35 (Checking for damaged comes 1. Vaal enact fr camaoed, broken or ising 1 ter is NO valle damage. othe eamape ent Page 54 VEHICLE MANAGEMENT AND CONTROL, 8-201LOW COOLANT LEVEL NO DIAGNOSTIC BLINK CODE DIAGNOSTIC PROCEDURE FLOW CHART 21 VEHICLE MANAGEMENT AND CONTROL age ss,MALFUNCTION nerton of tnt amp octes MALFUNCTION LOW COOLANT LEVEL. in, NO DIAGNOSTIC BLINK CODE Gach NOTE When performing your electrical test, it ‘important fo. wiggla wires Connectors find intermittent conne= tion probes. Tost 1 (Cnecing ime andalarmturcton stat Sat ene son lap ar 8m oA ne saree at ur nO eam on # he tro end alarm work proper, proeed to Tost 2 pe V-MAG module wens O te faut mp, Svan rope Taras not 9 proba e Pages VEHICLE MANAGEMENT AND CONTROL 8-201LOW COOLANT LEVEL NO DIAGNOSTIC BLINK CODE & “Test 5 (crechig vo axe pro) ‘pou geome center re vonage eer an rt ec he Vitae me “Test 11 (chock lor vonage tothe probe) 1. Disconect th supp wre from the corr amass to 8 pod around conmactro teace th coolant ove! probe ste otageslasethan 4 vote, proceed totes 2, i ‘Motsuog wotuge on he ares 6-201 VEHICLE MANAGEMENT AND CONTROL Page 57LOW COOLANT LEVEL NO DIAGNOSTIC BLINK CODE V-AAG Hesnase Consactor BS 88SO 89889 O88 ©OOOG) oO 0 Ccecking comity om pa Ccecking coninaty on pe Tost 25 (Cnecing for» sho to grins) 2. Turn OFF ha ignton Key nd dacomnet the 42, chao for cominty between pa onthe weg 1 tera ie NOT contr, procee to ae 47 Test 47 (Checking for # pint pn anon in the ames) 1. Cnet or int la canny trom pn on the 1 ter econ, locate the shrine wing 1 meres NO cntinty, vat nspect he V-MAC ‘Crrsin, a eepn mata om pint ancthe Page 58 VEHICLE MANAGEMENT AND CONTROL e201COOLANT TEMPERATURE SENSOR #r. DIAGNOSTIC BLINK CODES 2-10R2-2 ee) | promprprprerere @ 1 1 1 4 e+e 1 { @>@+o+®e 1 Or OrOr Ore Or OrO+® DIAGNOSTIC PROCEDURE FLOW CHART hen performing your eloctical test, it |g important to. wiggio wires and Connectors t0 find Intermittent connec- ion problems. Test 1 (Cracking for sens resistance In the aga of 2000 80 ob) 2-201 VEHICLE MANAGEMENT AND CONTROL Page 59Ge COOLANT TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES 2-10R2-2 ‘eal Terperiue Sense ‘Chek for ontty rom einer pn Aor a “i Page 60 Tost 2 (checing fr © shot to ground in the 1. Check for contnuty frm eter loss of te sensor to «good greuna Tost 3 (checking the sige nef wotage) 1. tan he bay on ime vote ine vote ies than 6 vot, vu inepct be Fepavant consion,fepeco tha sent VEHICLE MANAGEMENT AND CONTROL e201COOLANT TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES 2-1 0R 2-2 Test 4 (Cracking for pope spl wonege 19 me 2 Measure he vlape on the srl, 0 A, at et “Test 6 (Cheating fora shor to 12 vs on he spa! ne) 2 Daconeet the IC connector. 4. Messina velage from pin onthe FIC ond ot honed to 12 vole somewhere ite {ent andepa ne aban andvesace tne BE fapratalaanee TetsletstelTeleran eae aa sa VEHICLE MANAGEMENT AND CONTROL rogectCOOLANT TEMPERATURE SENSOR @#é#) DIAGNOSTIC BLINK CODES 2- 1 OR 2-2 arrose Comecior a Tost 8 (cnesing or paper vtage an he ground lta arose fo 8 900d rou se votage & peter than 05 vats, proceea to Tost 9 (cheating for « shor in the hares 2. otsconect he FC connect. 3. Conoct»junper betwen pins A and 8 at he there = NOT canny. tere en ape in ne Sino connector or at tha Mtrass ae of be FC Page 62 VEHICLE MANAGEMENT AND CONTROL e201COOLANT TEMPERATURE SENSOR & DIAGNOSTIC BLINK CODES 2-10R2-2 “Tost 12 chectng fora show st tno MC cornea) Gnd of the names ond al the pte on the Tost 16 (Crack for conto run nthe 2. Cpe tr contny rom in @ atthe sense ans thw ines Tos oad ground. 1 theres eeninuy, proceed ott 22 thera NOT earn, presses 1 et 33, 7 Wot Haroae Gores lalalataiata al Eesistse \sietsTars ges sent toon on 8 isle e201 VEHICLE MANAGEMENT AND CONTROL Pago 62COOLANT TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES 2-10R2-2 es coe Tost 17 (cnc tor ner sno vege ® cn te goin ns) 2. ctsconect he FC connector, 3. Tum th tay on the pemecs to a good pour eons wotage 0 6 8 Fo wade Paes Comes )~—~«CTASt 18 (Crecking fran cen votage shor 0 Jumper tthe sensor ond of ne IEE 3. Massie tte vag Koma at heFIC and ot Gus the armen ow goed grou aaa SELES EE SEDI AGL he vote mens nen.s os roster S ine votag greater than0.5 vats the sgnation Masao wohapo on in 83 mess ia ona sone FC connector. Locle Pages VEHICLE MANAGEMENT AND CONTROL 2-201COOLANT TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES 2-1 OR2 ent 24 (ota fr bd comec oF ot sven and te Fc connector for stat Detweon pn 6 and 12 vst spot bra the RC mole. " “Test 32 (cneckg for en ocelot 0 vlogs the sgl tne nha harness). 1. Baconect the FC connecter 2 Tun te Ko. 1 the ogee than 0.5 vrs, pocoed tet aaa aaa a eee . Ss stestesiolbaastaldpgor| [iietstelsterselona ropa Isaranag’n evarece, oo ie trmas et f the engor conor ete fares age fe PC “Tost 39 (cnscingtoronpeninne rund in the harness) Farnese Connecter 2. conn in FC connector 4 oer NT cy mee a ae ee ez VEHICLE MANAGEMENT AND CONTROL age ss,COOLANT TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES 2-10OR2-2 Tost 34 (Checking fr © pn 0 pin stor nthe ee Check contrty Beteen pin 48 Tost 36 (Chacing fra shar tthe ound nthe 1. Check or cominuty betwean Pn 69 at ha FD nd ofthe nanan to 4 good pou uaa acaiefalaiaald Pages VEHICLE MANAGEMENT AND CONTROL e201Test 64 (Cree far pin 1 pn short in ne 1 Tun the Koy OFF Tost 66 (ceakny lor ancoenia ne FCcomecior corthe PC mou) 1. vaalynspet st aes fhe IC cancer aot ope, elses the FC COOLANT TEMPERATURE SENSOR @ee DIAGNOSTIC BLINK CODES 2-1 0R 2-2 regatta leg ila peste Telecare asly re cant betwen 59 2-201 VEHICLE MANAGEMENT AND CONTROL Page 67COOLANT TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES 2-10R 2-2 seats | | TH Wot ress Gomer Ga aaaeeee oe Sie” FO Wom Farves Goer ‘eck corny beween ln #3 Page 68 VEHICLE MANAGEMENT AND CONTROL & “Test 68 (Checking for ® bad sensor conection) a an nt ei the te Seteon 0 ana 90 degree © (Se and toe copes, 1 te restarce ewan 10 oh of te restance scros te bare sega aap 1 ove). proceed © 2 (Cracting te 9p 9 pla ston in ne fins the Condo he hares (ound ne tne snaor or Cormac, Locate eaCOOLANT TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES 2-1 OR 2-2 “Test 128 (choctng fr an opon atthe senso Sa omocior of ste tthe AG onnactar Fe mea, ‘Yau epec sensor tora open 7G Nose Faress Consacior Tae aaa dain ssa HPislelse Telnaes Comckig for sho around pn Test 138 (Crasing fer a shor at te AC cennecon then and repos the Pe medal (18 NOT e wepaable stot, replace the PC eee aes HEEEEEE Ee arr Ta Chak lar # eran arcund pin 46 nee, an 8-201 VEHICLE MANAGEMENT AND CONTROL Page 63COOLANT TEMPERATURE SENSOR @é) DIAGNOSTIC BLINK CODES 2-1 OR 2-2 no Nosia eaes Omen Tost 144 (Cracking for an open or enon a he the open or sor athe PC eomnecter, Jr sort around sn $9 re, and Page7? VEHICLE MANAGEMENT AND CONTROL 2-201INTAKE MANIFOLD AIR TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES 2 - 3 0R 2-4 Oe Pe Prom -@ ® ' f + § O { t { Or ©+o+@ Or @r Or O~@ Or Or8 DIAGNOSTIC PROCEDURE FLOW CHART NOTE nen performing your electrical tess, i |g important 0 wiggle wires and Connectors to find Intermittent connec: tion probe Tost 1 (Chocting sensor rsistance) Triste Wants Teroereure Sensor] 8-201 VEHICLE MANAGEMENT AND CONTROL Page 71INTAKE MANIFOLD AIR TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES 2 - 3 OR 2-4 Take Wanto Terporeue Sonor eres Connector Test 2 (checting for & shor to oFoun in the senso) 1 Chee for contnusty trom eter asd of the Tost 3 creck th sora ne fr vatage the sersor endothe harness 8 good gre hot of open on the there is NOT 8 Page72 VEHICLE MANAGEMENT AND CONTROL 2-201‘Test 4 (Cracking for proper supply votage to sonen totes 8 1 te votage ia sbeve er blow ta ange, proceed (ecg for @ short to 12 vot onthe 1 ere NO voage, proceed 1 test 12 & tore i 6 vote, the signal tno 2-201 VEHICLE MANAGEMENT AND CONTROL INTAKE MANIFOLD AIR TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES 2 - 30R 2-4 ah)) >| 7G weal fross Soar PREETI Fa olainlstomteloteip pate Measure otage a pin 82 Page 73INTAKE MANIFOLD AIR TEMPERATURE SENSOR in. DIAGNOSTIC BLINK CODES 2-30R2-4 (Was) > CConect a unger between ‘st 8 (cnecting or proper votag onthe round lng ate sonee nd of te Memes) Iles ton 0.8 vos proceed to ta 6 “Test 9 (cresting for contty the hana) 2, Dscomect ne FC connec. 2. Connaot a umes btwean pins A and 8 at he 4. check or entity rom Pa 529 Fin 8 the 1 mere cantina. proceed to te 18 the sensor comctoro connector, Page 74 VEHICLE MANAGEMENT AND CONTROL 8-201INTAKE MANIFOLD AIR TEMPERATURE ae DIAGNOSTIC BLINK CODES 2 - 3 OR 2 “Test 12 chectng ora shor atineRosammecto) [pS aaa ame Comes | 1. Tun the Ky ot tere NOT contr, proces 1 et 26 » | Sa ae i eis ver ne | HST Te SSS pra Test 16 (crecengtorcontnuty 19 ground en the (pound te inte meat) Hf mere i NOT conn. roEs6d to tes 38. J) e201 VEHICLE MANAGEMENT AND CONTROL Page 75INTAKE MANIFOLD AIR TEMPERATURE SENSOR: DIAGNOSTIC BLINK CODES 2 - 30R 2-4 a eer “Test 17 (Checking for an oaral shor to vtage . nthe ground Ina) aya) > theron a p08 pn ne vata i estan 0.5 vote, poceed to test 1 te votage geetar than 05 vas he grouns Ine i snoeto o 12 vote te aren tthe @f the Fe connector Loewe ans 7G Mosul Farnese Comnear “Test 18 (Chocing fran earl shor to vatage 1. Remoue the Jampar a he sngor end of te Spor Pils] tie votne i tes hen 0 one, proceed tsk EGRET EETE TTT gre) 1 ee ofthe enear cores oF Page 76 VEHICLE MANAGEMENT AND CONTROL e201INTAKE MANIFOLD AIR TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES 2-3 OR 2-4 “Test 24 (cneckrg for 9 bad connector or bad PC rosie) 1. aul repect ne sensor connector nthe FC son maa assis Ptetsieister tetera ay ia If hres NOT a vepsiabl contin, rpice the Fi mie and te mpertre senso Tost 32 (chaci or en etre! shart to vatege 1. Disconnact he AC conecior, 3. Rss the votage kom a 62 tthe Conde amoss to 8 goad gourd cy Messing voltage at pn 2 e201 VEHICLE MANAGEMENT AND CONTROL page 77Oe one MANIFOLD AIR TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES2-30R2-4 G2) “Test 33 (checing eran penn he oun tne harness) {tar is corto, proses to tot 68 tte NOT coninty. here tan open nthe (ound nein tne nanos at the harness se Seemenr comer, Lavete rapa th open 34 (Cheating fo @ gin 1 lo hort in he 8) Sno a oer pine at ha FA ond ofthe memes 1 ref NO coninty,prooeed 0 test 68 1 re contin, the ground ie Ie shor to ‘epor to shar and replace to FC modu Page 78 VEHICLE MANAGEMENT AND CONTROL 8-201INTAKE MANIFOLD AIR TEMPERATURE SENSOR DIAGNOSTIC BLINK CODES 2 - 3 OR 2-4 Tost 26 (Chacha fora stort to ground onthe 1. Check fr sontnuty between Pn 52 a he IC cna ofthe hemous on a good gra |e NO conta, precees 1 test 72 mcg sonty basen Test 64 (Cnesng la pin pa shorn we Fi Wai armen Concior 2, Chock or sino in conatybetroeh Pin $2 era NO contity, proceed 10 vst 128, PeCMma Erno Gy set ‘rine cnt, ne sgnalioeiasnoned into. | Hay SSIES oS a e201 VEHICLE MANAGEMENT AND CONTROL page 72& INTAKE MANIFOLD AIR TEMPERATURE SENSOR: @e DIAGNOSTIC BLINK CODES 2 - 3 OR 2- 4 (pecking fran open, Fano pin ‘her, and on te FC oa tense Page 80 VEHICLE MANAGEMENT AND CONTROL “Tost 68 crectng eran apenintePC made 1. avy nspact ot des fh FIC comector st the apn athe FG oomectr 1 ther 6 NOT 8 reparabie condton, repiace the “Test 68 (Chakig fer @ baa sensor conection) 2. Mansur he restance betwen pin 52 en 46 feos me bare sneer (step 1 abov). prooed To toot 18 e201INTAKE MANIFOLD AIR TEMPERATURE SENSOR ee) DIAGNOSTIC BLINK CODES 2 - 30R 2-4 ‘Test 72 (checkea lor pin © ein short the 1..Checklorpintpin conttyBewoen pin $28 1 tere 6 NO contol, proce to tet 184 ‘pound tne atthe serecrconnactor at he FC Test 128 (Crekng for an coon at he sensr conmectr of # sho at he FIC connector ote ound ping the Pi IEE 8201 VEHICLE MANAGEMENT AND CONTROL Page 81INTAKE MANIFOLD AIR TEMPERATURE SENSOR @e) _ DIAGNOSTIC BLINK CODES 2 - 3 0R2-4 1. Vast naect bon ace of ne FC comes at ease Ten 38 EERIE enna seme 55512 vote ane Fc comet. Locate andrei 5 Tapa | te sno en ropace the MC meu. He Sais felatodse ae GMAT] meres NOT a repsabe conan, repace tha Femeaia, SB Sen ane on the AC nae Sy “Test 144 (Cnecxng or an open sho at ne FC in catane cannacior 1. Vieuly post toh cas of he AC eamactoe anette ¥ teres NOT a repae0ble conten ele the HPOLEETEEEET TT eggTas] AO reduc ‘chctng for an apn oso stone! nee, aoa he 2 Pages? VEHICLE MANAGEMENT AND CONTROL 2-201BUFFERED RPM LINE (TACH DRIVE OUTPUT) DIAGNOSTIC BLINK CODE 3 - 1 OrOrOr' Oe Oe —@ DIAGNOSTIC PROCEDURE FLOW CHART NOTE When performing your elscticl test, it |g Important 10 wiggio wires and Connectors to fin Intermittent connec- ton problems NOTE ‘The engine mist be cunning in order to vWew active ink codes Test 1 (checking for muti fet) wan te engie ting, acoanect the TEM 5-2), reconnect he TEM aorae, end prooeed To 1 aera ew ony on nk 299 9-1). ten lnk (coves 3-2 (RPWDC) ans Sua (EM) ao ac Frocsed to Daptoste Bink Coae, 2-2. 8-201 VEHICLE MANAGEMENT AND CONTROL Page 83BUFFERED RPM LINE (TACH DRIVE OUTPUT) DIAGNOSTIC BLINK CODE 3 - 1 MALFUNCTION “Separang on ara For o9 exo VAC Hoenass Conpcter “Test 2 (Sepang entre! rom an ese tout) 1 Tun te ay OFF 2. Bsconnac ern uns the ‘rete sarl onthe od and on the se ‘he MH and series mols). 4. cent the tctorater cornet. 4, St ne eine Tost 4 (Checking fr 8 start te votage i he ames) 1 Tun te ky OFF 4, sconeet ne PC cornet at he F mas, 4, Tun te tay '5, check for voage onthe bllored RM ne Fn ha VMAC end 3 ha homes to 8 950d Page es VEHICLE MANAGEMENT AND CONTROL ez“Test 5 (cnectng tuto netechometer eran cetera aun 1. Tar te key OF. 2, Raconrat the achometr. hort to ground cr valape at tha tachometer. Tepe to stor, oF relece De Tost 8 (Cnckagtoca shonin tne V-MACHaro8e oF gaurd) 1 Tum the Koy OFF 2, Check opin gn coninuy at th V-MAC ed 1 are NO corte, recoed 1 0816. BUFFERED RPM LINE (TACH DRIVE OUTPUT) DIAGNOSTIC BLINK CODE 3 - 1 MALFUNCTION QBS 8 OGG) @228SlQ) 1B 9B QA 0 O@BoG) |[Leeeo 8-201 VEHICLE MANAGEMENT AND CONTROL Page 85& BUFFERED RPM LINE (TACH DRIVE OUTPUT) DIAGNOSTIC BLINK CODE 3 - 1 7 Hoag arene Comacor TE nse lasses CCrecking coninty between in 29 io Ol BBS, GOGH OO® Cones umper etwaen sin'9 ana p30 Tost 16 (Cnecing for hentia ha FC harness) +. Chee or pt la contnty the FAC ena ot the tameas Pe 2316 acter pine onthe FC 1 ter 6 NOT contruty, proceed to et 32 continu, he bere RPM nee roa “Test 32 (chestng or an openin he butler PM Ine nthe hrnss) 1. Connect jumper between Pa 19a Pi 90 at ‘he FIG ond 9 the nares + here i comity, pocead to test 6. # thee is NOT contin, there Is an pen inthe Pagess VEHICLE MANAGEMENT AND CONTROL 8-201BUFFERED RPM LINE (TACH DRIVE OUTPUT) DIAGNOSTIC BLINK CODE 3 - 1 “Test 64 (crac or one conection oa bad FIC mau) 2. Reconnect the ienomete 4. Sta tn eng lnk code 2-1 pest, repo te FC modus 1 ie NOT preset © conracor was Test 128 (Cracing fore bas V-MAC moc 1 blok cove 3-1 = present, sent he ot FIC rose. Repacethe MAC mode MALFUNCTION Ccpecking for loose conracton or abe e201 VEHICLE MANAGEMENT AND CONTROL. Page 87BUFFERED RPM (TACH DRIVE OUTPUT) NO DIAGNOSTIC BLINK CODE Or OHO+O DIAGNOSTIC PROCEDURE FLOW CHART NOTE When performing your electrical test, it Js important 0 wiggio wires and connectors (0 find intermittent connec tion prions. Test 1 (Crockng the suooly votage © the the watge on th 12 vt «sunny ne on 112 vate are NOT present, tere is NO sippy Test 2 (Checking for an onan he ground ia) eros contin, proceed to at Peoes VEHICLE MANAGEMENT AND CONTROL 6-201NO DIAGNOSTIC BLINK CODE BUFFERED RPM (TACH DRIVE OUTPUT) & ‘est 4 (cracking for an open nha tere 1 tare coins, proceed fo ast 8 Tost 8 (Cnsngtora ad nenometer, or bao loess connector) 2, Racoon he Y-MAC module an tchometer 23. Sat he ene. eta tachometer oes NOT work, replace the Seee6] [e000 ||oeece||ecea, loeess) ©0006] 1 Ooo: Cones» jumper between pin 18 eck coin cay VEHICLE MANAGEMENT AND CONTROL roses0RPM/TDC (ENGINE POSITION) SENSOR DIAGNOSTIC BLINK CODE 3 - 2 Or Or Or Or Or Or Or®8 DIAGNOSTIC PROCEDURE FLOW CHART NOTE When performing your electical tests, it | Important to. wiggle wires and connectors to fing intermittent connec: tion probions. NOTE ‘The engine must be running to see an ‘activo auton the RPMITOC clu. The RPMITDC sensor PLUS (+) Pin A is ‘connectod to the V-MAC RPM MINUS ()Pin 7 in order to invert tho signal Tost 1 (Creceg fr 2 open oF shart a he 0 200 an 900 oh ime restence is NOT wine tis rege, te fopan or sor Repair the connector el Pageso VEHICLE MANAGEMENT AND CONTROL 2-201RPM/TDC (ENGINE POSITION) SENSOR DIAGNOSTIC BLINK CODE 3 - 2 Test 2 (Checking for a short to ground in the [rang Semon sm 1. Chk for conti rm the RPM sonarus (B88 good roura 1 hore conn, loete an rap he shot ‘Checking coninaty tom Fin A Test 4 (chectng for # shor to vtiage Inthe revrass) 1 ecoanect he hanes rom the V.NAC modus 2. Tum the Hey on. 2. Rana te votge orn he RPM PLUS) (Pa 18) Sed RPA NANUS(} (Pa?) onthe VAC oe ho eter tne shows rere tnan 0.5 ot, the tt ne ‘opal te te Mosse vage on Fin 18a Pin 7. 8-201 VEHICLE MANAGEMENT AND CONTROL age 91RPM/TDC (ENGINE POSITION) SENSOR, DIAGNOSTIC BLINK CODE 3 - 2 — Test 8 sna twee we : Roatan reeset onsets poeee meet anes a esate taetienssaaeey 1 te gna is NOT eaustes propery, requ te ‘hecking adamant of sonar VW Hanase Conner “Test 16 (Checking fer & pn 10 pln shor inthe 2. Check or cnt tom the REM PLU () An 1a RPMS -) Pn 7 wa eer pine oe ancien wth cont, rep te shat "wing harass, between’ tha pibe wich Checking contin bewoen in 7nd pin 1 irs NO coninuy, proses to test 32 * ‘NOTE, 1 ner fs continuity with ground pins 30 and 3, there may also be cortuity with over pins. Repar the snort to pins 30 and 3 fst and retest. Page 92 VEHICLE MANAGEMENT AND CONTROL 8-201RPM/TDC (ENGINE POSITION) SENSOR & @ DIAGNOSTIC BLINK CODE 3 - 2 Tost 22 (Coaching for en open nthe arr) +. Comme a jumger between the RFA MINUS (-) Pa? endtne BRL (Bn Bate -HAC end 2, Check or contuty Bataan he RPM PLL 4) IMIS (-) Pn Bate sens end ‘Test 64 (Coeostg for sn open oF short he arse o sensor eomectn) 4. Measure th esr betwaen ne FEM MINUS ne restos ¢ between 200 and 300 ons, 1 he estance is HOT within th ange he Ines pools. Rapa the proto ‘herve rptce the sonst Oe6ee| D2Seeq) OOSeG) O®@OOO) ie @ckele) ToAG Farnese Comesior 2288s saan @ Ole | 0 2D OO) i anda 8 8-201 VEHICLE MANAGEMENT AND CONTROL Page 93©8639] 92886) O©@8a6) O®@O@O) ‘Cones «jumper between Firs 18 and 30, RPMTDC (ENGINE POSITION) SENSOR DIAGNOSTIC BLINK CODE 3 - 2 “Test 65 (cnc fran open n he PM An? Sie at he VAG eo he nares) og, Bn, and Pn 30" YMC ond he 2. Chek tor conn between the RM MINUS =) ng (8) arm good grou the sence ond ot (pound Hiner mtn contnly opsrsha RM “Test 128 (Checking for # bad V-MAC modu of 1 Wan tbe key off, raconnect the YMAC Founa,veptce tha V-AIAG mos ond retest I ink ce 2-2 not ctv the procecireshave Page 94 VEHICLE MANAGEMENT AND CONTROL 8-201INJECTION PUMP RPM (ENGINE SPEED) SENSOR DIAGNOSTIC BLINK CODE 3 - 3 —_ ~ 1990 - 1991 PS De = 1992 - Later re | (Also some remanufactured & service pumps) Po) ge 4 pRceemeneee h 4 LJ ‘NOTE \When connecting the harness connector fo the pur (ortho removable jumper tothe puro) tse extreme caution. Tho ful Injection pun side ofthe connector may become damagec 2y cross thvesdng, dve tothe combination of aluminum and plastic parts. Als, thre Is fan O-ring located in tho cable connector end. Be careful not to lose this O-ring. Apply lubricant (Lubr2ol #OS-S004s or equivalent) tothe O-ring. After assuring thatthe threads fare not crosses, tighten te connector to T5 bf. (20 Nm) torque using a cowloot wranct (Snap-On toa # ANBSOE-22A or equivalent). Wien the O-ring contacts the te coupling fing, a false Irlcation ofa fuly seated connector may be given. Tightening the connecter to the recomnended torque will prevent this trom occuring. \Winon removirg oF instaling a removable jumper hamess, be sure to follow he instructions Contained in the "System Connectors” section of this manual ‘NOTE Whenever this agnostic procedure asks you to mako a Continulty check, be sure 10 use the “Continuly” feature of your volmeter. Ree to tho Instructions for your voltmeter for the specific structions on how to use that foature, 8-201 VEHICLE MANAGEMENT AND CONTROL page osINJECTION PUMP RPM (ENGINE SPEED) SENSOR DIAGNOSTIC BLINK CODE 3 - 3 surcnow ute soe ‘i e—— SIR CC) CO PIN NUMBER DESIGNATION 3 Engine poss senor PWS (tno é & ck poo saree Se F : PLUS fo) 12s 6 NOTE The iniection pump RPM sensor is located Inside the injection pump. NOTE Before performing the folowing tests, be sure That the RPMITOC sensor is properly ‘adjusted, Refer to Diagnestic Bink Code 2-2, Test 6 for adjustment procedure. NOTE 1 tne versie Is equlpped with @ removable jumper harness, do not remove that hamess Unless instructed to do 30 Inthe folowing tests. Al tess are performed at the Deutsch Connector end of the jumper uness otherwise noted. page 98 VEHICLE MANAGEMENT AND CONTROL e201INJECTION PUMP RPM (ENGINE SPEED) SENSOR DIAGNOSTIC BLINK CODE 3 - 3 OrOrOr Or er > @ ' + t t ® © © @Q+O— DIAGNOSTIC PROCEDURE FLOW CHART NOTE When performing your electrical tests, it |g important to. wigio wires and Connectors to find Intermittent connee- ton probes Test 1 (Checking for an open or shoes RPM senso “Tos Warnes Asorby SO ln Somes 1. Tum te kay OF. 2, Disconnect the sngine harness from the injection ©0e 3, Conect the Bectene ction Amp Test ernas Reser (848) fo he ection pump enracor (sho = equopes wh (Deusen Pow ¢ on). 1 the resistance between $00 anc 1100 ob 8-201 VEHICLE MANAGEMENT AND CONTROL Page 97INJECTION PUMP RPM _ (ENGINE SPEED) SENSOR DIAGNOSTIC BLINK CODE 3 - 3 Test 2 cresting ors shana grovndin he pure 1..hecker ont Hem Fn 3 Oausch Fn) 12 tore eNO continu, reece to te Test 3 (Checking fr an open in the pimper 1 te pump uses a jumper hanes, ten visa ‘Comerisfortheacston a he sector ‘ction pun ena of th emper tars Rept dns ara Ent the begin othe ction, and rte pa os VEHICLE MANAGEMENT AND CONTROL e201INJECTION PUMP RPM (ENGINE SPEED) SENSOR DIAGNOSTIC BLINK CODE 3 - 3 “Test 4 (checking ora pinto pn shorn t pump Tea Hamoss Aesomaiy Seven pa onec] sssomb) “rb ot pare +. Cre or contr tom Pa 3 (etch Pa 6) 10 Png 2.56 ana? (Deutsch Ps A 8 EF 6) on 2. Papa he ts fr i &(Douseh Fin Tost & (check fer # stot 10 tours in the Sssemby, ortho regal joer Mrnes, on hen root hares, end eit te janper harness pump oo for ep of rep {sumo essomby. and ten ees. 8-201 VEHICLE MANAGEMENT AND CONTROL Page 99INJECTION PUMP RPM (ENGINE SPEED) SENSOR DIAGNOSTIC BLINK CODE 3 - 3 FIC Modu Harms Connector in Uzcatons iz eae eee EEC E PE aaa Test Harness Assert Seven emai Tost 8 (checing for stort to votige the 2 Tum the kay ON, 3, od mo votage Fer the RPM PLUS () ana eM uns) Pee a7 and 4 ot the FC end fhe “Test 9 (cnecing for 812 vot she othe REM YMRS (ne the pump) (Cy Bina Deaton PO) an 1 osu On ‘he pur test essen 1 ete NO caninsy, proceed ott 18 Page 100 +~-: VEHICLE MANAGEMENT AND CONTROL 8201INJECTION PUMP RPM (ENGINE SPEED) SENSOR DIAGNOSTIC BLINK CODE 3 - 3 “Test 16 (Checking for 8 pn to pn shore (poundes BPM LAS) Sw ate FI ond of ho Fc Module Hamase Conscter 1. Turn te ey OFF 2. Cys tr pinto coin om th RPM ELLIS fa) pn #7 toa her pina tthe For ofthe aaa Sara 1 re NO corny, procees to tt 2. thera is contin, te RAM PLUS (4) tne Tost 17 (Chasey 19 vt on he FEM MINUS amp Commas, (Sn inthe engin hemes) erga eness Sue B on th FM MUS (Pin 4 arose to 8 92d ound 12 wots are pasate PMMINUS (shorted {Beate ond reper the shon and rele the PC 1612 volte ara oT prasent, the APM PLUS (4 6 8-201 VEHICLE MANAGEMENT AND CONTROL Page 101& INJECTION PUMP RPM (ENGINE SPEED) SENSOR DIAGNOSTIC BLINK CODE 3 - 3 Test 19 (Cracking fra ther to ahr ns in tne root cenncten hrnate 1 somect othe engine names, OF the [Souaorsesomby, and thn ets. 1 0 pur sos a ner name sere a pro, neva he ena ‘Systeme Connector tecton of bie mera! (eee "abe OF Coments forthe coaon of ha secon 2. choc or contnuty between An C ad al tar pina on tha engine harness end of te jamper famess (Fn A. 8,D, EF ana) Segining a te eocton Rant he pump ed cluster easomby ae the atest, Test 32 (Crectng for an open othe enone hernens Fem PLUS Ts) nga harnsesbawon th FM PLUS) end PEM MINUS () "ine 3 ana (Gateoh ne and) 2. Check tr conaty between Pins 47 and 6 a ‘he FG ond of tha names 1 ret NO coninsy.proosed 0 tat 8. Page 102 VEHICLE MANAGEMENT AND CONTROL e201INJECTION PUMP RPM (ENGINE SPEED), SENSOR DIAGNOSTIC BLINK CODE 3 — “Test 64 (Crecing for an open at the pune comectn) 7 Moa arate Cooactor 1. Remove the pnger we (states ourhg st {eae he pump endo the angie Paros 2 Recannac he sump comet fe eee ap Seneca Tost 65 (Crecing for an open in he enone nest) Pre hand) Ste FAC ond of he hare [MINUS (a in engin ames oe connecter. e201 VEHICLE MANAGEMENT AND CONTROL rage 103INJECTION PUMP RPM (ENGINE SPE) SENSOR DIAGNOSTIC BLINK CODE 3 - Test 128 (nooing fora bes FC module er & aoe comecton) i lnk code 2 = 9m peso, reac the FC hve eoacted he problem. Check a cormectos MALFUNCTION Page 104 VEHICLE MANAGEMENT AND CONTROL e201INJECTION PUMP RPM (ENGINE SPEED) SENSOR NO DIAGNOSTIC BLINK CODE Oor® DIAGNOSTIC PROCEDURE FLOW CHART NOTE This feut is usualy found in the inactive fault table. When it does appear in the sctve faut table, i usualy lasts for only 110 2 secanes. It then alsaopears without the Elecironic Fault Light turing on. ‘NOTE This fait 10s similar to Blink Code 3-3, but its very aifrent, This foult says thatthe ‘engine speed exceeded the customer's engine overspeed limit sot in Customer Data, To ‘tinguish th fault rom Blink Code 9-2, 100K a tne inactive feut table with the clagrostic tool. The Tau generating Blink Code 3°3 will show a flashing "33". This fault does not have a flashing number. Test 1 (checking for proper RPMIOG setae adustert) 1 the sonsor was oper acued, pccted 10 test 2. the sonar was NOT properly tos, roast the Sonor “Test 2 (Checking the Customer Engine Overspeed setting) 1. Using agate to, enact Customer Oat sto for he overap00d stg. ele caer or top foreman hat ine engine hac onceded the coms severapeed it (20 nt Fety the sve). Pop te muro o accurarces tat ha has Nappaned rm the nace 0 tad. Record on ne eps Order long win the numberof cccrences. Recheck te nacive faut tbe ater you have fnthed you sarin of ha vc toe aie tht the nce procedure Mave tested mee e201 VEHICLE MANAGEMENT AND CONTROL age 105TIMING EVENT MARKER (TEM) DIAGNOSTIC BLINK CODE 3 - 4 Oo ORO Om -@ DIAGNOSTIC PROCEDURE FLOW CHART NOTE When performing your electrical tests, it ‘important to. wiggle wires and connectors (0 find intemittant connec: tion problems. NOTE ‘The engine must Be runing to eee an ‘active faut on the TEM clout Test 1 (Crocing for s9 open oF ston the sn 1. Tunthe kay OFF ans connect he TEM sensor trom te mess. ‘eps he somector or eloce th sono. 1 ne resistance f Between 10D and 600 ots, VEHICLE MANAGEMENT AND CONTROL 8-201 Page 108Tost 2 (Cowcking for a sho to ound the 1. ackor conti tom te TEM PLUS (4) PA Tost 4 (Checking for 9 sort vatape in me ess) 1. scomct he atrass fom the: YMAC 2. Tun he anton key ON, 2. Ra tn votog rom the TEM PLUS no (nn 20) and the TEM MOUS (-) le (ph Tat the 1 ho wage on bot oe lass he 0.5 ve, ez VEHICLE MANAGEMENT AND CONTROL TIMING EVENT MARKER (TEM) DIAGNOSTIC BLINK CODE 3-4 & ‘Checking cntinty Hom Pin A ‘VMAS Fess Consocor 2ee8e| [eoeee |2@SS8l0) 1 O28@eQ| lO®O@O} 1 ||O @ Page 107& TIMING EVENT MARKER (TEM) DIAGNOSTIC BLINK CODE 3-4 Test 8 (Checking fr proer TBA sang) NOTE 1 te tining event marker ie removed and reinstalled, and it does not have a jam rut on the body (G4MT2894N), i is essential to ensure that 8 new washer (part number 835 2916710613) is also installed and the sensor i tightoned to 22 ib. of torque. Ifthe sensor has a jam nut (64MT283BM) @ washer Is not ‘required. Coat the sensor threads with Silastic and then tun the sensor body by hand into the pump housing until it bottoms out then tighten tne jam nut to 22 it of torque, “Ting Event Matkor (TEM) Sensor 1. Check na the sensor eprops stan te 1 e ropey seated, proceed tet 16 {he above NOTE andnen ets ee te eat 18 (Croce fr 9 19 in ah nthe [SSSS6] [OSSSO]| 2 once @2e8s6| oO} 1B line (gin 20) an joeees| eal (0@@oo) 1 G ty between the TEM PLUS) Mats) ie pO) ad ther 6 NO cont recoed to tou 32 rang coniny between pit 10 on 20 areas botwecn the pine whieh snowed ‘NOTE 1 thee is continuity with ground pin 30 fang 31, there may also be continuity with other pins. Repair the short to pins 50 and 31 first and retest. Page 100 VEHICLE MANAGEMENT AND CONTROL 201& “Test 32 (Checking fran open inthe nae 1. Comect amps between the TEM MUS -) {on 10) and the TeM PLUS 4) fain 20) on to Vis ano th Pros. 2 Chock for continty between the TEM LUSK) Tn (A) andthe TEMMINLS(-) (pn) ‘cor ang ho ros. 1 ters NO cont, proceed to tet 8. “Test 64 chectinglor en apn atte sensor ono ‘ne hemes) 1. Remove te Jambar atthe V-MAC ene of to armas tom pine 10 and 20st he V-MAC ond of PLUS () or MINUS) ngs are open TIMING EVENT MARKER (TEM) DIAGNOSTIC BLINK CODE 3 ‘AAG Farnese Connector Connect jumper betwsen pi 10 and ‘Shae, Chak crtay beeen pa 8 88886 lo 1808S essing rsieance between pin 20 e201 VEHICLE MANAGEMENT AND CONTROL Page 109TIMING EVENT MARKER (TEM) DIAGNOSTIC BLINK CODE 3-4 808e] [eoeeg jeeeeelg jSeeee [©©0@6) Gone» jumoorsetaeon ping 29 and 20 nae Graco serrybetwaon gn a rand V-MAC MODULE COncking fra damaged sonectr Test 65 (Checking te an cpeninthe TEM PLS (s) 1. Connectajunpse beeen ne TEM PLS (ne (on 20) and in 30 ov he VMAC df tho 2. Check for cont ram he TEM PLLS() ne {pina) ote sensor endo te arnaes to a nann ine (an 10), (roe. ihre si NO eons, eparne TEM PLUS (tre (pe 20) Tost 128 (Cneckg fra bad VMAC rose o& wih he kay OFF, reconnect the VAMC 2. Sean ma eran. lnk ode 3-4 st act, obec te Y-MAC 7208 the V-MAC mode ‘onected the probem. Cracr a conractos 10 Page 110 VEHICLE MANAGEMENT AND CONTROL 8-201TIMING ACTUATOR DIAGNOSTIC BLINK CODE 3 - 5 ‘The diagnostic tests for this assembly are divided into wo individual sections, ‘electrical and mechanical. The results trom the first test wil Indicate which section of te tests, electrical or mechanical, to perform. Test 1 (cresting the leedback ting) A, Connect agoste reader (Pro-Lik $000 or Bo) to etc ros rede tay Cc. Runt engin sigh ior atleast 30 seconde ‘awn n tbe spacteatons vy 1 eogree oF moe, froveod to tet 13h tha mectaneal secon. ek engin ring ing th Fro trom zoo (0) 0 eo (2) degoos loss an Ie tow, proces 0 tet? of te elec there, proceed! 1 tat 17 ofthe mechanical e201 VEHICLE MANAGEMENT AND CONTROL age 111& TIMING ACTUATOR DIAGNOSTIC BLINK CODE 3 - 5 ELECTRICAL DIAGNOSTIC TEST SECTION Om ® ' ® ' Or® DIAGNOSTIC PROCEDURE FLOW CHART ‘NOTE \Whon performing your electrical test, it Js Important to” wiggle wires. and ‘connectors to find intermittent connec- tion problems. Test 1 (Crockng fran eral shor oF open a 1 Ta the ton bay OFF. oe etn non on Page 12 VEHICLE MANAGEMENT AND CONTROL. e201TIMING ACTUATOR DIAGNOSTIC BLINK CODE 3 - 5 Test 2 (Chectng fora short to ground the selon) Tost 11 (Checking for short nth nena) 1. Tun te ition hay OFF. 5. Tun te lotion Key ON 4 measure te tage Hom theming sloroid PuUste) Ine in 21) on tho Ramess Yo 8 good ‘checking cminy Hem eter to gun Measzing voage on pin 21 8-201 VEHICLE MANAGEMENT AND CONTROL Page 113TIMING ACTUATOR x DIAGNOSTIC BLINK CODE 3 - 5 [Qe8ee] [e00e0) 28 |0/92299 Og se|V|e0eee) 1 [99008 Ccnckag contin on in 21 VAG Vesnase Consctor |B OBSO| o|@22e9) |G O8@@| J ©ooos| ‘eoking comity Bewoen pint ana pn 21 “Test 28 (crookng fora srt te round i the rarnaes) 1. Tn te ton ey OFF 2. cna fr conn botwoen te tring sland FLUS{H) te (an 21} 0 he ernee an 8 good ond if erie contnty, eet ar rap te ahr 0 1 ret NO cont proceed to 18 47. “Test 47 (Cnscking fran open the hanes) ene ee as gsr ire resistance not es han 3 os, leet ad Page 14 VEHICLE MANAGEMENT AND CONTROL. e201Tost 94 (Checking fr pn to ps storm he mess) 2. Checker inte cominty tal er pins on ting soled LUS(e) tne pin 21) 0d ting ‘end MINUS! ne fe) 1 tar contr, sate end epirno pao plo foro motes te V-MAG mode conmetr TIMING ACTUATOR & DIAGNOSTIC BLINK CODE 3 - 5 ‘VAG Hames Comer ‘cracking coninty bewaen pnt and tar e201 VEHICLE MANAGEMENT AND CONTROL page 115TIMING ACTUATOR m DIAGNOSTIC BLINK CODE 3 - 5 ee MECHANICAL DIAGNOSTIC TEST ‘SECTION sr! veto the Ecorovnce leper Sganas wt Eororecn Eerrparson wih ear rau, in ron OF mcton page 6. VEHICLE MANAGEMENT AND CONTROL e201TIMING ACTUATOR DIAGNOSTIC BLINK CODE 3 - 5 F, foosd fw bw Wie ning Guglayed on he 1. Compare the dlagnoste reader ting to me pected command tng by mare Be 1 deo, 1 she diagnose asc ining is win 1 degree of IF ne dsgnati ender tng is Nahe ante H. Compare th saprce Checking ol spp fom the sles cars 1 he dlagoste po ot pressure i aunty toner Save toe ooonovaon than the galery ot possi, Bo 1. Compare te dagran prt ot pressure 1 the bile presse won te Yeodback tig = te dlngnoste prt preter is Ops proces etna sapnort pr ol pressure is her than 0 8-201 VEHICLE MANAGEMENT AND CONTROL page 117sh TIMING ACTUATOR Ce) DIAGNOSTIC BLINK CODE 3 - 5 Test 4 (Chootng for of sippy tom the ssorocenee) (open top C of tat 3 vrneprassur i, ves operating prover mane and ropsa on af Tt 3. vate egace the soenod contra “alve and proces tot “est & (Cnecking to so correct acon taken as retovea the prebion) euscrronc from ele to maura FM MALFUNCTION ie aut imp 608 rh, an no fa sos fine VAG meal, the probiom tae Been fordcamandal ects bythe ede) present Page 118 VEHICLE MANAGEMENT AND CONTROL e201Test 6 (Chackig fr» locked of tle TIMING ACTUATOR DIAGNOSTIC BLINK CODE 3 - 5 2. nackte esonvance ol sup ole “Br the aco tng at ow argh ‘A CAUTION ] Test 7 (cresting foro poor VANAC module ©. epee toe & and 8 of Tes Weide ow ie tn mae an 2 ‘Sack tht hla shown by te arom ‘degre ler than povcunty torte, {he VMAS mod and proceed tot 6. e201 VEHICLE MANAGEMENT AND CONTROL rage 119TIMING ACTUATOR DIAGNOSTIC BLINK CODE 3 - 5 Tost 8 (Chackng ssc ving) 1A. Chek the engine sate tring See Ceting Engine Ting Stor) Econovence unt reusing the solenoid waive Proce to tot 8 1 esa ting amore than 2 degra terost Eeenovance Timing Advance (Current production) Test 9 (crexng fr sup oom the eyncer lee othe Esanovence) Romar th etl sy ne sng Yom 2, nen ste fing st he Eoonovanes housing, (Aeon a pressure paige too se of he 88 the es tothe oyna ck Eeanovenoe ol SUPIY siya on te gone. na ol pressive 5 pao ss, STOP he engine ate A Toe Fitng An Pressure Gauge As Saraoe Manu ie ll presse ie gree nen 6p proceed 1 Page 120 VEHICLE MANAGEMENT AND CONTROLTIMING ACTUATOR DIAGNOSTIC BLINK CODE st 10 (Cracing or impropey ratalea sero ‘yoked ols cont ve poy ase (Popa et 1, to A rough 1. Comeare the surrent lagna reader ting fo the species command bring (998 engine Derameter vues ‘Specled ommend timings, proceed to fst 8 Cenk Fite, tnd Chack For Proper Gasket, of owe com Parameter value} fortis erp, gYoc860 1 Tes 1 feedback ning 1 degre o mor es than oe Tost 12 (Crackig noni feedback tins) operating at hah oe fr mins) of igh ie command tng forthe frome me spenaalveiwacecive.Mepace ne \ Fedbsck ting within door piso miu) {han igh idle commend ing, procees ooo 13 8-201 VEHICLE MANAGEMENT AND CONTROL page 12TIMING ACTUATOR Duucnosnic BLINK CODE 3 - 5 Test 19 Checking sno ong) 1A. Check engine stat tn ta proce ttt 8 Ihe stati ting corect ana tne rocorcad Lom fr iign ise enag = higher than te aera Tr poy oa NTC (rg ono) (engne poston) sanoo” comer. 1 there fe no contnty, tepie te nemess, ‘hachng oc conny been pn Bath VM onmecon Proceed to ta 6. 2 pote ne sta ning correct and the wo pn le tring sot hah: the engine, ropace tei ana recon fo et rovence hau er is tho ote aha ‘lu suaraton ‘ad’ side est Fm he create teresa page 22 VEHICLE MANAGEMENT AND CONTROL. e201TIMING ACTUATOR Gd DIAGNOSTIC BLINK CODE 3 ~ 5 Test 14 chectnc fr stra ing contvahe curen) |A. Tum eign hoy OFF. 2. iaconect th anlenat ning conte! vee (O) Betts "o neaeue euret (A¥FS) nme Wk mocule ans procead Tot 8 he faut amp dos ot gh an feu ogg inte VAC mdue, the probm has been uccosty reso oonovenes it musing the sora orl ave e201 VEHICLE MANAGEMENT AND CONTROL Page 123MPH BorD SPEED) SENSOR DIAGNOSTIC Sink CODES 4 - 1,4-2,4- Cen t t t @ t @ © t ® © 1 ® { DIAGNOSTIC PROCEDURE FLOW CHART Page 12¢ VEHICLE MANAGEMENT AND CONTROL 3 6-201& MPH (ROAD SPEED) SENSOR & DIAGNOSTIC BLINK CODES 4 - 1, 4-2,4-3 NOTE When performing your electrical tests, it (Important to. wigglo wires and ‘connaetors to find intermittent connec- tion probes. Test 1 (Checking fron open, shone or active 1. ake eran tha V-MAC module ON. (Tokay ‘Short (link code 41), proceed 0 ts 2. ‘open ink code 2) procaod to ts 3. Inactive (lnk code 4-3), neta MPH sonar or lst to proper ating. (For Brn bok tout vay one, Tore te ‘NOTE When Blink Code 4-3 Is logged, the Electronic Mallunetion Lamp may not 0 fut (ater repatr) unt! the vehicle has been driven a short cistance. MALFUNCTION eck fran open, stated or eto “Test 2 (verying bine codes reset) ihe -Mae mole row sees an ope, (code Ik code 4-2 is NOT precnt, proceso eet, ‘uPa Sensor 2-201 VEHICLE MANAGEMENT AND CONTROL Page 125fA MPH (ROAD SPEED) SENSOR @#éz) DIAGNOSTIC BLINK CODES 4~1,4~2,4-3 age 128 VEHICLE MANAGEMENT AND CONTROL 8-201MPH (ROAD SPEED) SENSOR DIAGNOSTIC BLINK CODES 4 - 1, 4 - 2,4~3 “Test § (Checking fr contuty mth hanes) VRE Vmass Coma 2. oaconnec he V-MAC modu connector at ho O868s| |Seeeo a Besee ol @22e9) 3. Check fr contrat rm the MPH PLUS) fe OB Ge OO @8| rs an SSee0 i} Oelelols) “Test 6 (Cwcrng for rsinarc in the sense. 1. olsconect he MPH sensor 2. Creche co tha senor po. (8 8-201 VEHICLE MANAGEMENT AND CONTROL rage 127MPH g DIAGNOSTIC (OAD SPEED) SENSOR INK CODES 4 - 1, VoWAG Farnese Comestor [H2E8e| [@2eea 28888|9/82e00) 0 O@OOO} OOOH) ig coin beter Sno eo pn Moran wage ass i & ‘Test 11 (choctng for contnuty on the MPM PLUS(+ end MPH MINUS) Ine) 1. cock fr cortuty betwen te MPH PLUS(s) inom) anne ww) tn 1 are NO contnty, proceed tots 23. Tost 12 (Cncing te vtage in te harness) 1. Wear the votage acoes tho MPH PLUS) ns {pm A) ana me MPH WIS) Ine (an 8) on the Page 128 ~~ VEHICLE MANAGEMENT AND CONTROL 8-201MPH (ROAD SPEED) een DIAGNOSTIC BLINK CODES 4 - 1 Test 23 (checking for contnuty in he harness) 1. Check for contuly betwen tha MPN FLUS(s) Ice (an 6) and a ter png ato V-WAC ond of the nena ofa pn in shor Is preset, wera NO ston, procced to est 47 “Test 24 (Checking the valtage on he MPH PLUS (ote) 1. Tun te gion kay OFF 4 Tum the gon Key 65, ed he votag om he MPH PLUS) Ho (pn 65 ethe WMAG ana of he harness 10 pone ound ithe vote grater an sero vot, acete and He the wotuge ie NOT grata than 2010 vas, VAG Varna Comecior ren cnt baton Seem Sta ae TAG Tmase Conseco | ———— 2» 2 ©2886] [@9ee0 B@88B/0) S988) BOO) OG OOO] 1 OOO) eosuing votes en pn 6 8-201 VEHICLE MANAGEMENT AND CONTROL age 129MPH g (OAD SPEED) SENSOR DIAGNOSTIC BLINK CODES 4 - 1, & Toa Waa Comer Test 25 (Cnecung te estos in the hanes) 28688] [S2eee 2 vet ns O288O/ 9/8280) eaa) 3. Diconect the V-MAC mode cons ©0O@6| 1 |[OROOB} 4 Road the eitance fromthe MPH PLUS) ae {on ) tothe MEM MINUS) tne (in 1) on te Coking reitance between inte hanes, “Test 47 (Checking for 8 pnt pln shen) vatac moouLe 1 Muay nape ne VAG meant sn ‘he VeMAG connect. 4 ar ae NO resco sons ele the ‘crecing Vee modus eomactor on VEHICLE MANAGEMENT AND CONTROL e201& MPH (ROAD SPEED) SENSOR “as” DIAGNOSTIC BLINK CODES 4 ~ 1, 4 ~ 2, 4-3 Tost 49 (Checr fr eontnuty in me ramos) 1. Check or coninty am the MPM PLUS ne Un ete Ms made ona arn Coking sontnuty oetween pn’ anda oer ane Test 51 (Creo fra bad connecter) 1, Veuy spect ne V-MAC modus commctr, ne praia NO ong ets, rein he ko e201 VEHICLE MANAGEMENT AND CONTROL page 121RACK POSITION SENSOR (RPS) DIAGNOSTIC BLINK CODE 4 - 4 AND 4-5 F142 1990-1991 WS 7 1992 - Later ne (Also some remanufactured & service pumps) Lt wee [ple AO me, moe temoven 11 injection pump connector ® re ‘NOTE \Wnen connecting the hamess connector othe pum (or the removable jumper to the pump) se extreme caution. The fue! injection pump sce ofthe cannector may become dameged 2y cross treading, due to the combination of aluminum and plastic pats. Also, thee is ‘an O-ring located in he cable connector enc. Be carat not to lose this O-ring. and apply lubricant (Lubrizol 408-5044 or equivalent) to it. Alter assuring that the threeds are not ‘crossed, tighten the connector 9 15 1b. ft. (20 Nm) torque using a erowoot wrench (Snap-On too! # ANB508-224 or equivalent). When the O-ring contacts the the coupling ‘ing, @ false incication of a tly seated connector may be given. Tightening the connector to the recommended torque will prevent this trom occuring \When removing or instaling @ removable jumper haress, be sue to folow the instructions Contained in the “System Connectors" section of this manual ‘NOTE Whenever this dlagnostc procedure asks you 19 make @ Continuity check, be sure to use the “Continuity” feature of your volmeter. Refer to the Instructions for your voltmeter for the spectc Instructions an Row to use that featur. Page 132 + VEHICLE MANAGEMENT AND CONTROL 8201RACK POSITION SENSOR (RPS) DIAGNOSTIC BLINK CODE 4 - 4 AND 4-5 utonos eu ro Hamas ee an DIAGNOSTIC BLINK CODE 4 - 4 Test 1 (Cnsckingtorebas FC modus orinacton ene) ae ee weeemerammmenmes || a Ton ecetainaa nestvasine oss ojatment Poca. efor v0 the Tale OF 8-201 VEHICLE MANAGEMENT AND CONTROL page 33.RACK POSITION SENSOR (RPS) iy DIAGNOSTIC BLINK CODE4-4AND4-5 @ed) rr > @O) > @ oe © © DIAGNOSTIC PROCEDURE FLOW CHART NOTE DIAGNOSTIC BLINK CODE 4-5 We worice 's eaupped wih a NOTE emove that hamess unless ‘instructed When performing your electrical tests, it ‘odo 80 in the folowing tests. Al ests | important fo wiggle wires. and {are performed atthe Deutsch connector Connectors to find intermittent connec fond of the jumper unless otherwise tion problems. rote “Tout Ravats Resonsy SEA ETRE] _—_TeSt (Checking or an open or shrine enor ‘nbaccal pimp | nthe pump) ‘ imegr! heoer nerees, Gasormect athe ares Aesemby (38746) 0th wictan pr Connector anop = eaulpped nih). (Deuisan Pia F to €) ord Hom Ain 1 fo Pn 6 (Gauison Pe A oF. 25 oma, prosed to tet 2 ine reaetance NOT min range, rondo Page 14 + VEHICLE MANAGEMENT AND CONTROL 8-201RACK POSITION SENSOR (RPS) DIAGNOSTIC BLINK CODE 4 - 4 AND 4-5 ‘nthe puro) ‘ao the satan rom Pt (Dautseh Fn (Bouts Pn). Xe reitaoe ts between 90 and 60 orm, Tost 3. (Creckrg fo an open in the jarger 1. me igcton pure does NOT use 2 joer Fhe pump uses 2 umesr hanes. thon visu (Saharan) ft roar re oe pomp ae annyalamon hanes ane bump nop frreper tte pump ante umpe 1 me pump uses a jumper harness mat CAN bo “Table OF Content forthe lection of tis tec Removable Jumper anes 2 Check tor contrutybetacan Pa Fa he engine areas ona ejungertaross ana Pn on ‘action pun endothe hmper nameas- Ropes! ran pinahows NOcenuiy, han eps or repace ‘he Begining ofthe seen. e201 VEHICLE MANAGEMENT AND CONTROL age 125DIAGNOSTIC BLINK CODE 4 - 4 AND 4-5 & RACK POSITION SENSOR (RPS) & cr ‘onbagkg pum ©o OO © @0 Removabo Jumper ‘Haroens vatage i he puro) Choose ene of nse pin: Fn} (Deutsch Pn) Pe Samer neha 8 on Pa), Ok ‘ennacor uot each tar an othe es 1 ere NO contny rocees to 188 1 tne continu, proceed to ast 8. Tost § (Cneckng for an open fe jonpar conracer pump stop for repair ofthe pm, nega Ene pump uses » jumper arness mat CAN be Shear Comoctors socton of tis manus! (608 “ale ©F Comer forthe ean a ha econ. 2. check or contnty between Pn Aon terns the procegure fr Pn & and Pn 6, HF ether pn shows NO contty, thn rep ump shoo or rps. and rete, Page 128 VEHICLE MANAGEMENT AND CONTROL e201