Harley Davidson 2004 Touring Models. Service Manual — page 15
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COMBUSTION ABSENT/INTERMITTENT
5.18
GENERAL
s0475x9x
Diagnostic Trouble Codes P1353, P1356,
P1357, P1358: No Combustion
See Figure 5-42. A feedback voltage signal in the secondary
ignition circuit detects the presence of combustion each time
a cylinder fires on ECM Pin 27. For diagnostic purposes, this
signal is only analyzed under load above 2000 rpm where it
may be easily measured. Failure to detect combustion at high
Pin B
speed and load means one of following conditions exist.
● Cylinder is truly misfiring.
● There is a lack of continuity in the ignition coil secondary
circuit.
Figure 5-42. Ignition Coil
Table 5-22. Code Description
DTC
DESCRIPTION
P1353
Front cylinder no combustion
b. Using an ohmmeter, touch probes to terminals on
each end plug wire.
P1356
Rear cylinder no combustion
P1357
Intermittent secondary front
c. Compare resistance values to Table 5-20. Replace
cables not meeting specifications. Reinstall and
P1358
Intermittent secondary rear
repeat procedure on other spark plug cable.
Table 5-23. Spark Plug Cables
LOCATION
LENGTH
RESISTANCE
DIAGNOSTICS
Front/Rear
20.2 inch (513 mm)
4975-11960
Diagnostic Notes
The reference number below correlates with the circled num-
bers on the Test 5.20 flow charts.
1.
Connect BREAKOUT BOX
(Part No. HD-43876)
between wire harness and ECM. See Section 5.7 BREA-
KOUT BOX: EFI.
2.
Spark plugs must be correct Harley-Davidson resistor
type specified for this model.
3.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), gray pin probes and patch cords.
4.
Perform spark plug cable resistance test.
a. Remove spark plug cable from spark plug and igni-
tion coil. For best results, use a needle nose pliers
for removal/installation on coil. Gently grasp cable
as close to terminals as possible.
5-64
2004 Touring: Engine Management (EFI)
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f2208h8x
[62B]
System relay
Y/GN
[78A]
[78B]
BE/GY
GN/O
W/BK
[13A] [13B]
Fuel pump
O/GY
System relay
GN/O
Y/GN
15 amp
fuel pump
W/Y
fuse
[141B] [141A]
[84B] [84A]
BK
Y/GN
Power gnd.
Coil R
Y/BE
[85B] [85A]
GY/BE
Ignition
Switch power
Y/BE
coil
BE/O
ECM
W/BK
[83B] [83A]
Inj. R
GN/GY
BE/GY
+
-
15 amp
Inj. F
W/Y
Battery
ECM fuse
R
BK
40 Amp
R
R
Maxi Fuse
R/BK
12
12
BK
11
11
DCBA
10
10
[33B]
Ion sense
9
9
[33A]
Power gnd.
15 amp
8
8
Coil F
BE/O
7
7
IGN fuse
6
6
Ignition
5
5
GY
Constant power
switch
4
4
3
3
2
2
W/BK
1
1
12 11 10 9 8 7 6 5 4 3
21
[1B]
12 11 10 9 8 7 6 5 4 3
21
[1A]
[8B] [8A]
BK
12 11 10 9 8 7 6 5 4 3
2
1
[22A]
BK
12 11 10 9 8 7 6 5 4 3
2
1
[22B]
Engine stop
switch
Figure 5-43. Battery Voltage Circuit (FLTR, FLHT/C/U)
Table 5-24. Wire Harness Connectors in Figure 5-43.
NO.
DESCRIPTION
TYPE
LOCATION
[1]
Main to Interconnect Harness
12-Place Deutsch (Black)
Inner Fairing (Right Fairing Bracket)
[8]
Main to EFI Harness
12-Place Deutsch (Gray)
Under Right Side Cover
[22]
Right Handlebar Switches
12-Place Deutsch (Black)
Inner Fairing (Right Fairing Support Brace)
[33]
Ignition/Light Key Switch
4-Place Packard
Inner Fairing (Top Fork Bracket)
[78]
ECM
36-Place Packard
Under Right Side Cover
[83]
Ignition Coil
4-Place Packard
Below Fuel Tank (Left Side)
[84]
Front Injector
2-Place Packard
Below Fuel Tank (Left Side)
[85]
Rear Injector
2-Place Packard
Below Fuel Tank (Left Side)
2004 Touring: Engine Management (EFI)
5-65
HOME
[62B]
System relay
f2208m8x
Y/GN
[78A]
[78B]
BE/GY
GN/O
W/BK
Fuel pump
Y/GN
System relay
GN/O
Y/GN
15 amp
fuel pump
W/Y
fuse
[141B] [141A]
[84B] [84A]
BK
Y/GN
Power gnd.
Coil R
Y/BE
[85B] [85A]
GY/BE
Ignition
Switch power
Y/BE
coil
BE/O
ECM
W/BK
[83B] [83A]
BE/GY
Inj. R
GN/GY
15 amp
+
-
W/Y
ECM fuse
Inj. F
Battery
R
BK
R
40 Amp
R
R/BK
Maxi Fuse
12
12
BK
11
11
I B A
10
10
[33B]
Ion sense
9
9
[33A]
Power gnd.
8
8
15 amp
Coil F
BE/O
7
7
IGN fuse
6
6
Ignition
5
5
GY
Constant power
switch
4
4
3
3
2
2
W/BK
1
1
12 11 10 9 8 7
6543
2
1
[22A]
12 11 10 9 8 7
6543
2
1
[22B]
[8B] [8A]
12-Place on
FLHP Only
BK
Engine stop
BK
switch
Figure 5-44. Battery Voltage Circuit (FLHR/C/S)
Table 5-25. Wire Harness Connectors in Figure 5-44.
NO.
DESCRIPTION
TYPE
LOCATION
[8]
Main to EFI Harness
12-Place Deutsch (Gray)
Under Right Side Cover
[22]
Right Handlebar Switches
12-Place Deutsch (Black)
Inside Headlamp Nacelle
[33]
Ignition/Light Key Switch
3-Place Packard
Under Console
[78]
ECM
36-Place Packard
Under Right Side Cover
[83]
Ignition Coil
4-Place Packard
Below Fuel Tank (Left Side)
[84]
Front Injector
2-Place Packard
Below Fuel Tank (Left Side)
[85]
Rear Injector
2-Place Packard
Below Fuel Tank (Left Side)
5-66
2004 Touring: Engine Management (EFI)
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Test 5.18 (Part 1 of 2)
COMBUSTION ABSENT: DTC P1353, P1356, P1357, P1358
Is vehicle
running properly?
YES
NO
Has vehicle run out
Check fuel pressure. See
of fuel recently?
Section 5.15 FUEL PRESSURE
TEST. Is fuel pressure 55-62
PSI (380-425 kPA)?
YES
NO
YES
NO
See Section 5.17
See Section
Clear codes, refill with fresh
MISFIRE AT IDLE
5.13 FUEL SYSTEM
fuel and restart. Does code
OR UNDER LOAD.
ELECTRICAL TEST.
return?
YES
NO
System
OK.
Check if spark plug terminal is fully
connected on spark plug.
YES
NO
Remove spark plug terminal from
Seat terminal
spark plug. Inspect cable and spark
on spark plug.
plug terminals for carbon tracking or
evidence of a loose terminal. Loose
terminal present?
YES
NO
Crimp spark plug terminal
slightly to improve connection
Clear codes using speedometer self diagnostics.
STOP
or replace spark plug cable.
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
Go to Test 5.18
(Part 2 of 2).
2004 Touring: Engine Management (EFI)
5-67
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Test 5.18 (Part 2 of 2)
COMBUSTION ABSENT: DTC P1353, P1356, P1357, P1358
Continued from Test 5.18 (Part 1 of 2).
1
Using Breakout Box, measure resistance between
spark plug center electrode and Breakout Box Terminal
27. Is resistance less than 60,000 ohms?
2
YES
NO
Replace spark plug.
Check continuity between coil
Condition still present?
3
Terminal B and Breakout Box
Terminal 27. Continuity present?
YES
NO
YES
NO
Replace spark plug
System
cable. Condition still
OK.
present?
Replace
Check spark plug cable resistance.
coil.
4
Resistance meet specifications?
YES
NO
YES
NO
Measure resistance between
System
Terminal A and B at coil.
OK.
Resistance should be greater
Replace spark
Replace spark
than 100k ohms.
plug.
plug cable.
Is it?
YES
NO
Replace ECM.
Replace coil and ECM.
Reprogram and learn
Reprogram and learn
password.
password.
Clear codes using speedometer self diagnostics.
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
5-68
2004 Touring: Engine Management (EFI)
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DTC P0107, P0108
5.19
GENERAL
f1939x9x
MAP Sensor
See Figure 5-45. The manifold absolute pressure sensor
(MAP sensor) is supplied 5 volts from the ECM (Pin 14) and
sends a signal back to the ECM (Pin 25). This signal varies in
accordance with engine vacuum and atmospheric barometric
pressure. Changes in barometric pressure are influenced by
weather and altitude.
Table 5-26. Code Description
DTC
DESCRIPTION
MAP Sensor
P0107
MAP sensor open/low
P0108
MAP sensor high
Figure 5-45. Induction Module (Top View)
DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the Test 5.19 flow charts.
Diagnostic Tips
1.
Connect BREAKOUT BOX
(Part No. HD-43876)
● These codes will set if the MAP sensor signal is out of
between wire harness and ECM. See Section 5.7 BREA-
range. Code P0108 can only be detected with the engine
KOUT BOX: EFI.
running.
2.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
● MAP sensor output check. Using the VACUUM PUMP
41404), gray pin probes and patch cords.
(Part No. HD-23738), apply a vacuum to the pressure
port of the MAP sensor. The signal voltage should lower
as the vacuum is applied.
● The MAP, TP and VSS sensors are connected to the
same reference line (+5V Vref). If the reference line goes
to ground or open, multiple codes will be set
(DTC
P0107, P0108, P0122, P0123, P0501, P0502).
2004 Touring: Engine Management (EFI)
5-69
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f1743q9s
MAP
Sensor
[80A]
A
B
C
[80B]
A
B
C
To TP, ET &
IAT Sensors
To TP and
VSS sensors
[78B]
14
25
26
[78A]
ECM
Figure 5-46. MAP Sensor Circuit
Table 5-27. Wire Harness Connectors in Figure 5-46.
NO.
DESCRIPTION
TYPE
LOCATION
[78]
ECM
36-Place Packard
Under Right Side Cover
[80]
MAP Sensor
3-Place Packard
Top of Induction Module
5-70
2004 Touring: Engine Management (EFI)
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Test 5.19 (Part 1 of 2)
MAP SENSOR: DTC P0107, P0108
Connect Breakout Box. With ignition ON,
1
measure voltage between terminal 25
and terminal 26 on Breakout Box.
With key ON, engine OFF, voltage must be
between 3.5 and 5.0 volts.
With key ON, engine running, voltage must
be between 1.5-3.0 volts at hot idle.
Does voltage fit specifications?
YES
NO
Perform 5.8 WIGGLE TEST
to check for intermittents.
STOP
Intermittents present?
Go to Test 5.19 (Part 2 of 2).
YES
NO
To identify the source of intermittents,
Replace MAP sensor. Clear codes and road
start with box marked by Bold Asterisk
test. Did check engine lamp illuminate and
under Test 5.19 (Part 2 of 2). Wiggle
set DTC P0107 or P0108?
harness while watching DVOM.
YES
NO
Install original MAP sensor.
System
Replace ECM (reprogram,
now OK.
relearn) and road test again
to verify.
At some point in the flow chart you
may be instructed to jump directly
to a the box with the bold asterisk.
Disregard the asterisk (but not the
instruction box) if your normal pro-
gression through the chart brings
you to this location.
Clear codes using speedometer self diagnostics.
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
2004 Touring: Engine Management (EFI)
5-71
HOME
Test 5.19 (Part 2 of 2)
MAP SENSOR: DTC P0107, P0108
Continued from
Test 5.19 (Part 1 of 2).
Check the 5 volt reference supply at
2
the MAP sensor connector [80B]. With
ignition ON, measure voltage between
terminal C (R/W) and terminal A (BK/W).
Voltage approximately 5.0 volts?
YES
NO.
NO.
Greater
Less
than 6V.
than 4.5V.
Connect Breakout Box to connector [78B]
leaving ECM disconnected.
OPEN CHECK: Measure resistance
Locate short to 12 volts on R/W
Connect Breakout Box to connector [78B]
between MAP connector [80B]
wire in wire harness. Repair as
leaving ECM disconnected.
2
Terminal B and Breakout Box terminal 25.
necessary.
Check continuity between MAP connector
Resistance less than 1 ohm?
[80B] Terminal C and Breakout Box
2
terminal 14. Then measure continuity
between MAP connector [80B] Terminal A
and Breakout Box terminal 26.
Resistance less than 1 ohm?
YES
NO
SHORT CHECK: Measure
Locate and repair
2
resistance between MAP con-
open on V/W wire.
nector Terminal B and chassis
ground. Resistance greater
than 1 megohm?
YES
NO
Check resistance between
Repair
MAP connector [80B]
open wire.
Terminal C and
YES
NO
Breakout Box terminal 26.
Resistance greater than
1 megohm?
Replace MAP sensor. See
Locate and repair
Touring Service Manual.
grounded V/W wire.
YES
NO
Replace ECM.
Locate and repair
Reprogram and learn
short between
password.
R/W and BK/W
wires.
At some point in the flow chart you
may be instructed to jump directly
to a the box with the bold asterisk.
Disregard the asterisk (but not the
Clear codes using speedometer self diagnostics.
instruction box) if your normal pro-
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
gression through the chart brings
Confirm proper operation with no check engine
you to this location.
lamp.
5-72
2004 Touring: Engine Management (EFI)
HOME
DTC P0112, P0113
5.20
GENERAL
DIAGNOSTICS
IAT Sensor
Diagnostic Tips
The ECM supplies and monitors a voltage signal (terminal 7)
An intermittent may be caused by a poor connection, rubbed
to one side of the intake air temperature sensor (IAT sensor).
through wire insulation or a wire broken inside the insulation.
The other side of the IAT sensor is connected to a common
sensor ground, which is also connected to the ECM (terminal
Check the following conditions:
26).
● Poor connection: Inspect ECM and harness connector
The IAT sensor is a thermistor device, meaning that at a spe-
[78] for backed out terminals, improper mating, broken
cific temperature, it will have a specific resistance across its
locks, improperly formed or damaged terminals, poor ter-
terminals. As this resistance varies, so does the voltage on
minal-to-wire connection and damaged harness.
(terminal 7).
● At high temperatures, the resistance of the sensor is very
● Perform 5.8 WIGGLE TEST to locate intermittents: If
low, which effectively lowers the signal voltage on termi-
connections and harness check out OK, use a DVOM to
check the intake air temperature sensor voltage reading
nal 7.
while moving related connectors and wiring harness. If
● At low temperatures, the resistance is very high, allowing
the failure is induced, the intake air temperature sensor
the voltage to rise close to 5 volts.
voltage reading will change.
The ECM monitors this voltage to compensate for various
● Shifted sensor: Refer to Table 5-29. This table may be
operating conditions.
used to test the intake air temperature sensor at various
temperature levels in order to evaluate the possibility of a
shifted
(out-of-calibration) sensor which may result in
Table 5-28. Code Description
driveability problems.
DTC
DESCRIPTION
NOTE
P0112
IAT sensor voltage low
All voltage and resistance values are approximate (±20%).
Measure IAT sensor resistance between ECM Terminal 7 and
P0113
IAT sensor open/high
system ground (ECM Terminal 26).
Diagnostic Notes
Table 5-29. IAT Sensor Table
The reference numbers below correlate with the circled num-
TEMP °C
RESISTANCE
VOLTAGE
TEMP °F
bers on the Test 5.20 flow charts.
-20
29121
4.9
-4
1.
Connect BREAKOUT BOX (Part No. HD-43876) to EFI
wire harness only (leave ECM disconnected). See 5.7
-10
16599
4.8
14
BREAKOUT BOX: EFI.
0
9750
4.6
32
2.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
10
5970
4.3
50
41404), gray pin probes and patch cords.
20
3747
4.0
68
3.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
25
3000
3.8
77
41404), gray socket probes and patch cords.
30
2417
3.6
86
4.
Replace IAT sensor. See Touring Service Manual.
40
1598
3.1
104
50
1080
2.6
122
60
746
2.2
140
70
526
1.7
158
80
377
1.4
176
90
275
1.1
194
100
204
0.9
212
2004 Touring: Engine Management (EFI)
5-73
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f1743r9s
IAT
Sensor
A
B
[89A]
[89B]
A
B
To TP, ET &
MAP Sensors
[78B]
7
26
[78A]
ECM
Figure 5-47. IAT Sensor Circuit
Table 5-30. Wire Harness Connectors in Figure 5-47.
NO.
DESCRIPTION
TYPE
LOCATION
[78]
ECM
36-Place Packard
Under Right Side Cover
[89]
IAT Sensor
2-Place Packard
Below Fuel Tank (Right Side)
5-74
2004 Touring: Engine Management (EFI)
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Test 5.20 (Part 1 of 2)
IAT SENSOR: DTC P0112, P0113
Connect Breakout Box to connector [78B] leaving
ECM disconnected. With engine at room temperature
(60-90° F or 16-32° C), use a DVOM to measure
1
resistance across terminals 7 and 26 on Breakout
Box. If engine is warm, refer to Table 5-29.
Resistance between 2.0k ohms and 5.0k ohms at
room temperature?
YES
NO
Connect ECM to Breakout Box.
Perform 5.8 WIGGLE TEST to check for
STOP
intermittents. Intermittents present?
Go to Test 5.20 (Part 2 of 2).
YES
NO
While wiggling harness, perform
Disconnect IAT sensor connector [89].
steps marked by BOLD ASTER-
Turn ignition ON. Using a DVOM, mea-
ISKS under Test 5.20 (Part 2 of 2).
sure the voltage
Repair as necessary.
between ECM terminal 7 (positive) and
terminal 26 (negative) on Breakout Box.
Voltage approximately 5 volts?
YES
NO.
NO.
Less than
Greater than
4.7 volts.
5.3 volts.
Replace IAT sensor, clear codes and
road test. Did check engine lamp illu-
With IAT sensor disconnected,
Unplug ECM leaving Breakout Box con-
1
1
minate and set DTC P0112 or
disconnect ECM from breakout box.
nected at vehicle harness.
P0113?
Measure resistance between
Measure voltage between
Breakout Box terminal 7 and terminals
Breakout Box terminal 7 and terminals 10
10 or 28.
or 28.
Resistance less than 1 megohm?
Voltage 0 volts?
YES
NO
YES
NO
YES
NO
Install original IAT
System
Repair short to
Replace ECM.
Replace ECM.
Examine IAT sig-
sensor, replace ECM,
OK.
ground on
Reprogram and
Reprogram and
nal wire (Lt GN/Y)
perform password
Lt GN/Y wire.
learn password.
learn password.
for short to volt-
learning and road test.
age and repair.
At some point in the flow chart you
may be instructed to jump directly
to a the box with the bold asterisk.
Clear codes using speedometer self diagnostics.
Disregard the asterisk (but not the
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
instruction box) if your normal pro-
Confirm proper operation with no check engine
gression through the chart brings
lamp.
you to this location.
2004 Touring: Engine Management (EFI)
5-75
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Test 5.20 (Part 2 of 2)
IAT SENSOR: DTC P0112, P0113
Continued from
Test 5.20 (Part 1 of 2).
Disconnect IAT sensor connector [89B] and
examine for damage. Connector OK?
YES
NO
Using a DVOM, measure the resistance
Repair
between IAT sensor connector [89B]
connector.
Terminal A and ECM terminal 7 on Breakout
Box. Resistance less than 1.0 ohm?
2
YES
NO
Using a DVOM, measure the resistance
Examine Lt GN/Y wire in
between IAT sensor connector [89B]
harness for open circuit
Terminal B and ECM terminal 26 on Break-
and repair.
2
out Box. Resistance less than 1.0 ohm?
YES
NO
Using a DVOM, measure the resistance
Examine BK/W wire in
between ECM terminal 7 and terminal 26 on
harness for open circuit
Breakout Box. Resistance greater
and repair.
than 1.0 megohm?
YES
NO
Using a DVOM, measure the resistance
Examine Lt GN/Y and
between ECM terminal 7 on Breakout Box
BK/W wires in harness
and ground. Resistance greater
for short between these
than 1.0 megohm?
two circuits and repair.
YES
NO
Remove IAT sensor and measure resistance
Examine harness for
across the terminals of the IAT sensor
short to ground and
3
directly. Again, with sensor at room tempera-
repair.
ture 60-90° F or 16-32° C), is resistance
between 2.0k ohms and 5.0k ohms?
At some point in the flow chart you
may be instructed to jump directly
to a the box with the bold asterisk.
YES
NO
Disregard the asterisk (but not the
instruction box) if your normal pro-
gression through the chart brings
Perform 5.8 WIGGLE TEST on steps
Replace
you to this location.
4
marked with a BOLD ASTERISK above to
IAT sensor.
locate intermittents. Repair as necessary.
Clear codes using speedometer self diagnostics.
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
5-76
2004 Touring: Engine Management (EFI)
HOME
DTC P0117, P0118
5.21
GENERAL
DIAGNOSTICS
ET Sensor
Diagnostic Tips
The ECM supplies and monitors a voltage signal (terminal 6)
● Once the engine is started, the ET voltage should rise
to one side of the engine temperature sensor (ET sensor).
steadily.
The other side of the ET sensor is connected to a common
sensor ground (terminal 26) of the ECM.
● An intermittent may be caused by a poor connection,
The ET sensor is a thermistor device, which means that at a
rubbed through wire insulation or a wire broken inside
specific temperature it will have a specific resistance across
the insulation.
its terminals. As this resistance varies, so does the voltage
Check the following conditions:
(terminal 6).
● At high temperatures, the resistance of the sensor is very
● Poor connection: Inspect ECM and harness connector
low, which effectively lowers the signal voltage on termi-
[78] for backed out terminals, improper mating, broken
nal 6.
locks, improperly formed or damaged terminals, poor ter-
minal-to-wire connection and damaged harness.
● At low temperatures, the resistance is very high, allowing
the voltage to rise close to 5 volts.
● Perform 5.8 WIGGLE TEST to locate intermittents: If
The ECM monitors this voltage to compensate for various
connections and harness check out OK, use a DVOM to
operating conditions. The ECM also uses the sensor input as
check the engine temperature sensor voltage reading
a reference for determining IAC pintle position.
while moving related connectors and wiring harness. If
the failure is induced, the engine temperature sensor
voltage reading will change.
Table 5-31. Code Description
● Shifted sensor: Refer to Table 5-32. This table may be
DTC
DESCRIPTION
used to test the engine temperature sensor at various
temperature levels in order to evaluate the possibility of a
P0117
ET sensor voltage low
shifted
(out-of-calibration) sensor which may result in
P0118
ET sensor open/high
driveability problems.
NOTE
Table 5-32. ET Sensor Table
All voltage and resistance values are approximate (±20%).
Measure ET sensor resistance between ECM Terminal 6 and
TEMP °C
RESISTANCE
VOLTAGE
TEMP °F
system ground (ECM Terminal 26).
-20
28144
4.4
-4
Diagnostic Notes
-10
15873
4.0
14
0
9255
3.5
32
The reference numbers below correlate with the circled num-
bers on the Test 5.21 flow charts.
10
5571
3.0
50
20
3457
2.4
68
1. Connect BREAKOUT BOX (Part No. HD-43876) to EFI
wire harness only (leave ECM disconnected). See 5.7
25
2750
2.1
77
BREAKOUT BOX: EFI.
30
2205
1.8
86
2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
40
1442
1.3 or 4.1*
104
41404), gray pin probes and patch cords.
50
965
1.0 or 3.7*
122
3. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
60
661
3.3
140
41404), gray socket probes and patch cords.
70
462
2.9
158
4. Replace ET sensor. See Touring Service Manual.
80
329
2.5
176
90
238
2.1
194
100
175
1.7
212
* Between 40-50°C the ECM changes scaling. Voltages for ECT
sensor will shift scales in that range. This provides proper sensor res-
olution for all temperatures.
2004 Touring: Engine Management (EFI)
5-77
HOME
f1743s9s
ET
Sensor
A
B
[90A]
[90B]
A
B
To TP, IAT &
MAP Sensors
[78B]
6
26
[78A]
ECM
Figure 5-48. ET Sensor Circuit
Table 5-33. Wire Harness Connectors in Figure 5-48.
NO.
DESCRIPTION
TYPE
LOCATION
[78]
ECM
36-Place Packard
Under Right Side Cover
[90]
ET Sensor
2-Place Packard
Back of Front Cylinder (Left Side)
5-78
2004 Touring: Engine Management (EFI)
HOME
Test 5.21 (Part 1 of 2)
ET SENSOR: DTC P0117, P0118
Connect Breakout Box to connector [78B]
leaving ECM disconnected. With engine at
room temperature (60-90° F or 16-32° C),
1
use a DVOM to measure resistance across
terminals 6 and 26 on Breakout Box. If
engine is warm, refer to Table 5-32. Resis-
tance between 2.0k ohms and 5.0k ohms?
YES
NO
Connect ECM to Breakout Box.
Perform 5.8 WIGGLE TEST to check for
STOP
intermittents. Intermittents present?
Go to Test 5.21 (Part 2 of 2).
YES
NO
While wiggling harness, perform
Disconnect ET sensor connector [90].
steps marked by BOLD ASTER-
Turn ignition ON. Using a DVOM, mea-
ISKS under Test 5.21 (Part 2 of 2).
sure the voltage between
Repair as necessary.
terminal 6 (positive) and
terminal 26 (negative) on Breakout Box.
Voltage approximately 5 volts?
YES
NO.
NO.
Less than
Greater than
4.7 volts.
5.3 volts.
Replace ET sensor, clear codes and
road test. Did check engine lamp illu-
With ET sensor disconnected,
Unplug ECM leaving Breakout Box
minate and set DTC P0117 or
disconnect ECM connector [78B].
connected at vehicle harness.
P0118?
Measure resistance between
Measure voltage between
terminal 6 and terminals 10 or 28.
terminal 6 and terminals 10 or 28.
Resistance less than 1 megohm?
Voltage 0 volts?
YES
NO
YES
NO
YES
NO
Install original
System
Repair short to
Replace ECM.
Replace ECM.
Examine ET sig-
ET sensor,
OK.
ground on
Reprogram and
Reprogram and
nal wire (PK/Y) for
replace ECM, perform
PK/Y wire.
learn password.
learn password.
short to voltage
password learning
and repair.
and road test.
At some point in the flow chart you
may be instructed to jump directly
to a the box with the bold asterisk.
Disregard the asterisk (but not the
Clear codes using speedometer self diagnostics.
instruction box) if your normal pro-
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
gression through the chart brings
Confirm proper operation with no check engine
you to this location.
lamp.
2004 Touring: Engine Management (EFI)
5-79
HOME
Test 5.21 (Part 2 of 2)
ET SENSOR: DTC P0117, P0118
Continued from
Test 5.21 (Part 1 of 2).
Disconnect ET sensor connector [90B] and
examine for damage. Connector OK?
YES
NO
Using a DVOM, measure the resistance
Repair
between ET sensor connector [90B]
connector.
Terminal A and ECM terminal 6 on Breakout
Box. Resistance less than 1.0 ohm?
2
YES
NO
Using a DVOM, measure the resistance
Examine PK/Y wire in
between ET sensor connector [90B]
harness for open circuit
Terminal B and ECM terminal 26 on Break-
and repair.
2
out Box. Resistance less than 1.0 ohm?
YES
NO
Using a DVOM, measure the resistance
Examine BK/W wire in
between ECM terminal 6 and terminal 26 on
harness for open circuit
Breakout Box. Resistance greater
and repair.
than 1.0 megohm?
YES
NO
Using a DVOM, measure the resistance
Examine PK/Y and
between ECM terminal 6 on Breakout Box
BK/W wires in harness
and ground. Resistance greater
for short between these
than 1.0 megohm?
two circuits and repair.
At some point in the flow chart
you may be instructed to jump
directly to a the box with the bold
asterisk. Disregard the asterisk
(but not the instruction box) if your
YES
NO
normal progression through the
chart brings you to this location.
Remove ET sensor and measure resistance
Examine harness for
3
across the terminals of the ET sensor
short to ground and
directly. Again, with sensor at room tempera-
repair.
ture (60-90° F or 16-32° C), is resistance
between 2.0k ohms and 5.0k ohms?
YES
NO
Perform 5.8 WIGGLE TEST on steps
Replace
4
marked with a BOLD ASTERISK above to
ET sensor.
Clear codes using speedometer self diagnostics.
locate intermittents. Repair as necessary.
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
Confirm proper operation with no check engine
lamp.
5-80
2004 Touring: Engine Management (EFI)
HOME
DTC P0122, P0123
5.22
Check for the following conditions:
GENERAL
● Poor Connection: Inspect ECM and harness connector
[78B] for backed out terminals, improper mating, broken
TP Sensor
locks, improperly formed or damaged terminals, poor ter-
minal-to-wire connection and damaged harness.
The ECM supplies a 5 volt signal (terminal 14) to the throttle
position sensor (TP sensor). The TP sensor sends a signal
●
Perform 5.8 WIGGLE TEST to locate intermittents: If
back to the ECM (terminal 24). The returned signal varies in
connections and harness check out OK, monitor TP sen-
voltage according to throttle position.
sor voltage using a DVOM while moving related connec-
tors and wiring harness. If the failure is induced, the TP
● At idle (closed throttle), the signal is typically in the range
sensor voltage reading will change.
of 0.20-0.80 volts.
● At wide open throttle, the signal is normally 4.0-4.9 volts.
●
TP sensor scaling: Observe the TP sensor voltage dis-
play while opening the throttle with engine stopped and
A code P0122 or P0123 will set if the TP sensor voltage sig-
ignition key ON. Display should vary from closed throttle
nal does not fall within the acceptable range.
TP sensor voltage (when throttle is closed) to greater
than 4.0 volts (when throttle is held wide open). As the
● Check TP sensor voltage reading with DVOM. If TP sen-
sor is equal to or greater than 3.8 volts then the system is
throttle is slowly moved, the voltage should change
gradually without spikes or low voltages being observed.
in
“clear flood” mode and engine will not start. While
spark is present, fuel is shut off. Problem can be
mechanical, such as stuck throttle cables.
Diagnostic Notes
The reference numbers below correlate with the circled num-
Table 5-34. Code Description
bers on the Test 5.22 flow charts.
DTC
DESCRIPTION
1.
Connect a BREAKOUT BOX
(Part No. HD-43876)
between EFI wire harness and ECM before measuring
P0122
TP sensor open/low
voltage. See 5.7 BREAKOUT BOX: EFI. If using a DVOM
to measure voltage, take reading across terminal 24
P0123
TP sensor high
(positive lead) and terminal 26 (negative lead) on Break-
out Box.
DIAGNOSTICS
2.
Replace TP sensor. See Touring Service Manual.
3.
Use HARNESS CONNECTOR TEST KIT (Part No. HD-
41404), gray pin probes and patch cords.
Diagnostic Tips
The DVOM reads throttle position in volts. Voltage should
increase at a steady rate as the throttle is moved from idle to
wide open. A short to ground or open on the GY/V or R/W
wires also will result in a DTC P0122. A short to ground or
open on the R/W wire (+5v REF) sets multiple codes as
described below.
NOTE
The MAP, TP and VSS sensors are connected to the same
reference line (+5V Vref). If the reference line goes to ground
or open, multiple codes will be set (DTC P0107, P0108,
P0122, P0123, P0501, P0502). Start with the trouble code
having the lowest ranking value.
2004 Touring: Engine Management (EFI)
5-81
HOME
s0452x9x
TP
sensor
A
B
C
[88A]
[88B]
A
B
C
To MAP, ET &
IAT sensors
To MAP
sensor
[78B]
14
24
26
[78A]
ECM
Figure 5-49. TP Sensor Circuit
Table 5-35. Wire Harness Connectors in Figure 5-49.
NO.
DESCRIPTION
TYPE
LOCATION
[78]
ECM
36-Place Packard
Under Right Side Cover
[88]
TP Sensor
3-Place Packard
Below Fuel Tank (Right Side)
5-82
2004 Touring: Engine Management (EFI)
HOME
Test 5.22 (Part 1 of 2)
TP SENSOR: DTC P0122, P0123
With ignition key ON, measure TP sensor voltage while gradu-
ally opening throttle. Does voltage increase steadily
with no spikes or low voltages from 0.2-0.8 volts at idle
1
(closed throttle) to 4.0-4.9 volts at wide open throttle?
YES
NO
Voltage is
Low voltage
Check engine lamp ON
greater than
or spikes
continuously and
4.95 volts.
observed.
DTC P0122 or P0123
the only one set?
Unplug TP sensor connector [88B]
STOP
and measure voltage between
Terminal B (+) and Terminal A (-)
with ignition ON.
Go to Test 5.22 (Part 2 of 2).
Is reading 4.8-5.0 volts?
YES
NO
YES
NO
Replace ECM.
Perform 5.8 WIGGLE TEST
Measure
Reprogram and
to check for intermittents.
Disconnect ECM from
resistance
learn password.
Intermittents present?
Breakout Box. Check
between
resistance between ECM
TP sensor
terminal 24 on Breakout
connector [88B]
Box to chassis ground.
Terminal B to
Greater than 1 megohm?
ECM terminal 14
on Breakout Box.
Less than
YES
NO
1.0 ohm?
While wiggling harness,
Replace TP sensor, clear
2
start with the first step of
codes and road test.
YES
NO
Test 5.22 (Part 2 of 2)
Did check engine lamp
(marked by BOLD ASTER-
illuminate and set DTC
ISK). Repair as necessary.
P0122 or P0123?
Replace
Find short to
2
TP sensor.
ground on GY/V
signal wire.
YES
NO
YES
NO
Install original
System
TP sensor, replace ECM
OK.
(reprogram and learn
password) and road test.
Repair open
Repair open
in BK/W wire.
in R/W wire.
At some point in the flow chart you
may be instructed to jump directly
to a the box with the bold asterisk.
Disregard the asterisk (but not the
Clear codes using speedometer self diagnostics.
instruction box) if your normal pro-
See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
gression through the chart brings
Confirm proper operation with no check engine
you to this location.
lamp.
2004 Touring: Engine Management (EFI)
5-83
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