2002 F-150 Workshop Manual

Transcription

1 Page 1 of 23 SECTION : Speed Control 2002 F-150 Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 08/07/2006 Speed Control Refer to Wiring Diagrams Cell 31, Speed Control for schematic and connector information. Special Tool(s) 73III Automotive Meter 105-R0057 or equivalent Flex Probe Kit 105-R025B or equivalent Diagnostic Tool, Restraint System (2 req'd) 418-F088 (105-R0012) Principles of Operation The speed control system is designed to maintain vehicle speed between 48 and 200 km/h (30 and 125 mph). Whenever the system is engaged and active, a speed control set indicator will be illuminated in the instrument cluster. The brake pedal position (BPP) switch is normally closed to ground. When the brake pedal is applied with the speed control system engaged, the BPP switch closes (to battery voltage), putting the speed control in stand-by mode. NOTE: A redundant brake deactivator switch is provided as an additional safety feature. NOTE: The speed control module is integral to the speed control servo. rmally, when the brake pedal is depressed, the speed control module deactivates the speed control system. Under increased brake pedal effort, the deactivator switch, a normally closed switch, will open and remove power to the speed control servo clutch, releasing the throttle independently of the speed control module The air bag sliding contact provides the electrical interface between the steering column wiring and the speed control switches in the steering wheel. The inputs to the speed control servo are the: vehicle speed signal speed control switches brake pedal position (BPP) switch clutch pedal position (CPP) switch deactivator switch The outputs of the speed control servo are the: speed control indicator speed control cable controlled throttle position Inspection and Verification NOTE: If any concerns are noted with the speedometer, stoplamps, or horn, address those concerns by referring to the appropriate sections before continuing speed control diagnosis. 1. Verify the customer concern by operating the speed control system. 2. NOTE: Any aftermarket modifications, including but not limited to those listed below, may cause the speed control to not operate correctly: Any wiring or lamp modifications affecting the brake lamp operation LED brake lamps n-factory installed trailer wiring Radios (speed sensitive, auto mute) Remote starters and alarms Lighting and electrical accessory modifications Visually inspect for obvious signs of mechanical or electrical damage: Visually inspect the speed control actuator and accelerator controls. Visually inspect the speed control cable without removing it and ensure smooth cable operation. Inspect the speed control cable connection to the throttle body. Visually inspect the accelerator cable without removing it and ensure smooth cable operation. Inspect the accelerator cable connection to the throttle body. Also check for cable interference with the carpet, bulkhead grommet, insulation and instrument panel wiring. 3. Visually inspect for obvious signs of mechanical and electrical damage.

2 Page 2 of 23 Visual Inspection Chart Mechanical Speed control cable Speed control cable not attached to throttle Electrical Central junction box (CJB) fuse(s): 5 (15A) 13 (20A) 15 (5A) Circuitry Loose, corroded or dirty connections Deactivator switch Brake pedal position (BPP) switch Speed control actuator switches Bulb Clutch pedal position (CPP) switch 4. If the fault is not visually evident, go to self-test diagnostics. Self-Test Diagnostics WARNING: This test is a key on engine off (KOEO) test only that is conducted in PARK only with the emergency brake fully engaged. NOTE: On vehicles equipped with a manual transmission, the clutch pedal must be released in order to correctly carry out the self-test. On vehicles equipped with an automatic transmission, the transmission selector needs to be in the NEUTRAL (N) position. NOTE: Review the following steps before carrying out the self-test diagnostic procedure. NOTE: After entering the diagnostic mode, the module times out if the mandatory switch sequence is not completed within 5 seconds and each button is not pressed within one second of the previous button. If a module time-out occurs (speed control lamp stops flashing part way through the test), the procedure must be re-initiated. The self-test is comprised of 2 parts. The first part is a static check of the speed control electronics module and system. The second part is a dynamic pull-test to check the actuator motor and gear mechanism. To perform the self-test: Connect the scan tool to a power source that is not interrupted when the ignition switch changes positions. With the ignition switch in the RUN position, set the scan tool to monitor the powertrain control module (PCM) throttle position PID while the speed control actuator carries out the self-test. Enter self-test diagnostics by firmly pressing and holding the speed control OFF switch while quickly cycling the ignition switch from RUN-to-OFF-to-RUN, making sure the engine does not start and is not running. The speed control indicator lamp on the instrument panel will flash once to indicate that the speed control module has entered the diagnostic mode. Release the OFF switch. If 5 additional flashes are displayed at this point, a speed control subsystem concern exists. GO to Symptom Chart. NOTE: The module times out if each button is not pressed within one second of the previous button. If a module time out occurs (speed control lamp stops flashing part way through test), the procedure must be re-initiated. Firmly press and release the remaining switches within one second of each other in the following sequence: ON RSM (resume) CST (coast) SET/ACCEL The speed control indicator lamp flashes once after each of the first 4 buttons is successfully pressed. Firmly press and release each switch in the sequence immediately after the light goes out for the previous switch. NOTE: There will be a slight delay from when the last button is pressed and the lamp flashes diagnostic codes. If the self-test will not start or cannot be completed after multiple attempts, GO to Symptom Chart. Follow the list below for diagnostic flash codes, then GO to Symptom Chart. 0 flashes: flash after the last button pressed: suspect circuitry or speed control switch. 1 flash: Static test passed. 2 flashes: The stoplamp switch is damaged, circuit is damaged, or brake pedal is applied; CPP switch is damaged, circuit is damaged, or clutch pedal is applied. 3 flashes: The speed control deactivator switch is open or the circuit is damaged. 4 flashes: The vehicle speed signal is out of range or circuit is damaged. 5 flashes: Speed control actuator internal failure. NOTE: Monitor the PCM throttle position PID after the last button is pressed. Within 0.25 second after the static test has passed, the speed control actuator carries out a dynamic pull test automatically by actuating the throttle lever from 1 to 10 mm (0.04 to 0.39 inches) of travel from the idle position for 3 seconds and then releasing the throttle. If the PID value does not change and holds steady for 3 seconds, GO to Symptom Chart. During the dynamic throttle pull, observe throttle movement to witness any binding or sticking of the speed control cable, verify the correct connection of the speed control cable to the throttle lever, and make sure that the throttle returns to the idle position. If incorrect connection and/or binding or sticking of the speed control is observed, GO to Symptom Chart. Turn the key to OFF and GO to Symptom Chart. Symptom Chart Symptom Chart Condition Possible Sources Action The speed control is inoperative no flash codes Speed control cable not attached to throttle. Central junction box (CJB) fuse(s): 5 (15A). 13 (20A). Circuitry. Brake pedal position (BPP) switch. Clutch pedal position (CPP) switch or jumper (if equipped). Deactivator switch. Speed control actuator switch. GO to Pinpoint Test A.

3 Page 3 of 23 The set speed fluctuates The speed control does not disengage when the brakes are applied The speed control does not disengage when the clutch is applied The speed control switch is inoperative Flash with last switch pressed and dynamic pull occurs at throttle Flash with last switch pressed, but no dynamic pull occurs at throttle and speed control inoperative Flash with last switch pressed, dynamic pull occurs at throttle and speed control inoperative Flash code 2 brake pedal position switch circuit failure Powertrain control module (PCM). Generic electronic module (GEM). Circuitry. Powertrain control module (PCM). Loose fit or binding between speed control cable and throttle body. Engine controls. Central junction box (CJB) fuse(s): 15 (5A). 13 (20A). Circuitry. Brake pedal position (BPP) switch. Deactivator switch. Binding speed control cable. Central junction box (CJB) fuse(s): 15 (5A). 13 (20A). Circuitry. Clutch pedal position (CPP) switch. Binding speed control cable. Speed control actuator switch. Speed control cable. Circuitry. GEM. Circuitry. Brake pedal position (BPP) switch. Flash code 3 deactivator switch circuit failure Central junction box (CJB) fuse 13 (20A). Circuitry. Deactivator switch. Flash code 4 vehicle speed sensor circuit failure The speed control indicator lamp is always on The speed control indicator is inoperative Circuitry. Powertrain control module (PCM). Circuitry. Instrument cluster. Circuitry. Bulb. Instrument cluster. GO to Pinpoint Test B. REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. REPAIR the engine as necessary. GO to Pinpoint Test C. GO to Pinpoint Test D. GO to Pinpoint Test E. Test passed. GO to Pinpoint Test F. GO to Pinpoint Test A. GO to Pinpoint Test G. GO to Pinpoint Test H. GO to Pinpoint Test K. GO to Pinpoint Test I. GO to Pinpoint Test J. Pinpoint Tests PINPOINT TEST A: THE SPEED CONTROL IS INOPERATIVE NO FLASH CODES NOTE: It is important to use a voltage drop test on some of the tests where specified. Circuits may indicate a good voltage and continuity but may not be capable of carrying sufficient current. CONDITIONS A1 CHECK THE SPEED CONTROL CABLE ATTACHMENT TO THE THROTTLE DETAILS/RESULTS/ACTIONS Remove the accelerator control splash shield (if equipped). Inspect the speed control cable attachment. Check the speed control cable by pulling on the speed control cable and noting the throttle movement. Is the speed control cable snapped onto the throttle body and speed control cable movement OK? A2 CHECK THE VOLTAGE TO THE SPEED CONTROL SERVO GO to A2. REATTACH the speed control cable. TEST the system for normal operation. Speed Control Servo C122

4 Page 4 of 23 Measure the voltage between the speed control servo C122 pin 7, circuit 295 (LB/PK), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. Is the voltage greater than 10 volts? A3 CHECK THE VOLTAGE DROP ON CIRCUIT 295 (LB/PK) GO to A3. GO to A4. Measure the voltage drop on the speed control actuator C122-7, circuit 295 (LB/PK). Is the voltage drop less than 0.3 volts? GO to A5. REPAIR the circuit. REPEAT the self-test. A4 CHECK THE SPEED CONTROL SERVO GROUND CIRCUIT 57 (BK) FOR AN OPEN Measure the resistance between the speed control servo C122 pin 10, circuit 57 (BK), harness side and ground. REPAIR circuit 295 (LB/PK). TEST the system for normal operation. REPAIR circuit 57 (BK). TEST for normal operation. A5 CHECK FOR BRAKE PEDAL POSITION (BPP) SWITCH INPUT WITH NO BRAKES APPLIED Measure the voltage between the speed control servo C122 pin 4, circuit 306 (TN/LB), harness side and speed control servo C122 pin 10, circuit 57 (BK), harness side. Is voltage present? REPAIR the circuit. TEST the system for normal operation. A6 CHECK THE BRAKE CIRCUIT GO to A6.

5 Page 5 of 23 Measure the resistance between the speed control servo C122 pin 4, circuit 306 (TN/LB), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. GO to A7. GO to A17. A7 CHECK THE DEACTIVATOR SWITCH INPUT TO SPEED CONTROL SERVO Measure the voltage between the speed control servo C122 pin 9, circuit 307 (BK/YE), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. Is the voltage greater than 10 volts? A8 CHECK THE VOLTAGE DROP ON CIRCUIT 307 (BK/YE) GO to A8. GO to A9. Measure the voltage drop on the speed control servo C122 pin 9, circuit 307 (BK/YE). Is the voltage drop less than 0.3 volts? GO to A11. A9 CHECK THE DEACTIVATOR SWITCH REPAIR the circuit. REPEAT the self-test. Deactivator Switch C1025 Measure the resistance between the deactivator switch pin 1 (component side), and the deactivator switch pin 2 (component side). GO to A10. A10 CHECK DEACTIVATOR SWITCH POWER INSTALL a new deactivator switch. REFER to Speed Control Deactivator Switch in this section. TEST the system for normal operation. Measure the voltage between the deactivator switch C1025, circuit 10 (LG/RD), harness side and ground.

6 Page 6 of 23 Is the voltage greater than 10 volts? A11 CHECK FOR STUCK SPEED CONTROL ACTUATOR SWITCH REPAIR circuit 307 (BK/YE). TEST the system for normal operation. REPAIR circuit 10 (LG/RD). TEST the system for normal operation. Measure the voltage between the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. Is voltage present? GO to A19. GO to A12. A12 CHECK THE SPEED CONTROL ACTUATOR SWITCH OPERATION Measure the voltage between the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side and speed control servo C122 pin 10, circuit 57 (BK), harness side; while depressing speed control actuator switch ON. Is the voltage greater than 10 volts? GO to A15. A13 CHECK CIRCUIT 151 (LB/BK) FOR AN OPEN GO to A13. Air Bag Sliding Contact C218b Measure the resistance between the air bag sliding contact C218b pin 1, circuit 151 (LB/BK), harness side and the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side.

7 Page 7 of 23 A14 CHECK THE AIR BAG SLIDING CONTACT FOR AN OPEN GO to A14. REPAIR the circuit. TEST the system for normal operation. Remove the driver air bag. Refer to Section B. Measure the resistance between the top of the air bag sliding contact pin 5 (component side), and the air bag sliding contact C218b pin 1 (component side). Is the resistance less than 1 ohm? INSTALL a new speed control actuator switch. REFER to Switch Speed Control Actuator in this section. INSTALL the driver air bag. REFER to Section B. TEST the system for normal operation. A15 CHECK THE SET/ACCEL SWITCH INSTALL a new air bag sliding contact. REFER to Section B. INSTALL the driver air bag. REFER to Section B. TEST the system for normal operation. Measure the resistance between the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side and the speed control servo C122 pin 6, circuit 848 (DG/OG), harness side; while depressing the speed control actuator switch SET/ACCEL. Is the resistance between 646 and 714 ohms? GO to A16. A16 CHECK THE SPEEDOMETER INSTALL a new speed control actuator switch. REFER to Switch Speed Control Actuator in this section. TEST the system for normal operation. Check the speedometer for correct operation by driving the vehicle. Does the speedometer operate correctly? GO to A17. A17 CHECK CIRCUIT 679 (GY/BK) FOR AN OPEN REFER to Section A, Section B, or Section C.

8 Page 8 of 23 PCM C175 Measure the resistance between the PCM C175 pin 68, circuit 679 (GY/BK), harness side and the speed control servo C122 pin 3, circuit 679 (GY/BK), harness side. GO to A23. A18 CHECK CIRCUIT 574 (BK/PK) FOR AN OPEN REPAIR the circuit. REPEAT the self-test. Brake Pedal Position (BPP) Switch C278 Measure the resistance between the BPP switch C278 pin 5, circuit 574 (BK/PK), harness side and ground. If automatic transmission, REPAIR circuit 810 (RD/LG) or install a new CPP jumper. TEST the system for normal operation. If manual transmission, GO to A21. A19 CHECK THE SPEED CONTROL ACTUATOR SWITCH REPAIR the circuit 574 (BK/PK) or circuit 875 (BK/LB). TEST the system for normal operation. Remove the driver air bag. Refer to Section B. Restraint System Diagnostic Tool 418-F088 (105-R0012) or Equivalent Connect the battery. Refer to Section

9 Page 9 of 23 Speed Control Actuator Switches Measure the voltage between the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. Is voltage present? A20 CHECK CIRCUIT 151 (LB/BK) FOR SHORT TO POWER GO to A20. INSTALL a new speed control actuator switch. REFER to Switch Speed Control Actuator in this section. DISCONNECT the battery. REFER to Section INSTALL the driver air bag. REFER to Section B. TEST the system for normal operation. Air Bag Sliding Contact C218b Measure the voltage between the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. Is voltage present? A21 CHECK THE CPP SWITCH OR JUMPER FOR AN OPEN REPAIR the circuit. DISCONNECT the battery. REFER to Section INSTALL the driver air bag. REFER to Section B. TEST the system for normal operation. INSTALL a new air bag sliding contact. REFER to Section B. DISCONNECT the battery. REFER to Section INSTALL the driver air bag. REFER to Section B. TEST the system for normal operation. CPP Switch or Jumper C257 Measure the resistance between the CPP switch or jumper pin 4 (component side), and the CPP switch or jumper pin 3 (component side).

10 Page 10 of 23 GO to A22. A22 CHECK CIRCUIT 306 (TN/LB) FOR AN OPEN INSTALL a new CPP switch or jumper. TEST the system for normal operation. Measure the resistance between the speed control servo C122 pin 4, circuit 306 (TN/LB), harness side and the CPP switch or jumper C257, pin 4 circuit 306 (TN/LB), harness side. A23 CHECK THE SPEED SIGNAL TO THE SPEED CONTROL SERVO REPAIR circuit 810 (RD/LG). TEST the system for normal operation. REPAIR circuit 306 (TN/LB). TEST the system for normal operation. CAUTION: Make sure the vehicle is secured correctly before attempting to place the transmission range selector lever in DRIVE (D) or in first gear if equipped with a manual transmission. PCM C175 Jack up the drive wheels and chock the other wheels. NOTE: For vehicles with manual transmission, place the transmission into first gear. Start the vehicle, place the transmission selector lever in the DRIVE (D) position and with the engine at idle allow the drive wheels to spin. Measure the AC voltage between speed control servo C122 pin 3, circuit 679 (GY/BK), harness side, and ground. Apply the brakes until the drive wheels come to a stop. Place the transmission selector lever in the PARK (P) position and turn the engine off. Is the AC voltage greater than 4.5 volts? GO to A24. A24 CHECK THE VEHICLE SPEED SIGNAL FREQUENCY GO to A25. CAUTION: Make sure the vehicle is secured correctly before attempting to place the transmission range selector lever in DRIVE (D), or in first gear if equipped with a manual transmission. NOTE: For vehicles with a manual transmission, place the transmission into first gear.

11 Page 11 of 23 Start the vehicle, place the transmission in DRIVE (D), and with the engine at idle, allow the drive wheels to spin. Measure and record the frequency between the speed control actuator C122-3, circuit 679 (GY/BK), harness side and ground with the vehicle drive wheels spinning a minimum of 8 km/h (5 mph) and the speedometer registers a speed. Record the speedometer reading. Apply the brakes until the drive wheels come to a stop. Place the transmission in PARK (P), fully engage the parking brake and turn the engine off. Divide the frequency reading by 2.2 to get a mph result and compare this to the reading of the speedometer. Does the frequency reading result match the speedometer reading? INSTALL a new speed control actuator. REPEAT the self-test. A25 CHECK FOR CORRECT PCM OPERATION GO to A25. Disconnect the PCM connector. Check for: corrosion damaged pins pushed-out pins Connect the PCM connector and make sure it seats correctly. Operate the system and verify the concern is still present. Is the concern still present? INSTALL a new PCM. REFER to Section REPEAT the self-test. The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. PINPOINT TEST B: THE SET SPEED FLUCTUATES CONDITIONS B1 CHECK SPEED CONTROL CABLE/THROTTLE BODY LINKAGE DETAILS/RESULTS/ACTIONS Hold the throttle open and remove the speed control cable from the speed control servo. Visually inspect the core wire and check the speed control cable by pulling on the cable and noting the throttle movement. Is the speed control cable OK? GO to B2. B2 CHECK THE SPEEDOMETER INSTALL a new speed control cable and/or REPAIR the throttle body linkage. For speed control cable installation, REFER to Speed Control Cable in this section. To repair the throttle body linkage, REFER to Section TEST the system for normal operation. Check the speedometer for correct operation by driving the vehicle. Does the speedometer fluctuate? REFER to Section A, Section B, or Section C. B3 CHECK FOR A BASE ENGINE CONCERN GO to B3. Drive the vehicle and determine if there is a base engine concern.

12 Page 12 of 23 Is a base engine concern present? REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual to continue diagnosis of the base engine concern. B4 CHECK THE VEHICLE SPEED SIGNAL VOLTAGE GO to B4. CAUTION: Make sure the vehicle is secured correctly before attempting to place the transmission range selector lever in DRIVE (D), or in first gear if equipped with a manual transmission. Speed Control Actuator C122 Jack up the drive wheels and chock the other wheels. NOTE: For vehicles with a manual transmission, place the transmission into first gear. Start the vehicle, place the transmission in DRIVE (D), and with the engine at idle, allow the drive wheels to spin. Measure and record the AC voltage between the speed control actuator C122-3, circuit 679 (GY/BK), harness side and ground with the vehicle drive wheels spinning a minimum of 8 km/h (5 mph) and the speedometer registers a speed. Apply the brakes until the drive wheels come to a stop. Place the transmission in PARK (P), fully engage the parking brake and turn the engine off. Is the AC voltage greater than 4.5 volts? GO to B5. B5 CHECK THE VEHICLE SPEED SIGNAL FREQUENCY GO to B6. CAUTION: Make sure the vehicle is secured correctly before attempting to place the transmission range selector lever in DRIVE (D), or in first gear if equipped with a manual transmission. NOTE: For vehicles with a manual transmission, place the transmission into first gear. Start the vehicle, place the transmission in DRIVE (D), and with the engine at idle, allow the drive wheels to spin. Measure and record the frequency between the speed control actuator C122-3, circuit 679 (GY/BK), harness side and ground with the vehicle drive wheels spinning a minimum of 8 km/h (5 mph) and the speedometer registers a speed. Record the speedometer reading. Apply the brakes until the drive wheels come to a stop. Place the transmission in PARK (P), fully engage the parking brake and turn the engine off. Divide the frequency reading by 2.2 to get a mph result and compare this to the reading of the speedometer. Does the frequency reading result match the speedometer reading? INSTALL a new speed control actuator. TEST the system for normal operation. B6 CHECK FOR CORRECT PCM OPERATION GO to B6. Disconnect the PCM connector. Check for: corrosion

13 Page 13 of 23 damaged pins pushed-out pins Connect the PCM connector and make sure it seats correctly. Operate the system and verify the concern is still present. Is the concern still present? INSTALL a new PCM. REFER to Section TEST the system for normal operation. The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. PINPOINT TEST C: THE SPEED CONTROL DOES NOT DISENGAGE WHEN THE BRAKES ARE APPLIED NOTE: It is important to use a voltage drop test on some of the tests where specified. Circuits may indicate a good voltage and continuity but may not be capable of carrying sufficient current. CONDITIONS C1 CHECK THE STOPLAMP OPERATION DETAILS/RESULTS/ACTIONS Check the stoplamps for correct operation by depressing and releasing the brake pedal and observing the stoplamps. Do the stoplamps operate correctly? GO to C2. C2 CHECK THE BRAKE PEDAL POSITION (BPP) SWITCH OPERATION REFER to Section Speed Control Servo C122 Measure the voltage between the speed control servo C122 pin 4, circuit 306 (TN/LB), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side, while pressing and releasing the brake pedal. Is the voltage greater than 10 volts with the brake pedal pressed and 0 volts with the brake pedal released? GO to C7. C3 CHECK CIRCUIT 1001 (WH/YE) FOR AN OPEN GO to C3. Brake Pedal Position (BPP) Switch C278 Measure the voltage between the BPP switch C278 pin 3, circuit 1001 (WH/YE), harness side and ground.

14 Page 14 of 23 Is the voltage greater than 10 volts? GO to C4. C4 CHECK CIRCUIT 810 (RD/LG) FOR AN OPEN REPAIR the circuit. TEST the system for normal operation. Clutch Pedal Position (CPP) Switch or Jumper C257 Measure the resistance between the BPP switch C278 pin 4, circuit 810 (RD/LG), harness side and the CPP switch or jumper C257 pin 3, circuit 810 (RD/LG), harness side. GO to C5. C5 CHECK CIRCUIT 306 (TN/LB) FOR AN OPEN REPAIR the circuit. TEST the system for normal operation. Measure the resistance between the CPP switch or jumper C257 pin 4, circuit 306 (TN/LB), harness side and the speed control servo C122 pin 4, circuit 306 (TN/LB), harness side. GO to C6. C6 CHECK THE CPP SWITCH REPAIR the circuit. TEST the system for normal operation. Measure the resistance between the CPP switch or jumper pin 3 (component side), and the CPP switch or jumper pin 4 (component side).

15 Page 15 of 23 INSTALL a new BPP switch. REFER to Section TEST the system for normal operation. INSTALL a new CPP switch or jumper. TEST the system for normal operation. C7 CHECK THE DEACTIVATOR SWITCH CIRCUITRY Measure the voltage between the speed control servo C122 pin 9, circuit 307 (BK/YE), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side, while firmly pressing and releasing the brake pedal. Is the voltage 0 volts with the brake pedal firmly pressed, and greater than 10 volts with the brake pedal released? C8 CHECK THE VOLTAGE DROP ON CIRCUIT 307 (BK/YE) GO to C8. GO to C9. Measure the voltage drop on the speed control servo C122 pin 9, circuit 307 (BK/YE). Is the voltage drop less than 0.3 volts? INSTALL a new speed control servo. REFER to Speed Control Servo in this section. TEST the system for normal operation. C9 CHECK THE DEACTIVATOR SWITCH REPAIR the circuit. REPEAT the self-test. Deactivator Switch C1025 Measure the resistance between the deactivator switch pins (component side), while firmly depressing and releasing the brake pedal. Is the resistance greater than 10,000 ohms with the brake pedal firmly pressed, and less than 5 ohms with the brake pedal released? GO to C10. C10 CHECK CIRCUIT 307 (BK/YE) FOR AN OPEN INSTALL a new deactivator switch. REFER to Speed Control Deactivator Switch in this section. TEST the system for normal operation. Measure the resistance between the speed control servo C122 pin 9, circuit 307 (BK/YE), harness side and the deactivator switch C1025, circuit 307 (BK/YE), harness side.

16 Page 16 of 23 REPAIR circuit 10 (LG/RD). TEST the system for normal operation. REPAIR circuit 307 (BK/YE). TEST the system for normal operation. PINPOINT TEST D: THE SPEED CONTROL DOES NOT DISENGAGE WHEN THE CLUTCH IS APPLIED CONDITIONS DETAILS/RESULTS/ACTIONS D1 CHECK THE CPP SWITCH FOR AN OPEN NOTE: It is normal for engine rpm to increase slightly and then drop off slowly when the clutch pedal is depressed during operation. CPP Switch C257 Measure the resistance between the CPP switch pin 4 (component side), and the CPP switch pin 3 (component side), while depressing and releasing the clutch pedal. Is the resistance less than 5 ohms with the clutch pedal released and greater than 10,000 ohms with the clutch pedal depressed? INSTALL a new speed control servo. REFER to Speed Control Servo in this section. TEST the system for normal operation. INSTALL a new CPP switch. TEST the system for normal operation. PINPOINT TEST E: THE SPEED CONTROL SWITCH IS INOPERATIVE CONDITIONS E1 CHECK THE SPEED CONTROL SWITCH OPERATION DETAILS/RESULTS/ACTIONS Speed Control Servo C122 Measure the resistance between the speed control servo C122 pin 5, circuit 151 (LB/BK) harness side and the speed control servo C122 pin 6, circuit 848 (DG/OG), harness side, while depressing the speed control actuator switch as follows: Speed Control Actuator Switch Resistance Value Coast Between 114 and 126 ohms SET/ACCEL Between 646 and 714 ohms Resume Between 2,090 and 2,310 ohms Off Less than 5 ohms Are the speed control actuator switch resistance values OK? INSTALL a new speed control servo. REFER to Speed Control Servo in this section. TEST the system for normal operation. INSTALL a new speed control actuator switch. REFER to Switch Speed Control Actuator in this section. TEST the system for normal operation.

17 Page 17 of 23 PINPOINT TEST F: FLASH WITH LAST SWITCH PRESSED, BUT NO DYNAMIC PULL OCCURS AT THROTTLE AND SPEED CONTROL INOPERATIVE CONDITIONS F1 CHECK THE SPEED CONTROL CABLE DETAILS/RESULTS/ACTIONS Check the speed control cable for correct attachment at the speed control servo and throttle body. Is the speed control cable attached correctly? GO to F2. RECONNECT the speed control cable. REPEAT the self-test. F2 CHECK FOR A STICKING OR BINDING SPEED CONTROL CABLE Check the speed control cable for sticking or binding. Is the speed control cable OK? INSTALL a new speed control servo. REFER to Speed Control Servo in this section. REPEAT the self-test. REPAIR or INSTALL a new speed control cable. REFER to Speed Control Cable in this section. REPEAT the self-test. PINPOINT TEST G: FLASH CODE 2 BRAKE PEDAL POSITION SWITCH CIRCUIT FAILURE CONDITIONS G1 CHECK STOPLAMP OPERATION DETAILS/RESULTS/ACTIONS Press and release the brake pedal while observing the stoplamps. Do the stoplamps operate correctly? GO to G2. G2 CHECK CIRCUIT 810 (RD/LG) FOR AN OPEN REFER to Section Speed Control Servo C122 Measure the voltage between the speed control servo C122 pin 4, circuit 306 (TN/LB), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side; while depressing the brake pedal. Is the voltage greater than 10 volts? GO to G3. G3 CHECK THE BRAKE CIRCUIT GO to G5. Measure the resistance between the speed control servo C122 pin 4, circuit 306 (TN/LB), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side.

18 Page 18 of 23 INSTALL a new speed control servo. REFER to Speed Control Servo in this section. REPEAT the self-test. G4 CHECK CIRCUIT 574 (BK/PK) FOR AN OPEN GO to G4. Brake Pedal Position (BPP) Switch C278 Measure the resistance between the BPP switch C278 pin 5, circuit 574 (BK/PK), harness side and ground. G5 CHECK THE CPP SWITCH OR JUMPER FOR AN OPEN INSTALL a new BPP switch. REFER to Section TEST the system for normal operation. REPAIR the circuit. TEST the system for normal operation. CPP Switch or Jumper C257 Measure the resistance between the CPP switch or jumper pin 4 (component side), and the CPP switch or jumper pin 3 (component side). GO to G6. G6 CHECK CIRCUIT 306 (TN/LB) FOR AN OPEN INSTALL a new CPP switch or jumper. TEST the system for normal operation. Measure the resistance between the speed control servo C122 pin 4, circuit 306 (TN/LB), harness side and the CPP switch or jumper C257, circuit 306 (TN/LB), harness side.

19 Page 19 of 23 REPAIR circuit 810 (RD/LG). TEST the system for normal operation. REPAIR circuit 306 (TN/LB). TEST the system for normal operation. PINPOINT TEST H: FLASH CODE 3 DEACTIVATOR SWITCH CIRCUIT FAILURE NOTE: It is important to use a voltage drop test on some of the tests where specified. Circuits may indicate a good voltage and continuity but may not be capable of carrying sufficient current. CONDITIONS H1 CHECK THE DEACTIVATOR SWITCH CIRCUITRY DETAILS/RESULTS/ACTIONS Speed Control Servo C122 Measure the voltage between the speed control servo C122 pin 9, circuit 307 (BK/YE), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. Is the voltage greater than 10 volts? H2 CHECK THE VOLTAGE DROP ON CIRCUIT 307 (BK/YE) GO to H2. GO to H3. Measure the voltage drop on the speed control servo C122 pin 9, circuit 307 (BK/YE). Is the voltage drop less than 0.3 volts? INSTALL a new speed control servo. REFER to Speed Control Servo in this section. REPEAT the self-test. H3 CHECK DEACTIVATOR SWITCH POWER REPAIR the circuit. REPEAT the self-test.

20 Page 20 of 23 Deactivator Switch C1025 Measure the voltage between the deactivator switch C1025, circuit 10 (LG/RD), harness side and ground. Is the voltage greater than 10 volts? GO to H4. H4 CHECK CIRCUIT 307 (BK/YE) FOR AN OPEN REPAIR the circuit. REPEAT the self-test. Measure the resistance between the speed control servo C122 pin 9, circuit 307 (BK/YE), harness side and the deactivator switch C1025, circuit 307 (BK/YE), harness side. INSTALL a new deactivator switch. REFER to Speed Control Deactivator Switch in this section. REPEAT the selftest. REPAIR the circuit. REPEAT the self-test. PINPOINT TEST I: THE SPEED CONTROL INDICATOR LAMP IS ALWAYS ON CONDITIONS I1 CHECK THE SPEED CONTROL SERVO DETAILS/RESULTS/ACTIONS Speed Control Servo C122 Check the speed control indicator lamp. Is the speed control indicator lamp always on? I2 CHECK CIRCUIT 203 (OG/LB) FOR A SHORT TO GROUND GO to I2. INSTALL a new speed control servo. REFER to Speed Control Servo in this section. TEST the system for normal operation.

21 Page 21 of 23 Instrument Cluster C238 Measure the resistance between the speed control servo C122 pin 1, circuit 203 (OG/LB), harness side and ground. Is the resistance greater than 10,000 ohms? REFER to Section A, Section B, or Section C. REPAIR the circuit. TEST the system for normal operation. PINPOINT TEST J: THE SPEED CONTROL INDICATOR IS INOPERATIVE CONDITIONS J1 CHECK THE SPEED CONTROL INDICATOR CIRCUITRY FOR AN OPEN DETAILS/RESULTS/ACTIONS Connect a fused (10A) jumper wire between the speed control servo C122 pin 1, circuit 203 (OG/LB), harness side and ground, while observing the speed control indicator. Is the speed control indicator illuminated? INSTALL a new speed control servo. REFER to Speed Control Servo in this section. TEST the system for normal operation. REFER to Section A, Section B, or Section C. PINPOINT TEST K: FLASH CODE 4 VEHICLE SPEED SENSOR CIRCUIT FAILURE CONDITIONS K1 CHECK THE SPEEDOMETER OPERATION DETAILS/RESULTS/ACTIONS Check the speedometer for correct operation by driving the vehicle. Does the speedometer operate correctly? GO to K2. K2 CHECK THE VEHICLE SPEED SIGNAL VOLTAGE REFER to Section A. CAUTION: Make sure the vehicle is secured correctly before attempting to place the transmission range selector lever in DRIVE (D), or in first gear if equipped with a manual transmission.

22 Page 22 of 23 Speed Control Actuator C122 Jack up the drive wheels and chock the other wheels. NOTE: For vehicles with a manual transmission, place the transmission into first gear. Start the vehicle, place the transmission in DRIVE (D), and with the engine at idle, allow the drive wheels to spin. Measure and record the AC voltage between the speed control actuator C122-3, circuit 679 (GY/BK), harness side and ground with the vehicle drive wheels spinning a minimum of 8 km/h (5 mph) and the speedometer registers a speed. Apply the brakes until the drive wheels come to a stop. Place the transmission in PARK (P), fully engage the parking brake and turn the engine off. Is the AC voltage greater than 4.5 volts? GO to K3. K3 CHECK THE VEHICLE SPEED SIGNAL FREQUENCY GO to K4. CAUTION: Make sure the vehicle is secured correctly before attempting to place the transmission range selector lever in DRIVE (D), or in first gear if equipped with a manual transmission. NOTE: For vehicles with a manual transmission, place the transmission into first gear. Start the vehicle, place the transmission in DRIVE (D), and with the engine at idle, allow the drive wheels to spin. Measure and record the frequency between the speed control actuator C122-3, circuit 679 (GY/BK), harness side and ground with the vehicle drive wheels spinning a minimum of 8 km/h (5 mph) and the speedometer registers a speed. Record the speedometer reading. Apply the brakes until the drive wheels come to a stop. Place the transmission in PARK (P), fully engage the parking brake and turn the engine off. Divide the frequency reading by 2.2 to get a mph result and compare this to the reading of the speedometer. Does the frequency reading result match the speedometer reading? INSTALL a new speed control actuator. TEST the system for normal operation. K4 CHECK CIRCUIT 679 (GY/BK) FOR AN OPEN GO to K5. Speed Control Servo C122 Powertrain Control Module (PCM) C175 Measure the resistance between the PCM C175 pin 68, circuit 679 (GY/BK), harness side and the speed control servo C122 pin 3, circuit 679 (GY/BK), harness side.

23 Page 23 of 23 GO to K5. K5 CHECK FOR CORRECT PCM OPERATION REPAIR the circuit. REPEAT the self-test. Disconnect the PCM connector. Check for: corrosion damaged pins pushed-out pins Connect the PCM connector and make sure it seats correctly. Operate the system and verify the concern is still present. Is the concern still present? INSTALL a new PCM. REFER to Section TEST the system for normal operation. The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.