Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual — page 17
1. ET Sensor Test
1.
Disconnect ET sensor [90].
2.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure the voltage between
ET sensor [90B] terminal A (PK/Y) and ground.
3.
Is the voltage reading greater than 6V?
a.
Yes. Repair short to voltage on (PK/Y) wire.
b.
No. Voltage is less than 4V.
2. ET Sensor Signal Wire Open Test
1.
Turn IGN OFF.
2.
Connect BREAKOUT BOX (Part No. HD-48637) to wiring
harness [78B], leaving ECM [78A] disconnected. See
3.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between ET
sensor [90B] terminal A (PK/Y) and breakout box terminal
51.
4.
Is continuity present?
a.
Yes.
b.
No. Repair open circuit in the (PK/Y) wire.
3. ET Sensor Open Ground Wire Test
1.
Test for continuity between ET sensor [90B] terminal B
(BK/W) and breakout box terminal 61.
2.
Is continuity present?
a.
Yes.
b.
No. Repair open in (BK/W) wire.
4. ET Sensor Signal Wire Shorted to Power
Test
1.
Test for continuity voltage between breakout box terminals
51 and 73.
2.
Is voltage present?
a.
Yes. Repair short to voltage in the (PK/Y) wire. Verify
ET sensor resistance value and if incorrect replace
ET sensor. See the service manual.
b.
No.
5. ET Sensor Resistance Test
1.
Measure the resistance of the ET sensor at ambient room
temperature.
2.
Is resistance reading between 900-10,000 Ohms?
a.
Yes. Replace the ECM. See the service manual.
b.
No. Replace the ET sensor. See the service manual.
2011 Touring Diagnostics: Engine Management 6-15
6.6
DTC P0120, P0122, P0123, P0220, P0222, P0223
DESCRIPTION AND OPERATION
. A dual TPS is integrated into the TCA, mounted
to the induction module.
Within the TCA, a set of potentiometers are designated as TPS
(TPS1 and TPS2). The ECM drives the motor in the TCA to
open and close the throttle plate based on the signals from the
twist grip sensor. The TPS (TPS1 and TPS2) send signals
back to the ECM based on throttle plate position to verify the
throttle plate movement.
The ECM supplies a 5.0V signal from terminal 50 of [78] to
TPS1 and TPS2. The signals from TPS1 and TPS2 are sent
back to the ECM [78] terminals 37 and 36 and vary in voltage
according to actual throttle plate position.
The two TP sensors work opposite each other. When one
sensor reads high, the other reads low. The sum of TPS1 and
TPS2 signals should measure around 5.0V.
for TCA (TPS1 and TPS2) circuitry diagram.
Refer to
for DTCs associated with TPS1 and TPS2
of the TCA.
Table 6-12. Code Description
DESCRIPTION
DTC
TPS1 range error
P0120
TPS1 low/open
P0122
TPS1 high
P0123
TPS2 range error
P0220
TPS2 low/open
P0222
TPS2 high
P0223
1
2
ed01264
1.
TCA
2.
Induction module
Figure 6-7. Throttle Control Actuator (TCA) Location
NOTE
The TMAP and TGS are both connected to the same reference
line (+5V REF). If the line goes to ground or open, multiple
trouble codes will be set (DTCs P0107, P0108 and P0122,
P0123, P1501 or P1502). Start with the highest priority DTC.
Refer to
.
Check for the following conditions:
•
Poor connection: Inspect ECM harness connector [78B]
for backed out terminals, improper mating, inoperative
locks, improperly formed or damaged terminals, poor ter-
minal-to-wire connection and damaged harness.
•
Perform
1.3 DIAGNOSTICS AND TROUBLESHOOTING,
to locate intermittents: If connections and
harness check out OK, monitor TPS voltage using a mul-
timeter while moving related connectors and wiring har-
ness. If the failure is induced, the TPS voltage will change.
•
An intermittent may be caused by poor connection, rubbed
through wire insulation or an inoperative wire within the
wire insulation.
•
A faulty sensor can negatively affect the signal voltage of
the other sensors sharing the same 5V reference. If the
wiring passes the following tests, disconnect one sensor
at a time on the 5V reference and verify the DTC is still
present. Additional DTCs will be set as each sensor is
disconnected, clear DTCs after this test. Be sure to per-
form this test before replacing a component.
6-16 2011 Touring Diagnostics: Engine Management
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see
Throttle Actuator Control HI
Throttle Actuator Control LO
TPS-2
TPS-1
TGS-2
TGS-1
5V Sensor Power-1
5V Sensor Ground-2
5V Sensor Power-2
29
30
36
37
39
50
59
62
68
29
30
36
37
39
50
ET Sensor
51
51
59
62
5V Sensor Ground-1
61
61
68
ECM
TGS
6 5 4 3 2 1
6 5 4 3 2 1
6 5 4 3 2 1
6 5 4 3 2 1
TCA
6
5
4
3
2
1
6
5
4
3
2
1
Vehicle Speed Input
JSS
Vehicle Speed Ground
Ground
40
56
64
73
40
56
64
73
JSS
(HDI only)
1 2 3
VSS
A
B
C
A
B
C
BN
BE
GY
BK
V/Y
R/W
R
V
BK/GY
BK/PK
BE/GN
BK/W
BK/W
BN/O
BN/O
BK/O
BN/R
BN/V
BK/PK
BK/O
BN/R
BN/V
V/Y
R/W
BE/GN
GN/BN
GN/BN
BK/GY
BK/GN
BK/GN
BN/O
PK/Y
PK/Y
BN/O
BN/O
W/GN
W/GN
BK/W
BK/W
BK/Y
BK/Y
Right
GND 2
[224A]
[224B]
[204A]
[204B]
[211A]
[211B]
[65A]
[65B]
ET Sensor
A
B
A
B
[90A]
[90B]
[78B]
[78A]
[133B]
TMAP Sensor
TMAP Sensor Input
IAT
1 2 3
4
1 2 3
4
[80A]
[80B]
LGN/Y
V/W
R/W
LGN/Y
BK/GY
V/W
24
49
24
49
em00700
Figure 6-8. Throttle Control Actuator Circuit
DTC P0120
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
BREAKOUT BOX
HD-48637
Table 6-13. DTC P0120 Diagnostic Faults
POSSIBLE CAUSES
Open in sensor power circuit
Short to voltage in TPS-1 circuit
Open in TPS-1 circuit
Short to ground in TPS-1 circuit
Open n sensor ground circuit
ECM malfunction
TCA malfunction
1. Sensor Power-1 Circuit Test
1.
Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A], leaving [78A] discon-
nected. See
2.
Disconnect TCA [211].
3.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
breakout box terminal 50 and TCA [211] terminal 5.
4.
Is continuity present?
a.
Yes.
b.
No. Repair open in (BN/O) wire.
2. TPS-1 Circuit Shorted Test
1.
Test continuity between breakout box terminal 50 and
terminal 37.
2.
Is continuity present?
a.
Yes. Repair short between (BN/V) and (BN/O) wires.
b.
No.
3. TPS-1 Circuit Continuity Test
1.
Test continuity between breakout box terminal 37 and TCA
[211B] terminal 6.
2011 Touring Diagnostics: Engine Management 6-17
2.
Is continuity present?
a.
Yes.
b.
No. Repair open in (BN/V) wire.
4. TPS-1 Circuit Short to Ground Test
1.
Test continuity between breakout box terminal 37 and
ground.
2.
Is continuity present?
a.
Yes. Repair short to ground on (BN/V) wire.
b.
No.
5. TPS-1 Circuit Short to Voltage Test
1.
Turn IGN ON.
2.
Test for voltage between breakout box terminal 37 and
ground.
3.
Is voltage present?
a.
Yes. Repair short to voltage on (BN/V) wire.
b.
No.
6. Sensor Ground Continuity Test
1.
Test continuity between breakout box terminal 61 and TCA
[211B] terminal 1.
2.
Is continuity present?
a.
Yes.
b.
No. Repair open in (BK/W) wire.
7. TCA Test
1.
Turn IGN OFF.
2.
Connect ECM [78A] to breakout box.
3.
Connect TCA [211].
4.
Turn IGN ON.
5.
Measure voltage between breakout box terminals 37 and
61.
6.
Is voltage between 0.4-4.8V?
a.
Yes. Replace the ECM. See the service manual.
b.
No. Replace the TCA. See the service manual.
DTC P0122
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
BREAKOUT BOX
HD-48637
Table 6-14. DTC P0122 Diagnostic Faults
POSSIBLE CAUSES
Short to ground in TPS-1 Circuit
TCA malfunction
Open in sensor power circuit
ECM malfunction
1. TCA Sensor-1 Circuit Test
1.
Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See
.
2.
Turn IGN ON and engine stop switch to run.
3.
Test for voltage at breakout box between terminal 37 and
terminal 61.
4.
Is voltage greater than 0.2V?
a.
Yes.
b.
No.
2. TCA Sensor-1 Circuit Short to Ground
Test
1.
Turn IGN OFF.
2.
Disconnect ECM [78A] from breakout box.
3.
Disconnect TCA [211].
4.
Test for continuity between breakout box terminal 37 and
ground.
5.
Is continuity present?
a.
Yes. Repair short to ground in (BN/V) wire.
b.
No.
3. TCA Power-1 Circuit Open Test
1.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
breakout box terminal 50 and TCA [211] terminal 5.
2.
Is continuity present?
a.
Yes. Replace the TCA. See the service manual.
b.
No. Repair open in (BN/O) wire.
4. TCA Sensor Test
1.
Turn IGN OFF.
2.
Disconnect TCA [211].
3.
Test for voltage between breakout box terminal 50 and
ground.
4.
Is voltage greater than 4V?
a.
Yes. Replace the TCA. See the service manual.
b.
No.
5. ECM Test
1.
Disconnect ECM [78A] from breakout box.
2.
Test for continuity at breakout box between terminals 37
and ground.
3.
Is continuity present?
a.
Yes. Repair short to ground in (BN/V) wire.
b.
No. Replace the ECM. See the service manual.
6-18 2011 Touring Diagnostics: Engine Management
DTC P0123
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
BREAKOUT BOX
HD-48637
Table 6-15. DTC P0123 Diagnostic Faults
POSSIBLE CAUSES
Open in TPS-1 circuit
Short to voltage in TPS-1 circuit
Short to voltage in sensor power circuit
TCA malfunction
ECM malfunction
Open in sensor ground circuit
1. TPS-1 Voltage Test
1.
Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See
2.
Turn IGN ON.
3.
Using a multimeter, measure voltage between breakout
box terminals 37 and 61.
4.
Is voltage less than 4.8V?
a.
Yes.
b.
No.
2. TPS-1 Circuit Test
1.
Disconnect TCA [211].
2.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure voltage between
TCA [211B] terminal 6 and ground.
3.
Is voltage between 4-5.25V?
a.
Yes.
b.
No. Less than 4V. Repair open in (BN/V) wire.
c.
No. Greater than 5.25V. Repair short to voltage in
(BN/V) wire.
3. Sensor Power Circuit Test
1.
Measure voltage between TCA [211B] terminal 5 and
ground.
2.
Is voltage less than 5.25V?
a.
Yes.
b.
No. Repair short to voltage in (BN/O) wire.
4. TCA Test
1.
Jumper TCA [211B] terminals 6 and 1.
2.
Measure voltage between breakout box terminals 37 and
61.
3.
Is voltage greater than 1.0V?
a.
Yes.
b.
No. Replace the TCA. See the service manual.
5. Sensor Ground Test
1.
Turn IGN OFF.
2.
Measure resistance between TCA [211B] terminal 1 and
ground.
3.
Is resistance less than 2 Ohms?
a.
Yes.
b.
No.
6. Sensor Ground Circuit Shorted Test
1.
Test for continuity between TCA [211B] terminals 5 and
6.
2.
Is continuity present?
a.
Yes. Repair short between (BN/V) and (BN/O) wires.
b.
No. Replace the ECM. See the service manual.
7. Sensor Ground Circuit Test
1.
Disconnect the ECM [78A].
2.
Test for continuity between TCA [211B] terminal 1 and
breakout box terminal 61.
3.
Is continuity present?
a.
Yes. Replace the ECM. See the service manual.
b.
No. Repair open in (BK/W) wire.
8. TPS-1 Circuit Function Test
1.
Disconnect TCA [211].
2.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure voltage between
[211B] terminal 6 and ground.
3.
Is voltage between 2-5.25V?
a.
Yes.
b.
No. Less than 2V. Repair open in (BN/V) wire.
c.
No. Greater than 5.25V. Repair short to voltage on
(BN/V) wire.
9. Sensor Ground Continuity Test
1.
Measure voltage between TCA [211B] terminal 5 and
ground.
2.
Is voltage less than 5.25V?
a.
Yes.
b.
No. Repair short to voltage on (BN/O) wire.
10. Ground Circuit Open Test
1.
Turn IGN OFF.
2.
Disconnect the ECM [78A].
3.
Test for continuity between TCA [211B] terminal 1 and
breakout box terminal 61.
2011 Touring Diagnostics: Engine Management 6-19
4.
Is continuity present?
a.
Yes.
b.
No. Repair open in (BK/W) wire.
11. TPS-1 Continuity Test
1.
Test for continuity between TCA [211B] terminal 6 and
breakout box terminal 37.
2.
Is continuity present?
a.
Yes. Replace the TCA. See the service manual.
b.
No. Repair open in (BN/V) wire.
DTC P0220
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
BREAKOUT BOX
HD-48637
Table 6-16. DTC P0220 Diagnostic Faults
POSSIBLE CAUSES
Open in sensor power circuit
Short to voltage in sensor power circuit
Open in TPS-2 circuit
Short to voltage in TPS-2 circuit
Short to ground in TPS-2 circuit
Open in sensor ground circuit
ECM malfunction
TCA malfunction
1. Sensor Power-2 Circuit Test
1.
Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A], leaving [78A] discon-
nected. See
2.
Disconnect TCA [211].
3.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
breakout box terminal 50 and TCA [211] terminal 5.
4.
Is continuity present?
a.
Yes.
b.
No. Repair open in (BN/O) wire.
2. Sensor Power-2 Short to Voltage Test
1.
Test for voltage between breakout box terminal 50 and
ground.
2.
Is battery voltage present?
a.
Yes. Repair short to voltage (BN/O) wire.
b.
No.
3. TPS-2 Circuit Shorted Test
1.
Test continuity between breakout box terminals 50 and
36.
2.
Is continuity present?
a.
Yes. Repair short between (BN/R) and (BN/O) wires.
b.
No.
4. TPS-2 Circuit Continuity Test
1.
Test continuity between breakout box terminals 36 and
TCA [211B] terminal 4.
2.
Is continuity present?
a.
Yes.
b.
No. Repair open in (BN/R) wire.
5. TPS-1 Circuit Short to Ground Test
1.
Test continuity between breakout box terminal 36 and
ground.
2.
Is continuity present?
a.
Yes. Repair short to ground on (BN/R) wire.
b.
No.
6. TPS-1 Circuit Short to Voltage Test
1.
Turn IGN ON.
2.
Test for voltage between breakout box terminal 36 and
ground.
3.
Is continuity present?
a.
Yes. Repair short to voltage on (BN/R) wire.
b.
No.
7. Sensor Ground Continuity Test
1.
Test continuity between breakout box terminal 61 and TCA
[211B] terminal 1.
2.
Is continuity present?
a.
Yes.
b.
No. Repair open in (BK/W) wire.
8. TCA Test
1.
Connect ECM [78A] to breakout box.
2.
Connect TCA [211].
3.
Measure voltage between breakout box terminals 36 and
61.
4.
Is voltage between 0.4-4.8V?
a.
Yes. Replace the ECM. See the service manual.
b.
No. Replace the TCA. See the service manual.
6-20 2011 Touring Diagnostics: Engine Management
DTC P0222
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
BREAKOUT BOX
HD-48637
Table 6-17. DTC P0222 Diagnostic Faults
POSSIBLE CAUSES
Open in sensor power circuit
Short to ground in TPS-2 circuit
TCA malfunction
ECM malfunction
1. TCA Sensor-2 Circuit Test
1.
Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See
2.
Turn IGN ON and engine stop switch to run.
3.
Test for voltage at breakout box between terminal 36 and
terminal 61.
4.
Is voltage greater than 0.2V?
a.
Yes.
b.
No.
2. TCA Sensor-2 Circuit Short to Ground
Test
1.
Turn IGN OFF.
2.
Disconnect ECM [78A] from breakout box.
3.
Disconnect TCA [211].
4.
Test for continuity between breakout box terminal 36 and
ground.
5.
Is continuity present?
a.
Yes. Repair short to ground in (BN/R) wire.
b.
No.
3. TCA Power-1 Circuit Open Test
1.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
breakout box terminal 50 and TCA [211] terminal 5.
2.
Is continuity present?
a.
Yes. Replace the TCA. See the service manual.
b.
No. Repair open in (BN/O) wire.
4. TCA 5V Ref Circuit Short to Ground Test
1.
Turn IGN OFF.
2.
Disconnect TCA [211].
3.
Test for voltage between breakout box terminal 50 and
ground.
4.
Is voltage greater than 4V?
a.
Yes. Replace the TCA. See the service manual.
b.
No.
5. ECM Test
1.
Disconnect ECM [78A] from breakout box.
2.
Test for continuity at breakout box between terminal 36
and ground.
3.
Is continuity present?
a.
Yes. Repair short to ground in (BN/R) wire.
b.
No. Replace the ECM. See the service manual.
DTC P0223
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
BREAKOUT BOX
HD-48637
Table 6-18. DTC P0223 Diagnostic Faults
POSSIBLE CAUSES
Open in sensor power circuit
Short to voltage in sensor power circuit
Open in TPS-2 circuit
Short to voltage in TPS-2 circuit
Short to ground in TPS-2 circuit
Open in sensor ground circuit
ECM malfunction
TCA malfunction
1. TPS-2 Voltage Test
1.
Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See
.
2.
Turn IGN ON.
3.
Measure voltage between breakout box terminals 36 and
61.
4.
Is voltage less than 4.8V?
a.
Yes.
b.
No.
2. TPS-2 Circuit Test
1.
Disconnect TCA [211].
2.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure voltage between
TCA [211B] terminal 4 and ground.
3.
Is voltage less than 0.2V?
a.
Yes.
b.
No.
2011 Touring Diagnostics: Engine Management 6-21
3. Sensor Power Circuit Test
1.
Measure voltage between TCA [211B] terminal 5 and
ground.
2.
Is voltage less than 5.25V?
a.
Yes.
b.
No. Repair short to voltage in (BN/O) wire.
4. Sensor Ground Test
1.
Turn IGN OFF.
2.
Measure resistance between TCA [211B] terminal 1 and
ground.
3.
Is resistance less than 2 Ohms?
a.
Yes. Replace TCA. See the service manual.
b.
No.
5. Shorted 5V Circuit Test
1.
Test for continuity between TCA [211B] terminals 4 and
5.
2.
Is continuity present?
a.
Yes. Repair short between (BN/R) and (BN/O) wires.
b.
No. Repair short to voltage on (BN/R) wire.
6. Sensor Ground Circuit Test
1.
Disconnect the ECM [78A].
2.
Test for continuity between [211B] terminal 1 and breakout
box terminal 61.
3.
Is continuity present?
a.
Yes. Replace the ECM. See the service manual.
b.
No. Repair open in (BK/W) wire.
7. TPS-2 Circuit Test
1.
Disconnect TCA [211].
2.
Measure voltage between TCA [211B] terminal 4 and
ground.
3.
Is voltage less than 1.0V?
a.
Yes.
b.
No. Repair short to voltage on (BN/R) wire.
8. Sensor Ground Continuity Test
1.
Measure voltage between TCA [211B] terminal 5 and
ground.
2.
Is voltage less than 5.25V?
a.
Yes.
b.
No. Repair short to voltage on (BN/O) wire.
9. Ground Circuit Open Test
1.
Turn IGN OFF.
2.
Disconnect the ECM [78A].
3.
Test for continuity between TCA [211B] terminal 1 and
breakout box terminal 61.
4.
Is continuity present?
a.
Yes. Replace the TCA. See the service manual.
b.
No. Repair open in (BK/W) wire.
6-22 2011 Touring Diagnostics: Engine Management
6.7
DTC P0031, P0032, P0131, P0132, P0134, P0151,
P0152, P0154
DESCRIPTION AND OPERATION
TOOL NAME
PART NUMBER
DIGITAL TECHNICIAN II
HD-48650
See
. The HO2S provides a signal to the ECM which
indicates whether the engine is running rich or lean.
•
A P0131 (front) or P0151 (rear) is set when the ECM
detects an excessively lean condition for a specified length
of time. This can be caused by mechanical issues such
as exhaust leaks. DTCs may also set if HO2S sensor fails.
•
A P0132 (front) or P0152 (rear) is set when the ECM
detects an excessively rich condition for a specified length
of time. This can be caused by oil contamination or fuel
injector malfunctions. DTCs may also set if HO2S sensor
fails.
•
A P0134 is set when the front O2 sensor circuit is open
or sensor is too cold to respond. A P0154 is set when the
rear O2 sensor circuit is open or sensor is too cold to
respond. Excessive oil usage may also cause these codes
to set.
When the air/fuel mixture is ideal, approximately 14.6 parts air
to 1 part fuel, the voltage will be approximately 0.45V when
measuring across the sensor. If the voltage is measured from
the sensor (terminals 46 or 66) to ground, the voltage will read
approximately 1.2V. This difference is due to an internal bias
in the ECM. When using DIGITAL TECHNICIAN II (Part
No. HD-48650), the O2 voltage reading is displayed in the
higher range 0.7-1.7V.
Table 6-19. Code Description
DESCRIPTION
DTC
Heater open/low
P0031
Heater shorted/high
P0032
Front O2 sensor low or engine running lean
P0131
Engine front O2 running rich
P0132
Front O2 sensor open/not responding/high
P0134
Rear O2 sensor low or engine running lean
P0151
Engine rear O2 running rich
P0152
Rear O2 sensor open/not responding/high
P0154
The heater portion of the HO2S is powered through the system
relay. The front and rear HO2S heaters share a common
ground through terminal 31 of the ECM. If the ECM recognizes
an open or short in the heater circuit it will set either DTC P0031
or P0032.
1
3
4
5
7
2
6
ed03081
1.
Front HO2S [138]
2.
ABS module [166] (if equipped)
3.
Active exhaust [179]
4.
Rear WSS [168]
5.
Rear HO2S [137]
6.
TSM/TSSM/HFSM [30]
7.
HFSM antenna jumper harness [208]
Figure 6-9. Under Right Side Cover
Diagnostic Tips
HO2S diagnostic codes may be seen during the vehicle break-
in period. The HO2S DTCs will not illuminate the check engine
lamp for current or historic codes and will only be indicated by
DIGITAL TECHNICIAN II (Part No. HD-48650) or odometer
self-diagnostics. If the DTCs are reported during the break-in
period, clear or ignore the codes until the break-in period is
completed. All historic HO2S DTCs are to be ignored and
cleared.
The multimeter displays the signal from the HO2S in Volts.
This voltage will have an average value tending towards lean,
rich or ideal value depending on operating temperature of the
engine, engine speed and throttle position. An open/short to
voltage or short to ground in the (PK/O) wire (front) and
(PK/GN) wire (rear) will cause the engine to run rich (short to
ground) or lean (short to voltage) until fault is detected. Once
fault is detected, vehicle will run in open loop.
Check for the following conditions:
•
Poor connection: Inspect the ECM [78], fuel injector [84,
85] and HO2S [137, 138] connectors for backed out ter-
minals, improper mating, inoperative locks, improperly
formed or damaged terminals, poor terminal-to-wire con-
nection and damaged harnesses.
•
Dirty/stuck open injectors: The vehicle may run lean
(dirty/clogged injectors) or rich (stuck open injectors) if
2011 Touring Diagnostics: Engine Management 6-23
there are injector problems. This could also cause poor
fuel economy and performance.
•
Loose HO2S: If an HO2S is loose, engine performance
may be affected. This could also show up as a slow
changing HO2S voltage.
•
Loose/leaking exhaust: This can cause a poor ground
connection for the sensor or allow fresh air into the exhaust
system. If fresh air enters exhaust system, the HO2S will
read a lean condition, causing the system to go rich.
•
Engine misfire: See
•
Leaking injectors: cause fuel imbalance and poor idle
quality due to different air/fuel ratios in each cylinder. To
check for leaky injectors, first remove the air box and air
filter. See the service manual. Then, with the throttle wide
open, turn IGN ON for 2 seconds and then OFF for 2
seconds five consecutive times. Replace the fuel injector
if there is any evidence of raw fuel in the bores. See Fuel
Injectors in the service manual.
•
Intake leaks: See the service manual.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see
6-24 2011 Touring Diagnostics: Engine Management
[13B]
[13A]
[78B]
[78A]
Y/GN
R
V/O
W/Y
V/Y
R/W
V/W
GN/GY
BK/PK
PK/GN
BE/GN
BK/GY
BK/GN
BK/BN
LGN/Y
GN/W
GY/BE
BN/R
BK
BN/V
BK/W
BK/Y
PK/O
BN/O
PK/Y
Y/GN
Y/BE
BE/O
PK/O
V/BE
BK/Y
BN/O
Y/GN
O/GY
O/GY
BN/O
BK/W
PK/Y
BK/W
Y/BE
BE/O
Y/GN
Y/GN
Y/GN
W/Y
V/BE
BK/O
GY/Y
V/GY
V/GY
W/GN
W/GN
BK
GY
BE
BN
V/W
R/W
R
R
V
LGN/Y
BK/GY
BE/GN
BK/GY
R/W
V/Y
1
2
3
4
A
A
B
A
B
A
B
A
B
B
C
D
A
Power
Ion Sense
Coil Rear
Coil Front
B
C
D
TGS
CKP
Sensor
ET
Sensor
TCA
TMAP
Sensor
Ignition Coil
VSS
Rear Fuel
Injector
Front Fuel
Injector
System
Relay
1
6
5
4
3
2
1
1
2
1
2
6 5 4 3 2 1
6 5 4 3 2 1
6 5 4 3 2 1
6 5 4 3 2 1
1
A
B
C
A
B
C
2
A B
A B
3 4
1 2
Front ACR
(If Equipped)
2 1
2 1
3 4
6
5
4
3
2
1
B
D
B
D
4
1
Fuel Tank
Harness
Fuel Pump
Assembly In Tank
4
Fuel
Pump
Fuse
15A
To 15A
ECM Fuse
To 15A
Exhaust
Control Fuse
Rear
HO2S
(BK)
Front
HO2S
Active
Exhaust
(HDI Only)
BK
V/O
BK
PK/GN
BK/BN
BK/BN
GN/GY
BK
LGN/R
Right
GND 2
Y/GN
Y/GN
V/GY
V/GY
Y/GN
Y/GN
GY/Y
Purge Solenoid
(Optional)
A
B
A
B
BE/GY
[79A]
[79B]
[224A]
[224B]
[204A]
[204B]
[90A]
[90B]
[203AF]
[203BF]
Rear ACR
(If Equipped)
2 1
2 1
[211A]
[211B]
[20A]
[20B]
[80A]
[80B]
[141A]
[141B]
[141B]
[65A]
[65B]
[179B]
ECM
Exhaust
Actuator
Rear
Fuel
Injector
TMAP
Sensor
Input
F
ront
Fuel
Injector
Throttle
Actuator
Control
HI
Throttle
Actuator
Control
LO
O2
Heater
Ground
TPS
2
TPS
1
Exhaust
F
eedbac
k
TGS
2
V
ehicle
Speed
Input
CKP
Sensor
Rear
HO2
Sensor
IA
T
Sensor
5V
Sensor
P
o
w
er
1
ET
Sensor
12V
P
o
w
er
Rear
Ignition
Coil
F
ront
Ignition
Coil
TGS
1
5V
Sensor
Ground
1
5V
Sensor
Ground
2
CKP
Sensor
(+)
V
ehicle
Speed
Ground
F
ront
HO2
Sensor
5V
Sensor
P
o
w
er
2
Ground
21
Purge
Solenoid
20
23 24
28 29 30 31
363738 39 4043 46
4950 51 52 53 54
59 61 62 63 64
66
68 73
HO2S
Retur
n
48
4
3
2
1
4
3
2
1
GY/BE
Ion
Sense
33
21
20
A
CR
Ground
19
19
23 24
28 29 30 31
363738 39 4043 46
4950 51 52 53 54
59 61 62 63 64
66
68 73
48
33
GN/W
GN/W
Y/GN
Y/GN
O/GY
14
B
D
15
BK
14
15
85
86
30
87
3
5
3D
4C
O/GY
BK
O/GY
BK
FLHR/C
EXCEPT
FLHR/C
BK
BK/W
BK/O
BN/R
BN/O
BN/V
BK/PK
4A
4B
[84B]
[84A]
[85B]
[85A]
[95B]
[95A]
[83B]
[83A]
[138A]
[137A]
[203AR]
[203BR]
em00702
Figure 6-10. EFI Simplified Schematic
2011 Touring Diagnostics: Engine Management 6-25
DTC P0031
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
BREAKOUT BOX
HD-48637
Table 6-20. DTC P0031 Diagnostic Faults
POSSIBLE CAUSES
Open in sensor ground circuit
ECM malfunction
HO2 malfunction
Open in sensor power circuit
1. HO2S Voltage Test
1.
Disconnect front HO2S [138].
2.
Turn IGN ON using HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-C) and a multimeter, test for
battery voltage between front HO2S [138A] terminal 1 and
ground.
a.
Yes.
b.
No. Repair open in (Y/GN).
2. HO2S Ground Test
1.
With IGN OFF, connect BREAKOUT BOX (Part No. HD-
48637) between wire harness [78B] and ECM [78A]. See
2.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for continuity between
ECM [78A] terminal 31 and front HO2S [138A] terminal 2.
3.
Is continuity present?
a.
Yes.
b.
No. Repair open in (GN/W).
3. HO2S Resistance Test
1.
Measure resistance between front HO2S [138B] terminal
1 and terminal 2.
2.
Is resistance between 13.5-23.5 Ohms?
a.
Yes. Replace ECM. See the service manual.
b.
No. Replace both HO2S. See the service manual.
DTC P0032
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
Table 6-21. DTC P0032 Diagnostic Faults
POSSIBLE CAUSES
ECM malfunction
HO2 malfunction
Short to voltage in sensor ground circuit
1. Rear HO2S Resistance Test
1.
Disconnect rear HO2S [137].
2.
Turn IGN ON, using HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-C) and a multimeter, measure
resistance between rear HO2S [137B] terminal 1 and ter-
minal 2.
3.
Is resistance between 13.5-23.5 Ohms?
a.
Yes.
b.
No. Replace rear HO2S. See the service manual.
2. Front HO2S Resistance Test
1.
With IGN OFF, disconnect front HO2S [138].
2.
Measure resistance between front HO2S [138B] terminal
1 and terminal 2.
3.
Is resistance between 13.5-23.5 Ohms?
a.
Yes.
b.
No. Replace front HO2S. See the service manual.
3. HO2S Short to Voltage Test
1.
With IGN ON, test for voltage between front HO2S [138A]
terminal 2 and ground.
2.
Is voltage present?
a.
Yes. Repair short to voltage in (GN/W) wire.
b.
No. Replace ECM. See the service manual.
DTC P0131
TOOL NAME
PART NUMBER
BREAKOUT BOX
HD-48637
Table 6-22. DTC P0131 Diagnostic Faults
POSSIBLE CAUSES
Front HO2S malfunction
ECM malfunction
Short to ground in signal circuit
Fuel system malfunction
Leak in exhaust system
1. Front HO2S Test
1.
Disconnect front HO2S [138].
2.
Turn IGN ON.
3.
Measure voltage between front HO2S [138A] terminal 3
(PK/O), to chassis ground.
4.
Is voltage approximately 5V?
a.
Yes.
b.
No.
2. Front HO2S Signal Wire Shorted to
Sensor Ground Test
1.
Turn IGN OFF.
6-26 2011 Touring Diagnostics: Engine Management
2.
Disconnect ECM [78].
3.
Test for continuity between front HO2S [138A] terminals
3 (PK/O) and 4 (BK/BN).
4.
Is continuity present?
a.
Yes. Repair short between (PK/O) and (BK/BN) wires.
b.
No.
3. Front HO2S Signal Wire Shorted to
Ground Test
1.
Test for continuity between front HO2S [138A] terminal 3
(PK/O) and vehicle ground.
2.
Is continuity present?
a.
Yes. Repair short between (PK/O) wire and ground.
b.
No. If ECM [78] connections are good, replace ECM.
See the service manual.
4. Front HO2S Operation Test
1.
Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See
2.
Place transmission in neutral, engine stop switch to RUN
and IGN ON. Start engine and allow to reach operating
temperature.
3.
With engine speed at a steady rpm, measure voltage
between breakout box terminals 66 and 73.
4.
Is voltage approximately 1.2V?
a.
Yes. Replace ECM. See the service manual.
b.
No, constant 0.7-1.1V. Perform fuel pressure test.
See the service manual. Look for incorrect ECM cal-
ibration, low fuel pressure, air leaks and dirty injectors.
If no issues are found, replace HO2S.
DTC P0132
TOOL NAME
PART NUMBER
BREAKOUT BOX
HD-48637
Table 6-23. DTC P0132 Diagnostic Faults
POSSIBLE CAUSES
Front HO2S malfunction
ECM malfunction
Fuel system malfunction
Oil contamination on sensor
1. Front HO2S Operation Test
1.
Turn IGN OFF.
2.
Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See
3.
Start the engine and allow it to reach operating temper-
ature.
4.
With engine speed at a steady rpm, measure voltage
between breakout box terminals 66 and 73.
5.
Is voltage approximately 1.2V?
a.
Yes. Replace the ECM. See the service manual.
b.
No, constant 1.3-1.7V. Perform fuel pressure test.
See the service manual. Look for incorrect ECM cal-
ibration, high fuel pressure, stuck open or leaking
injectors. If no issues are found, replace the HO2S.
DTC P0134
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
BREAKOUT BOX
HD-48637
Table 6-24. DTC P0134 Diagnostic Faults
POSSIBLE CAUSES
Front HO2S malfunction
ECM malfunction
Open or short to voltage in signal circuit
Open sensor ground
Heavy oil contamination
1. Front HO2S Signal Wire Short Circuit
Voltage Test
1.
Disconnect front O2 sensor [138].
2.
Turn IGN ON.
3.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure voltage between
front HO2S [138A] terminal 3 to chassis ground.
4.
Is voltage greater than 5V?
a.
Yes. Repair short to voltage on (PK/O) wire.
b.
No, voltage greater than 4V.
c.
No, voltage less than 4V.
2. Front HO2S Open Sensor Ground Test
1.
Turn IGN OFF.
2.
Connect BREAKOUT BOX (Part No. HD-48637) to wire
harness [78B], leaving ECM [78A] disconnected. See
.
3.
Test for continuity between front HO2S [138A] terminal 4
(BK/BN) and breakout box terminal 48.
4.
Is continuity present?
a.
Yes. Replace the front HO2S. See the service
manual.
b.
No. Repair open on (BK/BN) wire.
3. Front HO2S Signal Wire Open Test
1.
Test for continuity between front HO2S [138A] terminal 3
(PK/O) and breakout box terminal 66.
2011 Touring Diagnostics: Engine Management 6-27
2.
Is continuity present?
a.
Yes. Replace ECM. See the service manual.
b.
No. Repair open (PK/O) wire.
DTC P0151
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
BREAKOUT BOX
HD-48637
Table 6-25. DTC P0151 Diagnostic Faults
POSSIBLE CAUSES
Rear HO2S malfunction
ECM malfunction
Short to ground in signal circuit
Fuel system malfunction
Leak in exhaust system
1. Rear HO2S Test
1.
Disconnect rear HO2S [137].
2.
Turn IGN ON.
3.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, measure voltage between
rear HO2S [137A] terminal 3 (PK/GN) to ground.
4.
Is voltage approximately 5V?
a.
Yes.
b.
No.
2. Rear HO2S Signal Wire Shorted to Sensor
Ground Test
1.
Turn IGN OFF.
2.
Disconnect ECM [78].
3.
Test for continuity between rear HO2S [137A] terminals
3 (PK/GN) and 4 (BK/BN).
4.
Is continuity present?
a.
Yes. Repair short between (PK/GN) and (BK/BN)
wires.
b.
No.
3. Rear HO2S Signal Wire Shorted to Ground
Test
1.
Test for continuity between rear HO2S [137A] terminal 3
(PK/GN) and ground.
2.
Is continuity present?
a.
Yes. Repair short between (PK/GN) wire and ground.
b.
No. If ECM [78] connections are good, replace ECM.
See the service manual.
4. Rear HO2S Operation Test
1.
Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See
.
2.
Place transmission in neutral, engine stop switch to RUN
and IGN ON. Start engine and allow to reach operating
temperature.
3.
With engine speed at a steady rpm, measure voltage
between ECM breakout box terminals 46 and 73.
4.
Is voltage approximately 1.2V?
a.
Yes. Replace ECM. See the service manual.
b.
No, constant 0.7-1.1V. Perform fuel pressure test.
See the service manual. Look for incorrect ECM cal-
ibration, low fuel pressure, air leaks and dirty injectors.
If no issues are found, replace HO2S.
DTC P0152
TOOL NAME
PART NUMBER
BREAKOUT BOX
HD-48637
Table 6-26. DTC P0152 Diagnostic Faults
POSSIBLE CAUSES
Rear HO2S malfunction
ECM malfunction
Fuel system malfunction
Oil contamination on sensor
1. Rear HO2S Operation Test
1.
Turn IGN OFF.
2.
Connect BREAKOUT BOX (Part No. HD-48637) between
wire harness [78B] and ECM [78A]. See
.
3.
Start the engine and allow it to reach operating temper-
ature.
4.
With engine speed at a steady rpm, measure voltage
between breakout box terminals 46 and 73.
5.
Is voltage approximately 1.2V?
a.
Yes. Replace the ECM. See the service manual.
b.
No, constant 1.3-1.7V. Perform fuel pressure test.
See the service manual. Look for incorrect ECM cal-
ibration, high fuel pressure, stuck open or leaking
injectors. If no issues are found, replace the HO2S.
6-28 2011 Touring Diagnostics: Engine Management
DTC P0154
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-48637
Table 6-27. DTC P0154 Diagnostic Faults
POSSIBLE CAUSES
Rear HO2S malfunction
ECM malfunction
Open or short voltage in signal circuit
Open sensor ground
Heavy oil contamination
1. Rear HO2S Signal Wire Short Circuit
Voltage Test
1.
Disconnect rear HO2S [137].
2.
Turn IGN ON.
3.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
48637) and a multimeter, measure voltage between rear
HO2S [137A] terminal 3 to chassis ground.
4.
Is voltage greater than 5.5V?
a.
Yes. Repair short to voltage on (PK/GN) wire.
b.
No, voltage greater than 4V.
c.
No, voltage less than 4V.
2. Rear HO2S Open Sensor Ground Test
1.
Turn IGN OFF.
2.
Connect BREAKOUT BOX (Part No. HD-48637) to wire
harness [78B], leaving ECM [78A] disconnected. See
.
3.
Test for continuity between rear HO2S [137A] terminal 4
(BK/BN) and breakout box terminal 48.
4.
Is continuity present?
a.
Yes. Replace the rear HO2S. See the service manual.
b.
No. Repair open on (BK/BN) wire.
3. Rear HO2S Signal Wire Open Test
1.
Test for continuity between rear HO2S [137A] terminal 3
(PK/GN) and breakout box terminal 46.
2.
Is continuity present?
a.
Yes. Replace ECM. See the service manual.
b.
No. Repair open in (PK/GN) wire.
2011 Touring Diagnostics: Engine Management 6-29
6.8
DTC P0261, P0262, P0263, P0264
DESCRIPTION AND OPERATION
The fuel injectors are solenoids that allow pressurized fuel into
the intake tract. The injectors are timed to the engine cycle and
triggered sequentially. The power for the injectors comes from
the system relay. The system relay also provides power for
the fuel pump and the ignition coil. The ECM provides the path
to ground to trigger the injectors.
NOTE
ECM fuse and system relay failures or wiring harness problems
will cause 12V power to be lost to both injectors, ignition coils
and fuel pump.
Table 6-28. Code Description
DESCRIPTION
DTC
Front injector open/low
P0261
Front injector high
P0262
Rear injector open/low
P0263
Rear injector high
P0264
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see
1
2
3
ed03075
1.
Front fuel injector [84]
2.
Rear fuel injector [85]
3.
ET sensor [90]
Figure 6-11. Between Cylinders Left Side
6-30 2011 Touring Diagnostics: Engine Management
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