_7A96 PENNTEX HIGH IDLER

Transcription

1 Idler Kit # PI-1029 Toat _7A96 PENNTEX HIGH IDLER wchevy 8.1L L18 G-CHASSIS with Automatic Transmission Installation and Testing Pg- IOZq.** READ THIS FIRST ***** l At this time GM does not include the PCM calibrations in the OEM programming that are required for the High ldle feature to function! Gurrently chassis must be programmed by a GM dealer according to the instructions in Upfitter Integration Bulletin # 46 Rev. 1 or higher. This bulletin is available and should be downloided from the Internet at The dealer is only required to reflash feprogramlfr-e PCM to load the newtalibraffi and change the fast idle engine speed parameters. There are 3 of these parameters that should be set to the customer's requirements for fast idle RPM: "PTO Max. Engine Speed', "PTO Standhy Speed' &"PTO Max. Engage Speed'. The recommended engine speed is 1200 RPM. This may be changed to meet the customer's needs. The dealer should NOT install any of the wiring, switches or relays shown in Ul Bulletin # 46 because these are used for manual only operation and are not required. The installation of the PennTex High ldler kit includes all of the wiring and hardware for automatic & manual High ldler operation. rt : s s INSTALLATION: NOTES: The air cleaner has air flow sensors mounted in it that feed information to the PCM. The engine will not run properly without the air cleaner and all air intake ducts connected to the throttle body! Chassis that are not yet equipped with brake lights will not high idle because the voltage on the brake circuit will rise to around 5 volts causing the PCM and High ldler to disengage. LED brake lights may also cause a similar problem if not properly designed. DTCs (Diagnostic Trouble Codes) set in the PCM may also prevent the PCM from going into High ldle mode. lf after High ldler installation the Yellow LED on the GM 8.1 L ldler Adapter P/N: Pl-0426 (module attached to the middle of the harness under the dash, not the black ldle Controller box mounted on the dash) stays illuminated constantly and the engine will not high idle, then the PCM may not have been programmed with the correct calibration. Modifications to chassis and idler may be necessary in some applications. "**** D/SCO N N ECT TH E G RO U N D CAB LE FROM ALL BATT ERI ES. ****** 1. Mounthe idle controller (inside the vehicle) in a location that is both easily accessible to driver and within wiring harnesses reach. 2. Connect the red wire from the idler to a source that provides +12 volts when the ignition switch is in the'run" position (ex. brown wire from fuse # 18 (circuit #441), also found at the "TCC/Brake Switch" cavity D). 3. Connect the green wire from the idler to a white wire (circuit # 17) from the "TCC/Brake Switch" cavity F. This wire should pullto +12 volts when the brake pedal is pressed. This wire is also available at positionumber E4 in the "Convenience Center" (GM terminology for connector C202). 4. Gonnect the yellow wire from the idler to a light green wire (circuit #275) from the "TCC/Brake Switch" cavity B. This wire should pull to +12 volts when the ignition switch is in the "RUN" position and the gear selector (automatic transmission) in the "PARK" position. 5. Connecthe black wire from idler to a known goodchassis ground. Do not just assume any screw in the dash is a good ground. PD-00182

2 Idler Kit #Pl Remove the air cleaner assembly (2 bolts 1Omm drive, 2 connectors, hose clamp 8mm). l Drill a 112 inch hole through the fire wall under the drive/s side of the dash for the harness to be routed to the PCM (Powertrain Control Module). Be careful not to drill through harnesses, hose etc Feed harness through to grommet. Be sure gronitnffseats properly in hole. Fasten and secure the Adapter module and any loose wires or harness away from sharp edges and moving parts that could cause damage. Route the idler harness over to the PCM. Secure the harness away from heat sources, sharp edges or moving parts. Install the purple wire and terminal into the upper PCM connector at J1-31: a. Remove the upper connector J1 from the PCM by unscrewing the center bolt (9/32' drive). The front (terminal side) of this connector has two blue terminal retainers or TPA (Terminal Position Assurance). b. The gray plastic wire cover has two pieces. Remove the side piece by sliding it off. To remove the main part of the cover you must cut the zip tie & carefully release 6 clips. Start at the opposite end from the harness. Squeeze the clip tabs toward each other and pull the cover away from the connector. While maintaining the pulling force release the 2 center clips using a small screw driver. Finally release the clips at the harness end and remove. c. Remove the blue TPA for cavity #31 by releasing the retaining tabs at either end. d. Carefully inserthe terminal on the purple wire into cavity'31" with enough force to break through the rubber terminal seal tower. The terminal should lock into place. To avoid PCM damage double check to insure that the purple wire is inserted into cavity "31" in connector J1 with the blue TPAs. e. Reassemble the connector and carefully reconnect it to the PCM. 12. lnstall the white wire and terminal into the lower PGM connector at J244. a. Remove the lower connector J2 from the PCM by unscrewing the center bolt (9/32' drive). The front (terminal side) of this connector has two red terminal retainers or TPA (Terminal Position Assurance). b. The gray plastic wire cover has two pieces. Remove the side piece by sliding it off. To remove the main part of the cover you must cut the zip tie & carefully release 6 clips. Start at the opposite end from the harness. Squeeze the clip tabs toward each other and pull the cover away from the connector. While maintaining the pulling force release the 2 center clips using a small screw driver. Finally release the clips at the harness end and remove, c. Remove the red TPA for cavity #44 by releasing the retaining tabs at either end. d. Carefully inserthe terminal on the white wire into cavity "44" with enough force to break through the rubber terminal seal tower. The terminal should lock into place. To avoid PCM damage double check to insure that the white wire is inserted into cavity "44' in connector J2 with the red TPAs. e. Reassemble the connector and carefully reconnect it to the PCM Secure ALL loose wires away from heat sources, sharp edges or moving parts. Reinstall the air cleaner assembly and reconnect all battery ground cables. TESTING AND ADJ U STMENT: 2. brake). Turn ignition switch to run position, but DO NOT START ENGINE. The "LO\N' battery indicator (red) should be lit. After 10 seconds the "HIGH IDLE' indicator (yellow) should light up. Press the brake pedal. The "HIGH IDLE" indicator (yellow) should turn off. Release the brake and it should come back on with no delay.! Press the brake pedal and move the gear shift to 'DRIVE.. Release the brake pedal. The "HIGH IDLE" indicator (yellow) should not be lit. Put the shifter in "PARK'. The "HIGH IDLE" indicator should light. 4. Starthe engine and press the "MANUAL ENGAGE'button. The "HIGH IDLE" indicator (yellow) should light up. fntl. 0 PD-00182

3 Idler Kit # PI-1029 l At the same time that the "HIGH IDLE" indicator lights up, the green LED on the Adapter should flash once. The Adapter is the module in the harness under the dash, not the ldle Controller black box. This green LED indicates that the Adapter is sending instructions to the PCM telling it to go into High ldle mode. Then the yellow LED on the Adapter should turn on. This indicates that the PCM received the message and switched into high idle mode. The engine should increase it's RPM to the level programmed by the dealerwith the Tech ll scan tool. The recommended RPM is Press the brake to insure idle speed returns to normal. 6. Installationcomplete. TROUBLESHOOTING: lf the engine fails to high idle and the status indicator (yellow) on the ADAPTER stays on continuously then the PCM may not have been reflashed with the correct calibration or the PCM may not have accepted the attempted reflash calibration. Several additional things can prevent the engine from going into high idle mode: a. Any DTCs that are set in the PCM for malfunctions of engine sensors. b. Incorrect wiring or PCM connector terminal installation. c. False PCM brake signal sense. The PCM senses the brake pedaldepression from the main lamp circuit #17 which goes to +12 volts when the pedal is pressed. lf no brake lamps are installed or LED brake lamps this circuit voltage will rise to approximately 5 volts and trick the PCM into thinking the brake is being pressed. d, The PCM also senses the brake through a redundant circuit # 420. This circuit uses a normally closed switch to send 12 volts to the PCM when the brake pedal is NOT pressed. This works opposite from circuit #17 listed above. e. The PCM monitors the DTR (DigitalTransmission Range) signal from the "ParUNeutral Position (PNP)" switch. A malfunction could cause the PCM to think the vehicle was in gear and prevent high idle. f. Future calibrations that get reflasheduring vehicle maintenance could remove the high idle function. Periodically calibrations are chariged and added to fix bugs and improve performance. In the past we have seen vehicles that suddenly stop high idling after the dealer serviced them. This happened when the PCM had been reflashed with newer software that for some reason disabled the fast idle function. Ir p,aoy,, PD-00182

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6 UI BULLETIN # 46 Rev. 1 SUBJECT: G Van High ldle MODELS AFFECTED: G Full'Bodied Vans and Cutaways w/ 8.1L Engine (RPO L18) MODEL YEAR(S): 2001 DATE: 3/16/2001 REVISION DATE: PAGE: 1 ot 12 ADVISORY This is a revision to Upfitrer Integration bulletin number 46, dated 3/16/01, to advise of a change to the wiring schematic of the high idle switch, the operation of the high idle ano tn" procedure to adjust rpm speed of the high idle' The purpose of this bulletin is to provide upfitters and Special Vehicle Manufacturers (svms) with information regarding high idle availability. This bulletin also provides installation instructions to interface with the new high idle calibrations now available. Upfitter Integration suggests the following procedures followed carefully if your applica-!e - tion requires a high idte feature for any ZOCif C Van or Cutaway equipped with the 8.1L (RPO 118) engine. Condition Some Upfitters and SVMs are requesting high idle capabilities for 2001 G vans or Cutaways equipped with the 8.1L engine, High idle refers to the increase in engine rpm to values higher than normal base idle speed, High idle historically has been provided through additional mechanical hardware to regulate an increased engine rpm speed. Cause The high idle calibrations were not included in the original production PCM calibrations for The 2001 model Year G Vans equipped with the 8,1L engine differ from their predecesincluding idle speed, are now controlled through electronic sors. Various engine functions, means due to the incorporationof an electronically controlled throttle versus a mechanically controlled throttle. Correction The new calibration, which includes the high idle feature, can be programmed into the PCM with a GM Tech 2 scan tool. The GM Tech 2 scan tool connects to the data link connector under the dash above the driver's foot well area' The Tech 2 scan tool MUST be used to enable the high idte option and adjust the factory default settings to the desired high idle rpm.

7 Ul BULLETIN # 46 Rev. (Gont'd) Correction (cont.) A GM dealer will be able to perform the reprogramming of the PCM. A Vehicle ldentification Number (VlN) will be required by the dealer to change the calibration. The dealer must call GM Techline Customer Assistance at for a VCI authorizatio number to access and obtain the calibration. Once the dealer performs the reflash of the PCM, the GM vehicle build record will be updated to reflect the new calibration in the vehicle. Calibration Part Numbers The new calibration part numbers, which include the high idle feature, are as follows: All Federal Emission Applications, Models 05/06/03/32 and California Emission Applications, Models 03/32 Galifornia Emission Applications, Models 05/06 Parts List Upfitters or SVMs requiring the high idle feature will need to install the following additional parts to allow the end user to activate the high idle feature:. Momentary switch, either push button or lever type. Quantity of 1 required.. Relay, GM part number or equivalent*. GM relay is available through service parts from a GM dealer. Quantity of 1 required.. Relay connector (Delphi Packard) part number Quantity of 1 required. (recommended if relay is to be mounted under dash). Refer to Delphi Packard Handbook for appropriate mating terminal ends and secondary locks.. Suitable electrical wire. Length and quantity dependent on switch and relay location. *Equivalent Relay Specifications: Relay Type: Normally Open Voltage: 10 to 16 Votts DC Contact Current Rating : 20 Amps Maximum Optional parts if relay is to be installed in the underhood bussed electrical center (BEC):. Terminal end, part number for cavities 87 and A9. Quantity of 2 required.. Terminal end, part number for cavities 89 and A7. Quantity of 2 required. Note: lf the relay is installed in the underhood BEC, it is recommended that the location of the high idle relay be noted on the BEC label. BULLZYS46/Rev.1 2ot / Rev. 1: 612O12001

8 UI BULLETIN# 46 Rev. 1 (Cont'd) ATTACHMENT 1 PAGE G Van High ldle Adjustment Procedure Tech 2 Menu Screens 6ot / Rev. 1:

9 Ul BULLETIN # 46 Rev. 1 (Cont'd) ATTACHMENT 1 PAGE 2 Tech 2 Main Menu Screen Main Menu F0: Diagnostics * F1: Service Programming SYstem F2: View Captured Data F3:... F4:... Tech 2 Vehicle ld Screen Vehicle ld (Model Years) (3) 2oo3 (2) 2002 (1) (Y) ot / Rev. 1: O1

10 UI BULLETIN # 46 (Cont'd) Rev. 1 ATTACHMENT 1 PAGE 3 Tech 2Vehicle ld Screen Vehicle ldentification Passenger Car LD Truck, MPV, Incomplete * Medium Duty Truck Saturn Tech 2 System Selection Screen System Selection Menu (1) 2001 LD Truck F0: Powertrain * F1: Body F2: Chassis F3: Diagnostic Circuit Check 8ot / Rev, 1:

11 UI BULLETIN# 46 Rev. 1 (Cont'd) ATTACHMENT 1 PAGE 4 Tech 2 Vehicle ld Screen Vehicle ld Select one of the following LD Truck Engine types (1) V8 LB7 Diesel (G)V81188.',1 L. (G)V HD Tech 2 Vehicle ld Screen Vehicle ldentification Select one of the following Transmissions 5 Speed Automatic Trans (M74) 4 Speed Automatic Trans (MT1). ManualTrans (MLO) Other 9of / Rev. 1: 612O120O1

12 UI BULLETIN# 46 Rev. 1 (Cont'd) ATTACHMENT 1 PAGE 5 Tech 2 Powertrain Screen Powertrain F0:... F1: Data Display F2: Special Funclions * F3: Snapshot F4:... F5:... Tech 2 Special Functions Screen Special Functions F1:... F2:... F3:... F4'.... F5:... F6: Service Bay Test F7: PTO Options * F8: Engine Shutdown F9: of / Rev. 1:

13 UI BULLETIN # 46 (Gont'd) Rev. 1 ATTACHMENT 1 PAGE 6 Fast ldle Mode Settings DisPlaY PTO Option PTO Fast ldle Option PTO Max. Engine SPeed PTO Standby Speed* PTO Max. Engage SPeed PTO Engine Shutdown PTO Engage Relay PTO Feedbacr Fast ldle XXXX RPM XXXX RPM XXXXRPM (No) (No) (No) Nl]te: No changes can be made to this screen' Press change options to get to the next menu PTO Operating Modes Screen F0; Fast ldle. PTO Option F1: Preset PTO SPeed Control F2: Variable PTO SPeed Control BULLZYS46/Rev.1 11 of / Rev. 1: 612O120O1

14 UI BULLETIN # 46 (Cont'd) Rev. 1 ATTACHMENT 1 PAGE 7 Fast ldle Mode Settings Update Screen PTO OPtions PTO Fast ldle Option PTO Max. Engine Speed PTO Standby Speed* PTO Max. Engage Speed PTO Engine Shutdown PTO Engage Relay PTO Feedback Fast ldle XXXX RPM XXXX RPM XXXX RPM (No) (No) (No) Press [Reprogram Options] when done Then scroll Decrease/l ncrease to change high idle rpm 12ot / Rev. 1: OO1