Operation CHARM: Car repair manuals for everyone.

Part 1 of 2

AUTOMATIC SHUTDOWN (ASD) RELAY SENSE - PCM INPUT
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location.

A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply.

This input is used only to sense that the ASD relay is energized. If the powertrain control module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC).

BATTERY VOLTAGE - PCM INPUT
The battery voltage input provides power to the Powertrain Control Module (PCM). It also informs the PCM what voltage level is supplied to the ignition coil and fuel injectors.

If battery voltage is low, the PCM will increase injector pulse width (period of time that the injector is energized). This is done to compensate for the reduced flow through injector caused by the lowered voltage.

BRAKE SWITCH - PCM INPUT
When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo.

ENGINE COOLANT TEMPERATURE SENSOR - PCM INPUT
The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket.

The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases.

At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return).

When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air- fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached.

The PCM uses inputs from the ECT sensor for the following calculations:
- for engine coolant temperature gauge operation through CCD or PCI (J1850) communications
- Injector pulse-width
- Spark-advance curves
- ASD relay shut-down times
- Idle Air Control (IAC) motor key-on steps
- Pulse-width prime-shot during cranking
- O2 sensor closed loop times
- Purge solenoid ON/OFF times
- EGR solenoid on/off times (if equipped)
- Leak Detection Pump operation (if equipped)
- Radiator fan relay ON/OFF times (if equipped)
- Target idle speed

FIVE VOLT SENSOR SUPPLIES - PRIMARY AND SECONDARY
Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary.

These 2 circuits will:
- supply the required 5 volt power source to the Crankshaft Position (CKP) sensor.
- supply the required 5 volt power source to the Camshaft Position (CMP) sensor.
- supply a reference voltage for the Manifold Absolute Pressure (MAP) sensor.
- supply a reference voltage for the Throttle Position Sensor (TPS) sensor.
- supply the required 5 volt power source to the oil pressure sensor.
- supply the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped).
- supply the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission).

FUEL LEVEL SENSOR - PCM INPUT
The fuel level sensor (fuel gauge sending unit) is located on the fuel pump module.

Refer to Fuel Gauge Sending Unit in the Fuel Delivery for information.

IGNITION CIRCUIT SENSE - PCM INPUT
This circuit ties the ignition switch to the Powertrain Control Module (PCM).

The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit.

Battery voltage is supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 5 volt primary and 5 volt secondary circuits. This allows the PCM to perform fuel, ignition and emissions control functions.

INTAKE MANIFOLD AIR TEMPERATURE SENSOR - PCM INPUT
The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream.

The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases.

The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit.

The PCM uses this input to calculate the following:
- Injector pulse-width
- Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures)

The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR - PCM INPUT
The Manifold Absolute Pressure (MAP) sensor is attached to the side of the engine throttle body with 2 screws. The sensor is connected to the throttle body with a rubber L-shaped fitting.

The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum.

A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 V and full scale is 4.5 V For a pressure swing of 0 - 15 psi, the voltage changes 4.0 V To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM.

The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-ON. The difference between current voltage and what it was at key-ON, is manifold vacuum.

During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor.

As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-ON, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively.

The PCM uses the MAP sensor input to aid in calculating the following:
- Manifold pressure
- Barometric pressure
- Engine load
- Injector pulse-width
- Spark-advance programs
- Shift-point strategies (certain automatic transmissions only)
- Idle speed
- Decel fuel shutoff

The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally The sensor also contains electronics that condition the signal and provide temperature compensation.

The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in.Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in.Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in.Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area.

OIL PRESSURE SENSOR - PCM INPUT
The 2-wire, electrical/mechanical engine oil pressure sensor (sending unit) is located in an engine oil pressure gallery.

The oil pressure sensor uses two circuits. They are:
- A signal to the PCM relating to engine oil pressure
- A sensor ground through the PCM's sensor return

The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure. This signal is then transferred (bussed) to the instrument panel on a CCD bus circuit to operate the oil pressure gauge and the check gauges lamp. Ground for the sensor is provided by the PCM through a low-noise sensor return.

OXYGEN SENSOR (O2S) - PCM INPUT
The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors.

Non-California Engines: On certain non-California (Federal) emissions packages, 2 sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor.

California Engines: On certain California emissions packages, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor.

An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0 - 1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7-to-1 air/fuel ratio necessary for proper engine operation and to control emissions.

The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the wire harness. This is why it is important to never solder an O2 sensor connector, or pack the connector with grease.

Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation.

Oxygen Sensor Heaters/Heater Relays
Depending on the emissions package, the heating elements within the sensors will be supplied voltage from either the ASD relay, or 2 separate oxygen sensor relays. Refer to Wiring Diagrams to determine which relays are used.

The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 4.5 ohms on 5.2 and 5.9L engines, and approximately 13.5 ohms on the 4.7L engine. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930 °F - 1100 °F (500 °C - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable.

Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle.

In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors.

Upstream Sensor (Certain Non-California Emissions)
The upstream sensor (1/1) provides an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensor. The PCM will change the air/fuel ratio until the upstream sensor inputs a voltage that the PCM has determined Will make the downstream sensor output (oxygen content) correct.

The upstream oxygen sensor also provides an input to determine catalytic convertor efficiency.

Downstream Sensor (Certain Non-California Emissions)
The downstream oxygen sensor (1/2) is also used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content).

The downstream oxygen sensor also provides an input to determine catalytic convertor efficiency.

The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package.

Downstream Sensors (Certain California Emissions)
Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content).

The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package.

Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information.