Harley Davidson 2004 Touring Models. Service Manual — page 13

    HOME
    [62B]
    CKP
    To Tachometer
    Y/GN
    [78]
    (FLHR/C/S Optional)
    System
    relay
    BE/GY
    [79A]
    1
    2
    GN/O
    [79B]
    1
    2
    3
    W/BK
    R
    30
    15 Amp
    [13A] [13B]
    BK
    12
    fuel pump
    fuse
    System relay
    4
    GN/O
    Fuel
    O/GY
    pump
    Y/GN
    Inj. F
    21
    W/Y
    [141B] [141A]
    [84B]
    [84A]
    BK
    Y/GN
    All Except
    FLHR/C/S
    [83B]
    [83A]
    Inj. R
    19
    GN/GY
    [85B]
    [85A]
    Coil
    Ion sense
    27
    GY/BE
    Coil R
    11
    Y/BE
    Coil F
    29
    BE/O
    A
    A
    BE/GN
    35
    40 Amp
    B
    B
    BN/R
    36
    Maxi fuse
    C
    C
    BK/PK
    18
    +
    -
    D
    D
    BK/O
    17
    15 Amp
    Battery
    ECM fuse
    R
    [87A]
    [87B]
    Constant
    31
    BE/GY
    Intake air
    power
    BK
    control
    Engine
    stop
    15 Amp
    IGN fuse
    switch
    Switch power
    13
    W/BK
    GY
    R/BK
    Ignition switch
    BK/W
    TP
    R/W
    sensor
    TP sensor
    24
    GY/V
    GY/V
    To right
    [90B] [90A]
    hand controls
    [88B] [88A]
    ET sensor
    6
    PK/Y
    ET sensor
    GY
    BK/W
    W/BK
    W/BN
    IAT sensor
    7
    LT GN/Y
    IAT sensor
    5v sensor gnd.
    26
    BK/W
    BK/W
    [22A]
    [89B] [89A]
    [80B] [80A]
    BK/W
    MAP sensor
    V/W
    V/W
    MAP
    25
    sensor
    5v sensor pwr.
    14
    R/W
    R/W
    Vehicle
    Vehicle speed sensor
    speed
    33
    W/GN
    sensor
    [65B] [65A]
    LT GN/V
    To speedometer
    Serial data
    5
    and tachometer
    [91A]
    3
    Data link
    1
    connector
    2
    Flash pin
    1
    LT GN/R
    4
    [30B]
    2
    3
    7
    TSM/
    Power gnd.
    10
    BK
    TSSM
    [30A]
    2
    3
    7
    Power gnd.
    28
    BK
    f2208g8x
    Figure 5-18. EFI System Circuit - Simplified
    5-24
    2004 Touring: Engine Management (EFI)
    HOME
    Table 5-8. Wire Harness Connectors in Figure 5-18.
    NO.
    DESCRIPTION
    MODEL
    TYPE
    LOCATION
    12-Place Deutsch
    Inner Fairing - Fork Stem Nut Lock Plate
    FLHT/C/U
    (Black)
    (Left Side)
    Right Handlebar Switch
    12-Place Deutsch
    [22]
    FLTR
    Inner Fairing - Right Side of Radio Bracket
    Controls
    (Black)
    Inside Headlamp Nacelle - Fork Stem
    FLHR/C/S
    6 - Place Deutsch
    Nut Lock Plate (Right Side)
    Cavity in Crossmember at Rear of
    [30]
    Turn Signal/Security Module
    All
    12 - Place Deutsch
    Battery Box (Under Seat)
    Under Right Side Cover
    [65]
    Vehicle Speed Sensor
    All
    3 - Place Deutsch
    (Behind Electrical Bracket)
    [78]
    Electronic Control Module
    All
    36-Place Packard
    Under Right Side Cover
    [79]
    Crankshaft Position Sensor
    All
    2 - Place Mini-Deutsch
    Bottom of Voltage Regulator
    Manifold Absolute Pressure
    [80]
    All
    3 - Place Packard
    Top of Induction Module
    Sensor
    [83]
    Ignition Coil
    All
    4 - Place Packard
    Below Fuel Tank (Left Side)
    [84]
    Front Injector
    All
    2 - Place Packard
    Below Fuel Tank (Left Side)
    [85]
    Rear Injector
    All
    2 - Place Packard
    Below Fuel Tank (Left Side)
    [87]
    Idle Air Control
    All
    4 - Place Packard
    Below Fuel Tank (Right Side)
    [88]
    Throttle Position Sensor
    All
    3 - Place Packard
    Below Fuel Tank (Right Side)
    [89]
    Intake Air Temperature Sensor
    All
    2 - Place Packard
    Below Fuel Tank (Right Side)
    [90]
    Engine Temperature Sensor
    All
    2 - Place Packard
    Back of Front Cylinder (Left Side)
    [91]
    Data Link
    All
    4 - Place Deutsch
    Under Right Side Cover
    2004 Touring: Engine Management (EFI)
    5-25
    HOME
    Test 5.10 (Part 1 of 4)
    ENGINE CRANKS, BUT WILL NOT START
    Fresh fuel in tank?
    NOTE
    Refer to IGNITION COIL in the Tour-
    ing Service Manual for proper coil ter-
    minal location.
    Spark plug wires firmly
    connected to proper coil terminals?
    Add fuel /connect
    NO
    spark plugs.
    YES
    Check for trouble
    1
    codes.
    Codes found?
    NO
    Is TSM/TSSM mounted in
    proper orientation?
    YES
    Refer to Table 5-5.
    Start with
    YES
    the lowest ranking
    NO
    code.
    Check battery connections
    2
    and voltage. Is voltage
    Install TSM/TSSM properly.
    above 12.60?
    YES
    NO
    Does battery pass
    Was battery allowed to dis-
    load test?
    charge? Was battery drawn
    down by starting problem?
    Recharge battery.
    YES
    NO
    Turn ignition key ON and engine stop
    Replace battery.
    switch to RUN. Did fuel pump run for 2
    seconds and check engine lamp illumi-
    nate for 4 seconds?
    YES
    NO
    No pump,
    NO
    light OK.
    No light or pump
    Connect breakout box to ECM [78]. Measure
    3
    voltage to breakout box with DVOM at terminal
    13 (+) and terminal 4 (-). Crank engine for
    See
    greater than 2 seconds to insure proper system
    5.13 FUEL SYSTEM
    See 5.11 NO ECM POWER.
    operation. 6-12 volts present continuously?
    ELECTRICAL TEST.
    YES
    NO
    Go to bold asterisk in
    Go to Test 5.10
    STOP
    Test 5.10 (Part 4 of 4).
    (Part 2 of 4).
    5-26
    2004 Touring: Engine Management (EFI)
    HOME
    Test 5.10 (Part 2 of 4)
    ENGINE CRANKS, BUT WILL NOT START
    Continued from Test 5.10 (Part 1 of 4).
    Install fuel pressure gauge (Part No. HD-41182).
    See 5.15 FUEL PRESSURE TEST. While
    cranking engine (for more than 2 seconds to
    ensure proper system operation), verify that
    fuel pressure rises to 55-62 PSI (380-427 kPa).
    Adequate fuel pressure present?
    YES
    NO
    Check spark plug condition, replace if fouled.
    Incorrect pressure. See 5.15
    Reinstall spark plugs before checking spark.
    FUEL PRESSURE TEST.
    Check spark at both plugs while cranking.
    Spark present?
    4
    YES
    NO
    Verify connector is securely attached
    Check battery voltage at
    to each injector. If so, disconnect fuel
    Terminal A (+) of coil connector
    injector connector and attach fuel
    [83B] using DVOM. Battery
    injector test lamp (HD-34730-2C).
    voltage present for 2 seconds
    Crank engine. Does lamp flash?
    5
    after key ON?
    YES
    NO
    YES
    NO
    Monitor IAC pintle for 10 seconds
    Correct problems with
    Open in Y/GN wire
    6
    after turning ignition OFF. Does pin-
    fuel injectors. See 5.23
    between splice for fuel
    tle extend and then retract during
    STOP
    DTC P0261, P0262,
    pump wire and ignition
    10 second key OFF
    P0263, P0264.
    coil. Repair open
    reset procedure?
    Go to Test 5.10
    (Part 3 of 4).
    YES
    NO
    Check for plugged fuel
    See 5.16 IDLE
    injectors. Injectors
    AIR CONTROL.
    plugged?
    YES
    NO
    Replace plugged
    Check engine compression.
    injector(s).
    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)
    5-27
    HOME
    Test 5.10 (Part 3 of 4)
    ENGINE CRANKS, BUT WILL NOT START
    Continued from Test 5.10 (Part 2 of 4).
    7
    Perform coil circuit test. Does lamp flash?
    YES
    NO
    Check coil connections.
    Disconnect ECM connector [78]. Inspect
    Connections OK?
    for damaged terminals, terminals backed
    out or corroded. Terminal problems
    present?
    YES
    NO
    Test spark plug cable resis-
    YES
    NO
    Repair.
    tance. See 5.17 MISFIRE AT
    IDLE OR UNDER LOAD.
    Resistance OK?
    Repair terminal
    Reconnect. Problem
    damage.
    still exist?
    YES
    NO
    YES
    NO
    Replace spark
    Replace
    plug cables.
    coil.
    Problem
    fixed.
    STOP
    Go to Test 5.10
    (Part 4 of 4).
    Clear codes using speedometer self diagnostics.
    See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    lamp.
    5-28
    2004 Touring: Engine Management (EFI)
    HOME
    Test 5.10 (Part 4 of 4)
    ENGINE CRANKS, BUT WILL NOT START
    Continued from Test 5.10 (Part 3 of 4).
    Check connectors for moisture and cor-
    rosion. Check wires for chafing. Con-
    nect DVOM to ECM terminals 12 and
    30 on Breakout Box and set it for AC
    volts. Crank engine. Does DVOM read
    1 VAC minimum?
    YES
    NO
    Replace ECM.
    Reprogram and
    Disconnect CKP connector
    learn password.
    [79]. Check connectors for
    moisture and corrosion. Check
    wires for chafing. Is connector
    or wire damage present?
    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
    Repair damage.
    you to this location.
    Connect DVOM to Terminals
    8
    1 and 2 of [79A]. Crank
    engine. Does DVOM read 1
    VAC minimum?
    YES
    NO
    Check for continuity between
    With meter still connected,
    terminal 30 on Breakout Box
    and Terminal 1 of connector
    check for resistance.
    Is resistance 600-1200 ohms?
    [79B].
    Continuity present?
    YES
    NO
    YES
    NO
    Locate and repair open on
    Locate and repair open on
    Loosen sensor at crankcase.
    Replace crank position sensor.
    BK wire between Terminal 2 of
    R wire between Terminal 1 of
    Check for contamination or
    connector [79B] and terminal
    connector [79B] and terminal
    damage. Tighten sensor.
    12 on Breakout Box.
    30 on Breakout Box.
    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)
    5-29
    HOME
    NO ECM POWER
    5.11
    GENERAL
    System Fuse Block (Under Left Side Cover)
    8
    No Spark/No Check Engine Lamp
    FLHR/C/S
    at Key ON
    9
    10
    Constant power is supplied to the ECM through terminal 31.
    The ECM turns on when power is applied to terminal 13 of
    5
    connector
    [78]. The ECM goes through an initialization
    11
    sequence every time power is removed and re-applied to ter-
    minal 13. The only visible part of this sequence is the check
    engine lamp. Upon starting, the check engine lamp will illumi-
    nate for 4 seconds and then (if parameters are normal) go
    4
    out.
    12
    If battery power is absent at ECM terminal 31:
    f2210x8x
    2
    3
    ● DTCs cannot be cleared. Tool will show them as cleared
    1
    but will be present next time ignition key is cycled.
    8
    7
    FLTR, FLHT/C/U
    ● ECM cannot be re-flashed.
    ● Vehicle will start but IAC pintle will not reset at key OFF.
    9
    6
    10
    Eventually pintle will be out of position causing perfor-
    mance problems.
    5
    11
    NOTE
    The key ON sequence also activates the idle air control
    motor. If power from terminal 31 is disrupted (blown fuse,
    etc.) always turn the key OFF wait 10 seconds then turn the
    4
    key ON to reset the motor to the default position.
    DIAGNOSTICS
    f2204x8x
    2
    3
    1
    Diagnostic Notes
    1.
    Headlamp
    7.
    Radio Power
    2.
    Ignition
    8.
    Accessory
    The reference numbers below correlate with the circled num-
    3.
    Lighting
    9.
    Battery
    bers on the Test 5.11 flow charts.
    4.
    Instruments
    10.
    Brake Light Relay
    5.
    Brakes/Cruise
    11.
    P&A
    1. Connect BREAKOUT BOX (Part No. HD-43876). See 5.7
    6.
    Radio Memory
    12.
    Starter Relay
    BREAKOUT BOX: EFI.
    NOTE
    EFI Fuse Block (Under Right Side Cover)
    Adapters are not used on FLTR and FLHT/C/U models.
    EFI System
    2. Connect BREAKOUT BOX
    (Part No. HD-42682)
    Relay
    Spare
    between connectors [22A] and [22B] using Adapters
    (HD-42962) on FLHR/C/S models.
    Fuel Pump
    ECM Power
    f2223x9x
    Figure 5-19. Fuse Locations
    5-30
    2004 Touring: Engine Management (EFI)
    HOME
    [78A] [78B]
    f2208f8x
    31
    BE/GY
    40 Amp
    Maxi Fuse
    15 Amp
    +
    -
    ECM Fuse
    Battery
    BK
    R
    13
    W/BK
    [8A]
    R/BK
    12
    11
    10
    9
    8
    7
    6
    5
    4
    3
    2
    1
    [8B]
    [33A]
    D
    CBA
    ECM
    [33B]
    15 Amp
    Ignition Fuse
    GY
    Ignition
    Switch
    [1A]
    12
    11
    10
    9
    8
    7
    6
    5
    4
    3
    2
    1
    [1B]
    [22A]
    12
    11
    10
    9
    8
    7
    6
    5
    4
    3
    2
    1
    [22B]
    10
    BK
    Engine Stop
    28
    BK
    Switch
    BK
    Figure 5-20. ECM Power Circuit (FLTR, FLHT/C/U)
    Table 5-9. Wire Harness Connectors in Figure 5-20.
    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)
    Inner Fairing
    [33]
    Ignition/Light Key Switch
    4-Place Packard
    (Front of Top Fork Bracket -Below Radio)
    [78]
    ECM
    36-Place Packard
    Under Right Side Cover
    2004 Touring: Engine Management (EFI)
    5-31
    HOME
    [78A] [78B]
    f2208e8x
    40 Amp
    31
    BE/GY
    Maxi Fuse
    15 Amp
    ECM Fuse
    +
    -
    Battery
    BK
    R
    13
    W/BK
    [8A]
    R/BK
    12
    11
    10
    9
    8
    7
    6
    5
    4
    3
    2
    1
    [8B]
    [33A]
    I
    BA
    ECM
    [33B]
    15 Amp
    Ignition Fuse
    GY
    Ignition
    Switch
    12-Place on FLHP
    [22A]
    12
    11
    10
    9
    8
    7
    6
    5
    4
    3
    2
    1
    [22B]
    10
    BK
    Engine Stop
    28
    BK
    Switch
    BK
    Figure 5-21. ECM Power Circuit (FLHR/C/S)
    Table 5-10. Wire Harness Connectors in Figure 5-21.
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [8]
    Main to EFI Harness
    12-Place Deutsch (Gray)
    Under Right Side Cover
    [22]
    Right Handlebar Switches
    6-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
    5-32
    2004 Touring: Engine Management (EFI)
    HOME
    Test 5.11 (Part 1 of 2)
    NO ECM POWER
    Check ECM and ignition fuse.
    Are fuses OK?
    NO
    YES
    Locate and repair short
    Disconnect ECM connector [78]. Inspect
    to ground. Replace 15
    for damaged terminals, terminals backed
    amp fuse.
    out or corrosion. Terminal problems
    present?
    YES
    NO
    Repair terminal
    Reconnect. Problem
    damage.
    still exist?
    YES
    NO
    With ignition ON, probe ECM Terminal 13 on
    Problem
    1
    Breakout Box with a circuit test lamp con-
    fixed.
    nected to ground. Does test lamp illuminate?
    NO
    STOP
    YES
    Go to Test 5.11
    (Part 2 of 2).
    Probe ECM Terminal 31 on
    Breakout Box with test lamp
    connected to ground. Does test
    lamp illuminate?
    YES
    NO
    Probe ECM Terminal 10 and
    Probe red wire terminal in
    28 on Breakout Box with test
    15 amp ECM fuse holder
    lamp connected to +12V (bat-
    with test lamp connected
    tery positive terminal). Does
    to ground. Does test lamp
    test lamp illuminate?
    illuminate?
    YES
    NO
    YES
    NO
    Replace ECM.
    Repair open in
    Repair open in BE/GY
    Repair open in
    Reprogram and learn
    BK wire between
    wire between fuse
    red wire between 40
    password.
    connector [78B] and
    holder and ECM con-
    amp maxi fuse and 15
    ground 1.
    nector [78].
    amp fuse holder.
    2004 Touring: Engine Management (EFI)
    5-33
    HOME
    Test 5.11 (Part 2 of 2)
    NO ECM POWER
    Continued from Test 5.11 (Part 1 of 2).
    2
    Measure voltage at terminal 3 (BK) of
    breakout box. Battery voltage present?
    YES
    NO
    Repair open (GY) wire between
    connector [22] and fuse.
    With ignition ON, Measure
    voltage at terminal A (BK).
    Battery voltage present?
    YES
    NO
    Repair open circuit on W/BK wire
    Repair/Replace engine stop
    between ECM and connector [22A].
    switch or wiring.
    Clear codes using speedometer self diagnostics.
    See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    lamp.
    5-34
    2004 Touring: Engine Management (EFI)
    HOME
    STARTS, THEN STALLS
    5.12
    GENERAL
    f1917x9x
    Diagnostic Trouble Codes U1300, U1301 or
    “BUS Er”
    See Figure 5-22. The typical serial data voltage range is 0
    volts (inactive) to 7 volts (active). Due to the short pulse, volt-
    ages will be much lower on a DVOM. In analog mode, a
    DVOM reading serial data will show continuous voltage when
    active, typically 0.6-0.8 volts. The range for acceptable opera-
    tions is greater than 0 and less than 7.0 volts.
    NOTE
    Problems in the fuel system or idle air control system may
    also create this symptom.
    Table 5-11. Code Description
    Data Link
    Connector [91]
    DTC
    DESCRIPTION
    U1300
    Serial data low
    Figure 5-22. Electrical Bracket (Under Right Side Cover)
    U1301
    Serial data open/high
    DIAGNOSTICS
    Diagnostic Tips
    ● If serial data is shorted, these codes will automatically
    trip the check engine light.
    ● DTCs P1009 and P1010 may accompany DTCs U1300
    and U1301.
    Diagnostic Notes
    The reference numbers below correlate with the circled num-
    bers on the Test 5.12 flow charts.
    1. Check for trouble codes. See RETRIEVING DIAGNOS-
    TIC TROUBLE CODES under 5.4 CHECKING FOR
    DIAGNOSTIC TROUBLE CODES: EFI.
    2. Use HARNESS CONNECTOR TEST KIT (Part No. HD-
    41404), black socket probes and patch cord.
    2004 Touring: Engine Management (EFI)
    5-35
    HOME
    [156B] [156A]
    f2208u8x
    Main to Interconnect
    6
    6
    5
    5
    Harness
    4
    4
    BK
    3
    3
    GY
    2
    2
    BK
    LtGN/V
    1
    1
    LtGN/V
    O
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [30B]
    BN/GY
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [30A]
    BN/GY
    TSM/TSSM
    BK
    [39B]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    GY
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [39A]
    Speedometer
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [8B]
    EFI
    [108B]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [8A]
    Harness
    [108A]
    Tachometer
    [1B] [1A]
    15A
    1
    Accessory
    Fuse
    2
    Main to Interconnect
    3
    Harness
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    4
    [2B]
    Data Link
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    15A
    [2A]
    Ignition
    Main to Interconnect
    Fuse
    [91A]
    Harness
    [78B]
    15A
    1
    5
    ECM
    Battery
    [78A]
    Fuse
    Figure 5-23. Serial Data Circuit (FLTR, FLHT/C/U)
    Table 5-12. Wire Harness Connectors in Figure 5-23.
    NO.
    DESCRIPTION
    MODEL
    TYPE
    LOCATION
    Main to Interconnect
    FLHT/C
    12-Place Deutsch (Black)
    Inner Fairing - Right Radio Support Bracket
    [1]
    Harness
    FLTR
    12-Place Deutsch (Black)
    Inner Fairing - Below Radio (Left Side)
    Main to Interconnect
    FLHT/C
    12-Place Deutsch (Gray)
    Inner Fairing - Right Fairing Support Brace
    [2]
    Harness
    FLTR
    12-Place Deutsch (Gray)
    Inner Fairing - Below Radio (Left Side)
    [8]
    Main to EFI Harness
    All
    12-Place Deutsch
    Under Right Side Cover
    Turn Signal/Security
    Cavity in Crossmember at Rear of
    [30]
    All
    12-Place Deutsch
    Module
    Battery Box (Under Seat)
    FLHT/C
    12-Place Packard
    Inner Fairing (Back of Speedometer)
    [39]
    Speedometer
    FLTR
    12-Place Packard
    Under Bezel (Back of Speedometer)
    [78]
    Electronic Control Module
    All
    36-Place Packard
    Under Right Side Cover
    [91]
    Data Link
    All
    4-Place Deutsch
    Under Right Side Cover
    FLHT/C
    12-Place Packard
    Inner Fairing (Back of Tachometer)
    [108]
    Tachometer
    FLTR
    12-Place Packard
    Under Bezel (Back of Tachometer)
    Main to Interconnect
    FLHT/C
    6-Place Deutsch
    Inner Fairing - Right Fairing Support Brace
    [156]
    Harness
    FLTR
    6-Place Deutsch
    Inner Fairing - Front of Right Fairing Bracket
    5-36
    2004 Touring: Engine Management (EFI)
    HOME
    f2208t8x
    BK
    GY
    LtGN/V
    LtGN/V
    BK
    BN/GY
    O
    1
    2
    3
    4
    5 6 7 8 9 10 11 12
    [30B]
    1
    2
    3
    4
    5 6 7 8 9 10 11 12
    [30A]
    BN/GY
    TSM/TSSM
    BK
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [39B]
    1
    2
    3
    4 5 6 7 8 9 10 11 12
    [39A]
    GY
    Speedometer
    1
    2
    3
    4
    5
    6
    7
    8 9 10 11 12
    [8B]
    EFI
    1
    2
    3
    4
    5
    6
    7
    8 9 10 11 12
    [8A]
    Harness
    15A
    15A
    Accessory
    Battery
    Fuse
    Fuse
    1
    15A
    2
    Ignition
    3
    Fuse
    4
    Data Link
    [91A]
    [78B]
    1
    5
    ECM
    [78A]
    Figure 5-24. Serial Data Circuit (FLHR/C/S)
    Table 5-13. Wire Harness Connectors in Figure 5-24.
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [8]
    Main to EFI Harness
    12-Place Deutsch
    Under Right Side Cover
    Cavity in Crossmember at Rear of
    [30]
    Turn Signal/Security Module
    12-Place Deutsch
    Battery Box (Under Seat)
    [39]
    Speedometer
    12-Place Packard
    Under Console (Back of Speedometer)
    [78]
    Electronic Control Module
    36-Place Packard
    Under Right Side Cover
    [91]
    Data Link
    4-Place Deutsch
    Under Right Side Cover
    2004 Touring: Engine Management (EFI)
    5-37
    HOME
    Test 5.12 (Part 1 of 2)
    STARTS, THEN STALLS: DTC U1300, U1301 or
    “BUS Er”
    Fresh gasoline
    in tank?
    YES
    NO
    Check for trouble codes using.5.6
    Add gasoline.
    1
    SPEEDOMETER SELF DIAG-
    NOSTICS. Codes found?
    YES.
    YES.
    YES.
    NO.
    BUS Er present.
    DTC P1009,
    U1300 or U1301
    No codes
    speedometer will not
    P1010 found. See
    codes found.
    found.
    communicate with other
    5.28 DTC P1009,
    modules.
    P1010.
    Will engine start with throttle
    STOP
    opened partially and stall when
    STOP
    Go to Test 5.12
    throttle closed?
    (Part 2 of 2).
    Go to Test 5.12
    (Part 2 of 2).
    YES.
    NO.
    See 5.16 IDLE AIR
    Check fuel pressure while
    CONTROL.
    cranking engine. See 5.15
    FUEL PRESSURE TEST. Is
    fuel pressure OK?
    YES
    NO
    Tap lightly on fuel injectors.
    Fuel pressure problem. See
    Problem still exist?
    flow chart under 5.15 FUEL
    PRESSURE TEST.
    YES
    NO
    Replace fuel injectors.
    System
    Problem still exist?
    OK.
    YES
    NO
    Clear codes using speedometer self diagnostics.
    See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
    Replace ECM.
    System
    Confirm proper operation with no check engine
    Reprogram and learn
    OK.
    lamp.
    password.
    5-38
    2004 Touring: Engine Management (EFI)
    HOME
    Test 5.12 (Part 2 of 2)
    STARTS, THEN STALLS: DTC U1300, U1301 or
    “BUS Er”
    Continued from Test 5.12 (Part 1 of 2)
    Set run/stop switch to RUN. Turn ignition key ON.
    Is BUS Er present?
    YES
    NO
    Turn ignition key OFF.
    Turn ignition key OFF. While wiggling
    Disconnect ECM at connector
    2
    harness, check for continuity to ground at
    [78]. Turn ignition key ON.
    terminal 3 of connector [91A].
    Is BUS Er present?
    Is continuity to ground present at any time?
    YES
    NO
    YES
    NO
    Turn ignition key OFF.
    Replace ECM.
    Disconnect TSM/TSSM at connector
    Reprogram and perform
    Locate and repair
    Turn ignition switch ON.
    [30]. Turn ignition key ON.
    password learn.
    intermittent short
    While wiggling harness,
    Is BUS Er present?
    to ground.
    check for voltage at terminal
    3 of connector [91A].
    Is voltage present at
    any time?
    YES
    NO
    Is vehicle equipped
    Replace TSM/TSSM. Per-
    YES
    NO
    with a tachometer?
    form password learn.
    Locate and repair
    No problem
    intermittent short
    found.
    NO
    YES
    to voltage.
    Turn ignition key OFF. Disconnect tachometer
    at connector [108]. Turn ignition key ON.
    Is BUS Er present?
    YES
    NO
    T
    urn ignition key OFF. Disconnect
    Replace tachometer.
    speedometer at connector [39].
    Check for continuity to ground at
    2
    terminal 3 of connector [91A].
    Is continuity to ground present?
    YES
    NO
    Locate and repair short
    Turn ignition switch ON.
    to ground.
    Check for voltage at terminal
    3 of connector [91A].
    Is voltage present?
    YES
    NO
    Clear codes using speedometer self diagnostics.
    See 5.6 SPEEDOMETER SELF DIAGNOSTICS.
    Confirm proper operation with no check engine
    Locate and repair short
    Replace
    lamp.
    to voltage.
    speedometer.
    2004 Touring: Engine Management (EFI)
    5-39
    HOME
    FUEL SYSTEM ELECTRICAL TEST
    5.13
    GENERAL
    f1924x8x
    With ignition switch turned to IGNITION and the engine stop
    switch at RUN, the ECM will energize the system relay to
    complete the circuit to the in-tank fuel pump. It will remain on
    as long as the engine is cranking or running, and the ECM is
    receiving ignition reference pulses from the CKP. If there are
    no reference pulses, the ECM will de-energize the system
    relay within 2 seconds after ignition is ON or engine has
    stalled, or immediately after the ignition is shut OFF.
    Fuel Tank
    The fuel pump delivers fuel to the injectors. The pressure reg-
    ulator is where the system pressure is controlled. Excess fuel
    flow is bypassed into the fuel tank through the pressure regu-
    lator. When the engine is stopped, the pump can be turned on
    by applying battery voltage and ground to the fuel pump con-
    nector [141A]. The fuel pump connector is located on the can-
    opy at the top of the fuel tank. Improper fuel system pressure
    may contribute to one or all of the following symptoms.
    Fuel Tank Harness
    Connector [13]
    Not Present on FLHR/C/S
    ● Engine cranks, but won’t run.
    ● Engine cuts out (may feel like ignition problems).
    Figure 5-25. Fuel Pump/Fuel Level Sender Connector
    (FLTR, FLHT/C/U)
    ● Hesitation, loss of power and poor fuel economy.
    NOTE
    EFI System Relay
    After turning ignition OFF, you must wait 10 seconds before
    Spare
    turning the ignition back ON to get the fuel pump to reprime.
    This time out period is necessary for the ECM and IAC to
    reset.
    Fuel
    Pump
    DIAGNOSTICS
    f2223x9x
    Diagnostic Notes
    ECM Power
    The reference numbers below correlate with the circled num-
    bers on the Test 5.15 flow charts.
    Figure 5-26. EFI Fuse Block
    1.
    Turns on fuel pump if wiring is OK. If pump runs, problem
    is in basic fuel delivery.
    2.
    Use HARNESS CONNECTOR TEST KIT (Part No. HD-
    41404), brown pin probe and patch cord.
    3.
    Connect BREAKOUT BOX (Part No. HD-43876). See
    Section 5.7 BREAKOUT BOX: EFI.
    4.
    Use HARNESS CONNECTOR TEST KIT (Part No. HD-
    41404), purple pin probe and patch cord.
    5-40
    2004 Touring: Engine Management (EFI)
    HOME
    [62B]
    Y/GN
    [78]
    System
    relay
    BE/GY
    GN/O
    W/BK
    [13A] [13B]
    Fuel
    System relay
    4
    GN/O
    pump
    O/GY
    Y/GN
    15 Amp
    fuel pump
    Inj. F
    21
    W/Y
    fuse
    [141B] [141A]
    [84B]
    [84A]
    BK
    Y/GN
    All Except
    FLHR/C/S
    Inj. R
    19
    GN/GY
    [85B]
    [85A]
    Idle air
    control
    [87A] [87B]
    A
    A
    BE/GN
    35
    40 Amp
    B
    B
    BN/R
    36
    Maxi Fuse
    C
    C
    BK/PK
    18
    +
    -
    D
    D
    BK/O
    15 Amp
    17
    Battery
    ECM fuse
    R
    Constant power
    31
    BE/GY
    BK
    Engine
    stop
    15 Amp
    switch
    IGN fuse
    Switch power
    13
    W/BK
    GY
    R/BK
    Ignition switch
    MAIN FUSE BLOCK COVER
    10A
    15A
    P&A
    IGN
    RADIO PWR
    BRAKE
    15A
    RELAY
    BATTERY
    RADIO MEM
    SPARE FUSES
    P&A
    ACCESS.
    CRUISE/BRK
    HEADLAMPS IGN
    LIGHTS
    INSTRUMENTS
    10A
    BRAKE
    RELAY
    15A
    15A
    15A
    15A
    15A
    15A
    15A
    15A
    15A
    Power gnd.
    10
    BK
    Power gnd.
    28
    MAIN FUSE BLOCK
    BK
    f2208d8x
    Figure 5-27. Fuel Pump Circuit
    Table 5-14. Wire Harness Connectors in Figure 5-27.
    NO.
    DESCRIPTION
    TYPE
    LOCATION
    [13]
    Fuel Tank Harness
    3-Place Multilock
    Behind Fuel Tank (Under Seat)
    [78]
    ECM
    36-Place Packard
    Under Right Side Cover
    [141]
    Fuel Pump/Fuel Level Sender
    3-Place Mini-Deutsch
    Top of Canopy (Under Console)
    2004 Touring: Engine Management (EFI)
    5-41
    HOME
    Test 5.13 (Part 1 of 4)
    FUEL SYSTEM ELECTRICAL TEST
    Is ECM fuse OK?
    YES
    NO
    STOP
    Go to 5.11 NO
    Is fuel pump fuse OK?
    ECM POWER.
    NO
    YES
    Check for 12 volts at terminals 1 (+) and 3 (-) of fuel
    STOP
    1
    Go to Test 5.13
    pump connector [141B] during first 2-3 seconds
    (Part 4 of 4).
    after key ON.
    2
    Voltage present?
    YES
    NO
    Check for corroded
    Check for continuity to
    ground on [141B] terminal 3.
    connections or loose
    Continuity present?
    connectors between fuel pump
    and pump connector [141B].
    Poor connections?
    YES
    NO
    YES
    NO
    Locate and repair open on
    BK wire between [141B]
    STOP
    and ground.
    Repair as
    With key OFF, check for open
    necessary.
    pump circuit. Connect ohmmeter
    between connector Pin 1 of [141A] and
    Go to Test 5.13
    Pin 3 of connector [141A].
    (Part 2 of 4).
    Continuity present?
    YES
    NO
    Check pump
    Remove fuel pump.
    connections and repair
    Check for continuity
    as required. If good,
    across fuel pump
    replace fuel pump.
    terminals.
    Does meter read
    continuity?
    YES
    NO
    Check for opening
    Replace
    in wiring.
    fuel pump.
    5-42
    2004 Touring: Engine Management (EFI)
    HOME
    Test 5.13 (Part 2 of 4)
    FUEL SYSTEM ELECTRICAL TEST
    Continued from Test 5.13 (Part 1 of 4).
    Is 12 volts present at terminal 87 of system
    relay (with relay in place) during first two sec-
    onds after key on?
    YES
    NO
    Locate and repair open between
    Is 12 volts present at terminal
    terminal 1 of [141B] and terminal 87
    of system relay.
    30 of system relay?
    YES
    NO
    With ignition and Run/Stop
    Locate and repair open on BE/GY wire
    switch on, is 12 volts present at
    between ECM fuse and terminal 30 of
    terminal 86 of system relay.
    system relay.
    YES
    NO
    Locate and repair open on
    STOP
    W/BK wire to system relay.
    Go to Test 5.13
    (Part 3 of 4).
    2004 Touring: Engine Management (EFI)
    5-43

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    Матвей Александрович10.06.2024 15:59
    Политика конфиденциальности