Harley Davidson 2008 Touring Models. Electrical Diagnostics Manual — page 10

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Table 4-3. Wire Harness Connectors

NO.

DESCRIPTION

MODEL

TYPE

LOCATION

[5]

MAXIFUSE

All

2-place Packard

Under left side cover

[13]

Fuel tank harness

All

4-place Multilock

Behind fuel tank (under seat)

[33]

Ignition switch

FLHT/C/U/

3-place Packard

Inner fairing - under radio (front of ignition

FLHTR

switch housing)

FLHR/C

3-place Packard

Under console

[65]

Vehicle Speed Sensor

All

3-place Delphi

Top of transmission case (under starter)

(VSS)

[78]

Electronic Control Module

All

73-place Delphi

Under seat

(ECM)

[79]

Crankshaft Position (CKP)

All

2-place Mini-Deutsch

Electrical caddie at bottom of lower frame

sensor

crossmember

[80]

emperature

Manifold

All

4-place Delphi

Top of induction module

Absolute Pressure (TMAP)

sensor

[83]

Ignition coil

All

4-place Delphi

Below fuel tank (left side)

[84]

Front injector

All

2-place Delphi

Below fuel tank (left side)

[85]

Rear injector

All

2-place Delphi

Below fuel tank (left side)

[90]

Engine T

emperature

(ET)

All

2-place Delphi

Back of front cylinder (left side)

sensor

[91]

Data link connector

All

4-place Deutsch

Under left side cover

[95]

Purge solenoid

All

2-place Delphi

Below fuel tank (left side)

[133]

Jiffy Stand Sensor

All

3-place Molex (black)

Domestic (not used): Electrical caddie

bottom of lower crossmember

HDI: Electrical caddie at bottom of lower

frame crossmember

[137]

sensor rear exhaust

All

2-place Amp (T

yco)

Under chrome starter cover

header

[138]

sensor front exhaust

All

2-place Amp (Tyco)

Back of cross brace front frame downtubes

header

(left side)

[141]

Fuel pump and fuel level

All

4-place Packard

Front right crankcase

sender

[179]

Active exhaust actuator

All

5-place Amp (Tyco)

Domestic (not used): Under right side

cover

HDI: Under right side cover (behind elec-

trical bracket)

[204]

wist Grip Sensor (TGS)

All

6-place Amp (T

yco)

Throttle control-handle bar (right side)

[211]

Throttle Control Actuator

All

6-place Molex

Right side of engine (Induction Module)

(TCA) and Throttle Position

(TP) sensor

4-6 2008 Touring Diagnostics: Engine Management

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EFI DIAGNOSTIC INTRODUCTION

4.3

SYSTEM PROBLEMS

Poor Performance

All system problems fall into at least one of three general cat-

The engine starts but there are performance problems. These

egories.

problems may include poor fuel economy, rough idle, engine

misfire, engine hesitation, severe spark knock, etc.

No Start

Check Engine Lamp

The engine cranks over freely, but will not start. This does not

include situations where the engine will not crank, such as a

See Figure 4-3. The check engine lamp indicates the Electronic

security disabled starter, dead battery, etc. This condition

Control Module (ECM) has determined a fault condition exists.

assumes that all obvious checks (fuel in tank, etc.) have been

There may also be starting or performance problems.

made.

ed01257

Check Engine Lamp

Figure 4-3. Speedometer

3. Diagnose system problems. This involves using special

RESOLVING PROBLEMS

tools and the diagnostic flow charts in this section.

To resolve system problems, five basic steps are involved. In

4. Correct problems through the replacement and/or repair

order of occurrence, they are:

of the affected components.

1. Check for Diagnostic Trouble Codes (DTCs) by using

speedometer self diagnostics. See 4.4 CHECKING FOR

5. After repairs are performed, the work must be validated.

DIAGNOSTIC TROUBLE CODES: EFI.

This involves clearing the DTCs and confirming proper

vehicle operation as indicated by the lack of DTCs.

2. Retrieve Diagnostic Trouble Codes

(DTCs) by using

speedometer self diagnostics. See 4.6 SPEEDOMETER

SELF-DIAGNOSTICS.

2008 Touring Diagnostics: Engine Management 4-7

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CHECKING FOR DIAGNOSTIC TROUBLE

CODES: EFI

4.4

CHECK ENGINE LAMP

1. See Figure 4-5. When the lamp turns off after being illu-

minated for the first four-second period, it will:

To diagnose system problems, start by observing the behavior

a. remain off if there are no fault conditions or trouble

of the check engine lamp.

codes currently detected by the Ignition Control

NOTES

Module.

•

See Figure 4-4. The Ignition Switch is turned to IGNITION

b. come back on for an 8-second period if only historic

and the Engine Stop Switch is set to RUN (although the

codes exist.

engine is not running).

c. come back on, and remain on, if a current trouble

•

When the Ignition Switch is turned to IGNITION, the check

code exists.

engine lamp will illuminate for approximately four seconds

and then turn off.

2. See

4.4 CHECKING FOR DIAGNOSTIC TROUBLE

CODES: EFI, Code Types for a complete description of

•

If the check engine lamp is not illuminated while in IGNI-

Diagnostic Trouble Code (DTC) formats.

TION position, or if it fails to turn OFF after the initial four-

second period, then the speedometer may need to be

NOTE

replaced. See 4.5 INITIAL DIAGNOSTIC CHECK: EFI.

Some DTCs can only be fully diagnosed during actuation. For

example, a problem with the ignition coil will be considered a

current fault even after the problem is corrected, since the ECM

will not know of its resolution until after the coil is exercised by

vehicle start sequence. In this manner, there may sometimes

be a false indication of the current trouble code.

om00705a

1. All except FLHR models

2. All FLHR models (cover shown closed)

3. All FLHR models (cover shown open)

Figure 4-4. Ignition Switch: Touring Models

4-8 2008 Touring Diagnostics: Engine Management

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ed01046

4 Sec.

Lamp OFF: No Current or Historic DTCs

OFF

Key On

Lamp ON 8 Seconds:

Only Historic DTCs Exist

4 Sec.

8 Sec.

Lamp OFF

OFF

4 Sec.

Key On

Lamp Remains ON: Current DTC*

4 Sec.

OFF

4 Sec.

Key On

* Historic DTCs May Also Exist

Figure 4-5. Check Engine Lamp Operation

Diagnostic charts are designed for use with current DTCs and

CODE TYPES

as a result they frequently suggest part replacement. When

There are two types of Diagnostic Trouble Codes (DTCs):

diagnosing a historic code the charts can be helpful, but should

current and historic. If a DTC is stored, it can be read using

not lead to part replacement without verification that a sus-

speedometer self diagnostics. See 4.6 SPEEDOMETER SELF-

pected component/part is faulty.

DIAGNOSTICS.

RETRIEVING DIAGNOSTIC TROUBLE

All DTCs reside in the memory of the ECM, TSM/TSSM/ HFSM,

CODES

speedometer, ABS or tachometer until the DTC is cleared by

use of the speedometer self diagnostics. See 4.6 SPEEDO-

PART NUMBER

TOOL NAME

METER SELF-DIAGNOSTICS.

HD-44750

DIGITAL TECHNICIAN

A historic DTC is also cleared after a total of 50 trips has

elapsed. A trip consists of a start and run cycle. After the 50

The engine management system provides two levels of dia-

trip retention period, the DTC is automatically erased from

gnostics.

memory providing that no subsequent faults of the same type

•

The most sophisticated mode employs a computer-based

are detected in that period.

diagnostic package called DIGITAL TECHNICIAN (Part

Current

No. HD-44750).

Current DTCs are those which are present during the current

•

The second mode requires using the speedometer self

ignition cycle. See the appropriate flow charts for solutions.

diagnostics. Speedometer, ABS, tachometer (if equipped),

TSM/TSSM/HFSM and ECM DTCs can be accessed and

Historic

cleared. See 4.6 SPEEDOMETER SELF-DIAGNOSTICS.

If a particular problem happens to resolve itself, the active

MULTIPLE DIAGNOSTIC TROUBLE CODES

status problem is dropped and it becomes a historic code rather

current code.

While it is possible for more than one fault to occur and set

more than one trouble code, there are several conditions which

Historic codes are stored for a length of time to assist in the

may result in one fault setting multiple trouble codes:

diagnosis of intermittent faults. See Figure 4-5. The check

engine lamp will come back on for 8 seconds to indicate the

•

The TMAP sensor, TGS, Jiffy Stand Sensor and VSS are

existence of only historic codes.

connected to the same reference line (+5 V Vref). If the

reference line goes to ground or open, multiple codes can

It is important to note that historic codes may also be present

be set.

whenever the system indicates the existence of a current code.

See 4.4 CHECKING FOR DIAGNOSTIC TROUBLE CODES:

•

Serial data codes (DTC U1300, U1301, U1016, U1064,

EFI, Multiple Diagnostic Trouble Codes if multiple trouble codes

and U1097) may be accompanied by other codes. Always

are found.

correct the serial data codes before resolving the other

codes.

2008 Touring Diagnostics: Engine Management 4-9

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Refer to Table 4-8. This table gives most ECM DTCs a priority

ranking.

4-10 2008 Touring Diagnostics: Engine Management

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INITIAL DIAGNOSTIC CHECK:

EFI

4.5

GENERAL

Diagnostic Tips

PART NUMBER

TOOL NAME

•

If speedometer reads "No Rsp" (no response) while in

diagnostic mode, check data bus for an open or short to

HD-44750

DIGITAL TECHNICIAN

ground between data connector [91A] terminal "3" and

ECM, TSM/TSSM/HFSM, speedometer or tachometer,

To locate faulty circuits or other system problems, follow the

and ABS (if equipped). For more information on speedo-

diagnostic flow charts in this section. For a systematic

meter diagnostic mode, see 4.6 SPEEDOMETER SELF-

approach, always begin with

4.5 INITIAL DIAGNOSTIC

DIAGNOSTICS.

CHECK: EFI, Initial Diagnostics. Read the general information

and then work your way through the flow chart box by box.

•

Check for an open diagnostic test terminal between data

terminal "3" and ECM terminal "5". With Ignition Switch at

Diagnostic Notes

IGNITION, transmit data should be typically 0.6-0.8 volt.

If a numbered circle appears adjacent to a flow chart box, then

The range of acceptable voltage is greater than 0.0 and

more information is offered in the diagnostic notes. Many dia-

less than 7.0 volts.

gnostic notes contain supplemental information, descriptions

•

If speedometer reads "BUS Er" (serial data bus error),

of various diagnostic tools or references to other parts of the

refer to flow charts in 2.5 BREAKOUT BOX: SPEEDO-

manual where information on the location and removal of

METER/TACHOMETER.

components may be obtained.

Diagnostic Notes

Circuit Diagram/Wire Harness Connector

Table

Each reference number below correlates to a circled number

on the flow chart(s).

When working through a flow chart, refer to the illustrations,

the associated circuit diagram and the wire harness connector

1. Compare engine behavior to symptoms tables.

table as necessary. The wire harness connector table for each

a. Engine starts hard. Refer to Table 4-5.

circuit diagram identifies the connector number, description,

b. Hesitates, stumbles, surges, misfires and/or sluggish

type and general location.

performance. Refer to Table 4-6.

In order to perform most diagnostic routines, a Breakout Box

c. Engine exhaust emits black smoke or fouls plugs.

and a digital volt/ohmmeter

(DVOM) are required. See

Refer to Table 4-7.

4.7 BREAKOUT BOX: EFI.

To perform the circuit checks with any degree of efficiency, a

2. Connect BREAKOUT BOX (Part No. HD-48637) and

familiarity with the various wire connectors is also necessary.

INSTRUMENT HARNESS ADAPTERS (Part No. HD-

46601) between wire harness and speedometer. See

Reprogramming ECM

2.5 BREAKOUT BOX: SPEEDOMETER/TACHOMETER

Diagnostic charts frequently suggest ECM replacement. In the

All EFI DTCs are listed in Table 4-8.

event an ECM needs to be replaced, it must be reprogrammed

using a computer-based diagnostic package called DIGITAL

Other Diagnostic Trouble Codes (DTCs)

TECHNICIAN (Part No. HD-44750). See your dealer. Password

See 3.10 INITIAL DIAGNOSTIC CHECK: TSM/HFSM for any

learn procedure must also be performed. See 3.26 TSM/HFSM:

codes related to the Turn Signal Module (TSM), Turn Signal

PASSWORD LEARN.

Security Module (TSSM) or Hands-Free Security Module

INITIAL DIAGNOSTICS

(HFSM).

See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER for

PART NUMBER

TOOL NAME

any codes related to the speedometer or tachometer.

HD-46601

INSTRUMENT HARNESS ADAPTERS

See 6.4 INITIAL DIAGNOSTIC CHECK: ABS for any codes

HD-48637

BREAKOUT BOX

related to the Antilock Brake System (ABS).

General Information

The diagnostic check is an organized approach to identifying

a problem caused by a electronic control system malfunction.

Table 4-4. Typical Scan Values for Engine Data

ITEM

MIN.

MAX.

HOT

VALUE

IDLE

TMAP sensor

10.3 kPa

104 kPa

10.3-13.3 in. Hg (35-45 kPa)

0 volts

5.1 volts

RPM

975

5,000 limited

1000

2008 Touring Diagnostics: Engine Management 4-11

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Table 4-4. Typical Scan Values for Engine Data

ITEM

MIN.

MAX.

HOT

VALUE

IDLE

ET sensor

3° F (-16° C)

464° F (240° C)

230-300° F (110-150° C)

0.0 volts

5.0 volts

0.5-3.23 volts

INJ PW front

50 mS

2-4 mSec

INJ PW rear

50 mS

2-4 mSec

Advance front

-4

45°

12-24°

Advance rear

-4

45°

12-24°

VSS

120

0 MPH

Battery voltage

14.5 volts

ENG RUN

OFF

RUN

Idle RPM

975

1450

975-1025

imately

260° F (127° C). Idle settings may be changed with

NOTE

the idle set procedure. See the Service Manual.

Hot idle specifications are with stock exhaust, the engine

operating at 1000 RPM and an engine temperature of approx-

Table 4-5. Engine Starts Hard

SYMPTOM

SOLUTION

Battery discharged

See 1.7 CHARGING SYSTEM, Troubleshooting.

Spark Plugs

4.16 MISFIRE AT IDLE OR UNDER LOAD.

Spark Plug wires

4.16 MISFIRE AT IDLE OR UNDER LOAD.

Ignition Coil

4.16 MISFIRE AT IDLE OR UNDER LOAD.

Valve sticking

See the Service Manual.

Contamination in fuel system

Drain and refill with fresh fuel.

Loss

of battery power to ECM terminal "71"*

4.11 NO ECM POWER.

* DTCs will not clear (although they appear to).

Table 4-6. Engine Performance Problems

CAUSE

SOLUTION

Manifold leak

4.9 INTAKE LEAK TEST.

TMAP sensor plugged or not operating

4.18 DTC P0107, P0108, P0112, P0113.

properly

Contamination in fuel system

Drain and refill with fresh fuel.

Spark plugs

4.16 MISFIRE AT IDLE OR UNDER LOAD.

Low fuel pressure

4.15 FUEL PRESSURE TEST.

4-12 2008 Touring Diagnostics: Engine Management

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Table 4-7. Engine Exhaust Emits Black Smoke or Fouls Plugs

CAUSE

SOLUTION

Clogged air filter

See Air Cleaner Filter in the Service Manual.

TMAP sensor plugged or not operating properly

4.18 DTC P0107, P0108, P0112, P0113.

Purge

solenoid or vent to evaporative canister not

4.24 DTC P0444, P0445.

routed or operating properly.

Table 4-8. EFI Diagnostic Trouble Codes (DTCs) and Fault Conditions

PRIORITY

DTC

FAULT CONDITION

SOLUTION

P0605

ECM FLASH Memory Error

4.29 DTC P0603, P0605

P0603

ECM EEPROM Memory Error

4.29 DTC P0603, P0605

U1300

ECM Serial Data Low

4.12 STARTS, THEN STALLS

U1301

ECM Serial Data High

4.12 STARTS, THEN STALLS

U1097

Loss

of Speedometer Serial Data To ECM

4.47 DTC U1097

U1064

Loss of

TSM/FSFM Serial Data To ECM

4.46 DTC U1064

P1003

System Relay Contacts Open

4.14 SYSTEM RELAY FAULT

P1002

System Relay Coil High/Shorted

4.14 SYSTEM RELAY FAULT

P1001

System Relay Coil Open/Low

4.14 SYSTEM RELAY FAULT

P1004

System Relay Contacts Closed

4.14 SYSTEM RELAY FAULT

P1009

Incorrect Password

4.31 DTC P1009, P1010

P1010

Missing Password

4.31 DTC P1009, P1010

P0641

5V +VRef 1 Out Of Range

4.30 DTC P0641, P0651

P0651

5V +VRef 2 Out Of Range

4.30 DTC P0641, P0651

P0373

CKP Sensor Intermittent

4.23 DTC P0373, P0374

P0107

MAP Sensor Open/Low

4.18 DTC P0107, P0108, P0112, P0113

P0108

MAP Sensor High

4.18 DTC P0107, P0108, P0112, P0113

P0374

CKP Sensor Synch Error

4.23 DTC P0373, P0374

P1600

EFI Module Processor - Internal Fault

4.38 DTC P1600

P1270

TGS

Validation Error

4.32 DTC P1270

P2107

EFI Module Processor Internal Error

4.41 DTC P2107

P2122

TGS1 Low/Open

4.43 DTC P2122, P2123, P2127, P2128

P2123

TGS1 High

4.43 DTC P2122, P2123, P2127, P2128

P2127

TGS2 Low/Open

4.43 DTC P2122, P2123, P2127, P2128

P2128

TGS2 High

4.43 DTC P2122, P2123, P2127, P2128

P2138

TGS Correlation Error

4.44 DTC P2135, P2138

P0120

TPS1 Range Error