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Circuit/System Testing

Clutch Pedal Position Sensor Malfunction (Manual Transmission)

  1. Ignition OFF, disconnect the harness connector of the B25B Clutch Pedal Position Sensor.
  2. Test for less than 5 Ω between the low reference circuit terminal A and ground:
    • If 5 Ω or greater 
    1. Disconnect the X1 harness connector at the K20 Engine Control Module.
    2. Test for less than 2 Ω in the circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the K20 Engine Control Module.
    • If less than 5 Ω 
  3. Ignition ON.
  4. Test for 4.8 - 5.2 V between the 5 V reference circuit terminal C and ground:
    • If less than 4.8 V 
    1. Ignition OFF, disconnect the X1 harness connector at the K20 Engine Control Module.
    2. Test for infinite resistance between the 5 V reference circuit and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. Test for less than 2 Ω in the 5 V reference circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the K20 Engine Control Module.
    • If greater than 5.2 V 
    1. Ignition OFF, disconnect the X1 harness connector at the K20 Engine Control Module.
    2. Test for less than 1 V between the 5 V reference circuit and ground.
      • If 1 V or greater, repair the short to voltage on the circuit.
      • If less than 1 V, replace the K20 Engine Control Module.
    • If between 4.8 - 5.2 V 
  5. Verify the scan tool CPP Sensor voltage parameter is less than 0.1 V.
    • If 0.1 V or greater 
    1. Ignition OFF, disconnect the X1 harness connector at the K20 Engine Control Module, Ignition ON.
    2. Test for less than 1 V between the signal circuit terminal B and ground.
      • If 1 V or greater, repair the short to voltage on the circuit.
      • If less than 1 V, replace the K20 Engine Control Module.
    • If less than 0.1 V 
  6. Install a 3 A fused jumper wire between the signal circuit terminal B and the 5 V reference circuit terminal C.
  7. Verify the scan tool CPP Sensor voltage parameter is greater than 4.9 V.
    • If 4.9 V or less 
    1. Ignition OFF, remove the jumper wire, disconnect the X1 harness connector at the K20 Engine Control Module.
    2. Test for infinite resistance between the signal circuit terminal B and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. Test for less than 2 Ω in the signal circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the K20 Engine Control Module.
    • If greater than 4.9 V 
  8. Test or replace the B25B Clutch Pedal Position Sensor.

Park/Neutral Position Switch Malfunction (Automatic Transmission)

  1. Ignition OFF, disconnect the X1 harness connector at the Q8 Control Solenoid Valve Assembly on the automatic transmission.
  2. Install the DT-47825-10  jumper harness to the X1 vehicle harness connector.
  3. Test for less than 5 Ω between the ground circuit terminal 5 at the DT-47825-10  jumper harness and ground at the transmission case.
    • If 5 Ω or greater 
    1. Ignition OFF.
    2. Test for less than 2 Ω in the ground circuit from wire end to wire end.
    • If 2 Ω or greater, repair the open/high resistance in the circuit.
    • If less than 2 Ω, repair the open/high resistance in the ground connection.
    • If less than 5 Ω 
  4. Ignition ON.
  5. Test for 11 - 13 V between the signal circuit terminal 3 at the DT-47825-10  jumper harness and ground at the transmission case.
    • If not between 11 - 13 V 
    1. Ignition OFF, disconnect the X1harness connector at the K20 Engine Control Module.
    2. Test for infinite resistance between the Park/Neutral signal circuit terminal 3 at the DT-47825-10  jumper harness and ground at the transmission case.
      • If less than infinite resistance, repair the short to ground in the signal circuit.
      • If infinite resistance.
    3. Test for less than 2 Ω in the Park/Neutral signal circuit wire end to wire end.
    • If 2 Ω or greater, repair the open/high resistance in the signal circuit.
    • If less than 2 Ω, replace the K20 Engine Control Module.
    • If between 11 - 13 V 
  6. Ignition OFF, disconnect the DT-47825-10  jumper harness from the X1 vehicle harness connector.
  7. Connect the DT-47825-10  jumper harness to the Q8 Control Solenoid Valve Assembly harness connector at the transmission case.
  8. Remove the transmission fluid pan.
  9. Disconnect the B15 Transmission Internal Mode Switch electrical connector from the Q8 Control Solenoid Valve Assembly.
  10. Test for less than 2 Ω between the ground circuit terminal 5 and terminal A at the B15 Transmission Internal Mode Switch connector on the Q8 Control Solenoid Valve Assembly.
    • If 2 Ω or greater 

      Replace the Q8 control solenoid valve assembly.

    • If less than 2 Ω 
  11. Ignition OFF.
  12. Connect the DT-47825-10  jumper harness to the X1 vehicle harness connector.
  13. Ignition ON.
  14. Test for 11 - 13 V between terminal F at the B15 Transmission Internal Mode Switch connector on the Q8 Control Solenoid Valve Assembly and ground at the transmission case.
    • If not between 11 - 13 V 

      Replace the Q8 control solenoid valve assembly.

    • If between 11 - 13 V 
  15. Connect a 3 A fused jumper wire between terminal F at the B15 Transmission Internal Mode Switch on the Q8 Control Solenoid Valve Assembly and ground at the transmission case.
  16. Verify the scan tool Engine Control Module Park/Neutral Position Switch parameter displays Park/Neutral.
    • If Park/Neutral is not displayed 

      Replace the K20 Engine Control Module.

    • If Park/Neutral is displayed 
  17. Replace the B15 Transmission Internal Mode Switch.

Starter Relay Malfunction

  1. Ignition OFF and all vehicle systems OFF, disconnect the KR27 Starter Relay. It may take up to 2 min for all vehicle systems to power down.
  2. Test for less than 10 Ω between the ground circuit terminal 85 and ground.
    • If 10 Ω or greater 
    1. Ignition OFF.
    2. Test for less than 2 Ω in the ground circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, repair the open/high resistance in the ground connection.
    • If less than 10 Ω 
  3. Ignition ON.
  4. Verify a test lamp illuminates between the B+ circuit terminal 30 and ground.
    • If the test lamp does not illuminate and the circuit fuse is good. 
    1. Ignition OFF.
    2. Test for less than 2 Ω in the B+ circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, verify the fuse is OK and there is voltage at the fuse.
    • If the test lamp does not illuminate and the circuit fuse is open 
    1. Ignition OFF.
    2. Test for infinite resistance between the B+ circuit and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance,
    3. Test for infinite resistance between the control circuit terminal 87 and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance, replace the KR27 Starter Relay.
    • If the test lamp illuminates 
  5. Connect a test lamp between the control circuit terminal 86 and the ground circuit terminal 85.
  6. Verify the test lamp turns ON and OFF when commanding the Starter Relay ON and OFF with a scan tool. If command is unavailable, verify by setting parking brake, press clutch (for manual), activate ignition CRANK to ON and OFF.
    • If the test lamp is always OFF 
    1. Ignition OFF, disconnect the harness connector at the K20 Engine Control Module.
    2. Test for infinite resistance between the control circuit and ground.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. Test for less than 2 Ω in the control circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the K20 Engine Control Module.
    • If the test lamp is always ON 
    1. Ignition OFF, disconnect the harness connector at the K20 Engine Control Module, ignition ON.
    2. Test for less than 1 V between the control circuit and ground.
      • If 1 V or greater, repair the short to voltage on the circuit.
      • If less than 1 V, replace the K20 Engine Control Module.
    • If the test lamp turns ON and OFF 
  7. Ignition ON, connect a 30 A fused jumper wire between the B+ circuit terminal 30 and the control circuit terminal 87.
  8. Verify the M64 Starter Motor is activated.
    • If the M64 Starter Motor does not activate 
    1. Ignition OFF, disconnect the harness connector at the M64 Starter Motor.
    2. Test for infinite resistance between ground and terminal X1 A or X1 1.
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance
    3. Test for less than 2 Ω in the control circuit end to end.
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the M64 Starter Motor.
    • If the M64 Starter Motor activates 
  9. Test or replace the KR27 Starter Relay.

Relay Test

  1. Ignition OFF, disconnect the KR27 Starter Relay.
  2. Test for 60 - 180 Ω between terminals 85 and 86.
    • If less than 60 or greater than 180 Ω 

      Replace the KR27 Starter Relay.

    • If between 60 - 180 Ω 
  3. Test for infinite resistance between the terminals listed below:
    • 30 and 86
    • 30 and 87
    • 30 and 85
    • 85 and 87
    • If less than infinite resistance 

      Replace the KR27 Starter Relay.

    • If infinite resistance 
  4. Install a 20 A fused jumper wire between relay terminal 85 and 12 V. Install a jumper wire between relay terminal 86 and ground.
  5. Test for less than 2 Ω between terminals 30 and 87A.
    • If 2 Ω or greater 

      Replace the KR27 Starter Relay.

    • If less than 2 Ω 
  6. All OK
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