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Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Electrical Diagnostics - page 14

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2. Is resistance less than 0.5 Ohm?

5. Output Test

a. Yes. Go to Test 4.

1. Connect CKP sensor [79].

b. No. Repair open on (BK) wire.

2. Test AC voltage between BOB [78-1] terminals 16 and

18.

4. Signal Wire Shorted to CKP Ground Wire

3. Crank engine for 5 seconds while observing multimeter.

Test

4. Is AC voltage greater than 2V?

1. Test continuity between BOB [78-1] terminals 16 and 18.

a. Yes. See diagnostic tips. If MAP and IAT sensors are

2. Is continuity present?

good, replace the ECM.

a. Yes. Repair short between [79B] terminals 1 (R) and

b. No. Replace CKP sensor.

2 (BK).

b. No. Go to Test 5.

6-48 2013 Softail Diagnostics: Engine Management

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DTC P0444,

P0445

6.13

DESCRIPTION AND OPERATION

ed03462

Purge Solenoid (CA and Select Foreign

Market Models Only)

See Figure 6-24 and Figure 6-25. The purge solenoid is

mounted in front of the rear tire above the BCM. The solenoid

connects to a fuel tank vent line and a vent canister.

A return line from the canister reconnects to the air intake

manifold allowing vented fumes to be recirculated, for emission

efficiency. The purge solenoid is timed to the throttle position

and is disabled during startup, low engine temperature, low

engine speed or low vehicle speed.

Power for the purge solenoid is supplied by the BCM. The BCM

also provides power for the VSS, fuel injectors, active exhaust,

active intake, ECM and the ignition coil.

The ECM provides a path to ground to trigger the purge

solenoid.

NOTES

•

BCM or wiring harness problems will cause 12V power to

be lost to the VSS, fuel injectors, active exhaust, active

intake, ECM, ignition coil and purge solenoid.

ECM

•

Purge solenoid is not installed on non-emission vehicles

ECM [78-2]

and DTCs P0444 and P0445 are not available. If these

ECM [78-1]

DTCs appear, the ECM should be reprogrammed.

Purge solenoid [95] (back side of purge

solenoid)

ed03308

Security siren

BCM

BCM [242] (back side of BCM)

Security siren [142]

Rear WSS [168]

10. ABS [166]

11. ABS ECU

Figure 6-25. Electrical Panel: FXSB

Table 6-41. Code Description

DTC

DESCRIPTION

P0444

Purge solenoid low/open

P0445

Purge solenoid shorted high

1. Purge valve [95]

2. BCM

Diagnostic Tips

3. Rear tire

When disconnecting any connectors always inspect connector

Figure 6-24. Purge Valve [95]: Except FXSB

for corrosion or backed out terminals and repair as required.

Connector Information

For additional information about the connectors in the following

diagram(s) and diagnostic procedure(s), including the color of

the harness test kit terminal probes, see B.1 CONNECTORS.

2013 Softail Diagnostics: Engine Management 6-49

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em00997

[242A] [242B]

BCM

System Power

R/GN

Purge

System Power

R/GN

Solenoid

Purge Solenoid

LGN/BK

[95A] [95B]

System Power

R/GN

Active

Ground

Exhaust

Exhaust Actuator

LGN/O

Exhaust Feedback

LGN/BE

[78B-2] [78A-2]

ECM

[179A] [179B]

GY/BN

Rear HO2 Sensor

Active

Active Intake

LGN/V

R/GN

System Power

Intake

LGN/BE

Exhaust Feedback

System Power

R/GN

BK/GN

Ground

BK/W

5V Sensor Ground

[178A] [178B]

LGN/BK

Purge Solenoid

LGN/R

ACR Enable

System Power

R/GN

LGN/O

Exhaust Actuator

Rear HO2

Rear O2 Heater Ground

BK/PK

LGN/V

Active Intake

Sensor

Rear O2 Sensor

GY/BN

5V Sensor Ground

BK/W

LGN/BN

Front HO2 Sensor

[138B] [138A]

BK/PK

Rear HO2 Heater Sensor

BK/GN

Ground

LGN/BN

ION Sense

System Power

R/GN

GY/Y

Rear Fuel Injector

Front HO2

Front O2 Heater Ground

BK/O

GN/Y

Front Fuel Injector

Sensor

Front O2 Sensor

GN/BN

BK/O

Front HO2 Heater Ground

5V Sensor Ground

BK/W

GN/BE

Front Ignition Coil

GY/BE

Rear Ignition Coil

[138B] [138A]

[78B-1] [78A-1]

A B C D

[83B]

[84B]

A B

[203FB]

A B

[203RB]

A B

[85B]

A B

A B C D

[83A]

[84A]

A B

[203FA]

A B

[203RA]

A B

[85A]

A B

GND 2

GND 1

Front Fuel

Front ACR

Rear ACR

Rear Fuel

Injector

Ignition Coil

Figure 6-26. System Power Circuit

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2. Verify ECM OVERLAY (Part No. HD-50390-4-P) is in

DTC P0444

position on BOB.

PART NUMBER

TOOL NAME

3. Test continuity between [95B] terminal B (LGN/BK) wire

and BOB [78-2] terminal 5.

HD-41404

HARNESS CONNECTOR TEST KIT

HD-50390-1

BREAKOUT BOX

4. Is continuity present?

a. Yes. Replace ECM.

HD-50390-2-P

BCM OVERLAY

HD-50390-4

ECM CABLE

b. No. Repair open in (LGN/BK) wire.

HD-50390-4-P

ECM OVERLAY

5. Power Wire Open Test

1. Connect BREAKOUT BOX (Part No. HD-50390-1) and

Table 6-42. DTC P0444 Diagnostic Faults

ECM CABLE (Part No. HD-50390-4) to wiring harness

[78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2]

POSSIBLE CAUSES

disconnected. See 1.2 DIAGNOSTIC TOOLS.

Purge solenoid malfunction

2. Verify BCM OVERLAY (Part No. HD-50390-2-P) is in

Short to ground in signal circuit

position on breakout box.

1. Purge Solenoid Test

3. Test continuity between [95B] terminal A (R/GN) wire and

BOB terminal 16.

1. Turn IGN OFF.

4. Is continuity present?

2. Disconnect purge solenoid [95].

a. Yes. Replace ECM.

3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

b. No. Repair open in (R/GN) wire.

41404), test resistance between [95A] terminals A (R/GN)

wire and B (LGN/BK) wire.

DTC P0445

4. Is resistance between 4-21 Ohms?

a. Yes. Go to Test 2.

PART NUMBER

TOOL NAME

b. No. Replace purge solenoid.

HD-41404

HARNESS CONNECTOR TEST KIT

2. Purge Solenoid Voltage Test

Table 6-43. DTC P0445 Diagnostic Faults

1. Test voltage between [95B] terminal A (R/GN) wire and

ground.

POSSIBLE CAUSES

2. Turn IGN ON.

Purge solenoid malfunction

Short to voltage in signal circuit

3. Is battery voltage present?

a. Yes. Go to Test 3.

1. Purge Solenoid Test

b. No. Go to Test 5.

1. Turn IGN OFF.

3. Control Wire Shorted to Ground Test

2. Disconnect purge solenoid [95].

1. Turn IGN OFF.

3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), test resistance between [95A] terminals A (R/GN)

2. Disconnect ECM [78-1] and [78-2].

wire and B (LGN/BK) wire.

3. Test continuity between [95B] terminal B (LGN/BK) wire

4. Is resistance between 4-21 Ohms?

and ground.

a. Yes. Go to Test 2.

4. Is continuity present?

b. No. Replace purge solenoid.

a. Yes. Repair short to ground on (LGN/BK) wire.

b. No. Go to Test 4.

2. Purge Solenoid Short to Voltage Test

1. Turn IGN ON.

4. Control Wire Open Test

2. Test voltage between [95B] terminal B (LGN/BK) wire and

1. Connect BREAKOUT BOX (Part No. HD-50390-1) and

ground.

ECM CABLE (Part No. HD-50390-4) to wiring harness

[78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2]

3. Is voltage greater than 5.0V?

disconnected. See 1.2 DIAGNOSTIC TOOLS.

a. Yes. Repair short to voltage on (LGN/BK) wire.

b. No. Replace ECM.

2013 Softail Diagnostics: Engine Management 6-51

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DTC P0502,

P0503

6.14

DESCRIPTION AND OPERATION

ed03304

See Figure 6-27. The VSS is powered and monitored by the

ECM. The ECM processes the vehicle speed signal and

transmits this signal to the BCM and the speedometer through

the CAN bus circuit.

NOTES

•

The ECM uses VSS input to calculate idle air control

position. Therefore problems with the vehicle speed signal

can lead to improper operation of the idle air control.

•

The MAP, JSS, TPS and VSS sensors are connected to

the same reference line (+5V REF). If the reference line

goes to ground or open, multiple codes will be set (DTC

P0107, P0108, P0122, P0123, P0502, P0503, P1501,

P1502). Start with the trouble code having the lowest

ranking value.

1. VSS

2. Oil tank

•

A faulty sensor can negatively affect the signal voltage of

3. Starter

the other sensors sharing the same 5V reference. If the

wiring passes the following tests, disconnect one sensor

Figure 6-27. VSS

at a time on the 5V reference and verify the DTC is still

present. Additional DTCs will be set as each sensor is

disconnected, clear DTCs after this test. Be sure to per-

Diagnostic Tips

form this test before replacing a component.

When disconnecting any connectors always inspect connector

for corrosion or backed out terminals and repair as required.

Table 6-44. Code Description

Connector Information

DTC

DESCRIPTION

For additional information about the connectors in the following

P0502

VSS failed low

diagram(s) and diagnostic procedure(s), including the color of

the harness test kit terminal probes, see B.1 CONNECTORS.

P0503

VSS failed high

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em00996

5V Sensor Power

R/W

VSS

VSS Input

LGN/Y

Ground

BK/GN

[65A] [65B]

5V Sensor Ground

BK/W

MAP

MAP Input

Sensor

5V Sensor Power

R/W

To BCM

[80A] [80B]

5V Sensor Power

R/W

TPS

5V Sensor Ground

BK/W

TPS

GN/V

[88A] [88B]

System Power

R/GN

Rear HO2

Rear O2 Heater Ground

BK/PK

Sensor

Rear O2 Sensor

GY/BN

5V Sensor Ground

BK/W

[138B] [138A]

5V Sensor Ground

R/W

JSS

JSS Signal

LGN/GY

(HDI)

Sensor Ground

BK/GN

[133A] [133B]

System Power

R/GN

Front HO2

Front O2 Heater Ground

BK/O

Sensor

Front O2 Sensor

GN/BN

5V Sensor Ground

BK/W

[138B] [138A]

IAT

GN/GY

IAT

Sensor

5V Sensor Ground

BK/W

[89A] [89B]

ET Sensor

Sensor

5V Sensor Ground

BK/W

[90A] [90B]

GND 1

[78B-1]

[78B-2]

[78A-1]

[78A-2]

ECM

Figure 6-28. Sensor Circuit

2013 Softail Diagnostics: Engine Management 6-53

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3. Is debris present?

DTC P0502

a. Yes. Clean debris from VSS and install.

PART NUMBER

TOOL NAME

b. No. Replace VSS.

HD-41404

HARNESS CONNECTOR TEST KIT

DTC P0503

HD-50390-1

BREAKOUT BOX

HD-50390-4

ECM CABLE

PART NUMBER

TOOL NAME

HD-50390-4-P

ECM OVERLAY

HD-41404

HARNESS CONNECTOR TEST KIT

HD-50390-1

BREAKOUT BOX

Table 6-45. DTC P0502 Diagnostic Faults

HD-50390-4

ECM CABLE

POSSIBLE CAUSES

HD-50390-4-P

ECM OVERLAY

VSS malfunction

Open or short to ground in signal circuit

Table 6-46. DTC P0503 Diagnostic Faults

Open or short to ground in 5V reference circuit

POSSIBLE CAUSES

1. VSS Connections Test

VSS malfunction

1. Turn IGN OFF.

Short to voltage in signal circuit

Open ground

2. Disconnect VSS [65].

5V reference shorted to battery voltage

3. Turn IGN ON.

4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

1. VSS Sensor Power Shorted to Voltage

41404), test voltage between [65B] terminal A (R/W) wire

Test

and ground.

1. Turn IGN OFF.

5. Is voltage approximately 5.0V?

2. Disconnect VSS [65].

a. Yes. Go to Test 2.

3. Turn IGN ON.

b. No. Repair open on (R/W) wire.

4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

2. Signal Wire Short to Ground Test

41404), test voltage between [65B] terminals A (R/W) wire

and C (BK/GN) wire.

1. Turn IGN OFF.

5. Is voltage greater than 6.0V?

2. Connect BREAKOUT BOX (Part No. HD-50390-1) and

a. Yes. Repair short to voltage on (R/W) wire.

ECM CABLE (Part No. HD-50390-4) to wiring harness

[78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2]

b. No. Go to Test 2.

disconnected. See 1.2 DIAGNOSTIC TOOLS.

2. Signal Wire Short to Voltage Test

3. Verify ECM OVERLAY (Part No. HD-50390-4-P) is in

position on BOB.

1. Test voltage between [65B] terminal B (LGN/Y) wire and

ground.

4. Test continuity between BOB [78-1] terminals 4 and 10.

2. Is voltage above 6.0V?

5. Is continuity present?

a. Yes. Repair short to voltage on (LGN/Y) wire.

a. Yes. Repair short to ground on (LGN/Y) wire.

b. No. Go to Test 3.

3. VSS Ground Wire Open Test

3. Signal Wire Open Test

1. Connect BREAKOUT BOX (Part No. HD-50390-1) and

1. Test continuity between BOB [78-1] terminal 4 and [65B]

ECM CABLE (Part No. HD-50390-4) to wiring harness

terminal B (LGN/Y) wire.

[78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2]

2. Is continuity present?

disconnected. See 1.2 DIAGNOSTIC TOOLS.

a. Yes. Go to Test 4.

2. Verify ECM OVERLAY (Part No. HD-50390-4-P) is in

b. No. Repair open on (LGN/Y) wire.

position on BOB.

3. Test continuity between BOB [78-1] terminal 10 and [65B]

4. Dirty or Damaged Test

terminal C (BK/GN) wire.

1. Remove VSS.

4. Is continuity present?

2. Check for debris on sensor tip.

a. Yes. Go to Test 4.

b. No. Repair open on (BK/GN) wire.

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4. Signal Wire Shorted to Sensor Power Test

5. VSS Test

1. Test continuity between BOB [78-1] terminal 4 and [78-2]

1. Connect [78A-1] and [78A-2] to breakout box.

terminal 9.

2. Clear DTC.

2. Is continuity present?

3. Did DTC reset?

a. Yes. Repair short between (LGN/Y) and (R/W) wires.

a. Yes. Replace ECM.

b. No. Go to Test 5.

b. No. Replace VSS.

2013 Softail Diagnostics: Engine Management 6-55

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DTC P0506,

P0507

6.15

number of conditions such as an intake air leak, improperly

DESCRIPTION AND OPERATION

adjusted throttle stop or a misfiring cylinder.

PART NUMBER

TOOL NAME

•

A non-OE engine configuration can lead to idle instability

and could generate a DTC.

HD-48650

DIGITAL TECHNICIAN II

•

Leaking injectors will cause fuel imbalance and poor idle

The ECM controls engine idle speed by moving the IAC to

quality due to different air/fuel ratios in each cylinder. To

open or close a passage around the throttle plates. It does this

check for leaky injectors, first remove the air box and air

by sending voltage pulses to the proper motor winding of the

filter. Then, with the throttle wide open, turn IGN ON for 2

IAC. This causes the pintle to move in or out of the IAC a given

seconds and then OFF for 2 seconds five consecutive

distance for each pulse received.

times. Replace the fuel injector if there is any evidence of

raw fuel in the bores.

•

To increase idle speed, the ECM retracts the pintle,

allowing more air to flow through the throttle body.

•

Intake leaks.

•

To decrease idle speed, the ECM extends the pintle,

•

Contaminated fuel.

allowing less air to flow through the throttle body. The IAC

•

TPS reading of greater than 1% (possible throttle cable

position can be measured in steps. This can only be done

misadjustment) or battery voltage reading of less than 9V

with DIGITAL TECHNICIAN II (Part No. HD-48650).

or a VSS greater than 0 will disable idle speed control.

•

A high number of steps represents a fully retracted pintle

When disconnecting any connectors always inspect connector

and open passage around throttle plate. This correlates

for corrosion or backed out terminals and repair as required.

with an increase in the amount of air flowing through the

throttle body.

ed03346

•

Zero steps represents a fully extended pintle. A zero

reading indicates an abnormal condition in which the pintle

has been fully extended and has consequently closed the

passage around throttle plate. Each time the ignition is

turned OFF, the ECM resets the IAC by sending enough

pulses to extend the pintle and effectively close the throttle

body. The fully extended value is the ECM reference point.

A given number of steps are then calculated by the ECM

for use in setting the proper idle speed and IAC position

for the next start event.

NOTE

Idle speed is controlled by the ECM and cannot be adjusted.

Loss of idle speed control will result if the idle rpm is ±200 from

IAC test light

preset idle speed and IAC motor is at zero or maximum for

IAC [87]

greater than 5 seconds. These DTCs may occur with others

for a multiple code situation. Resolve the other codes first to

Figure 6-29. IAC Test Light

correct. A misfire condition or similar symptom affecting idle

can cause P0506 to set. Inspect for these conditions before

diagnosing DTCs.

Table 6-47. Code Description

DTC

DESCRIPTION

P0506

Idle speed control - rpm too low

P0507

Idle speed control - rpm too high

Diagnostic Tips

The following items may impact engine idle speed:

•

A loss of idle speed control does not necessarily imply the

IAC actuator or wiring has failed. It can be caused by a

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Connector Information

ed03338

For additional information about the connectors in the following

diagram(s) and diagnostic procedure(s), including the color of

the harness test kit terminal probes, see B.1 CONNECTORS.

1. Rear fuel injector [85]

2. IAC [87]

3. Front fuel injector [84]

4. Active intake solenoid [178]

5. TPS [88]

6. IAT sensor [89]

7. MAP sensor [80]

Figure 6-30. Between Cylinders Right Side

2013 Softail Diagnostics: Engine Management 6-57

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em00995

[78A-1] [78B-1]

ECM

CKP Sensor Low

Sensor Low

CKP

CKP Sensor High

Sensor High

Ground

BK/GN

[79B] [79A]

Main

R/GN

System Power

BCM

Harness

[242B] [242A]

[179B] [179A]

System Power

R/GN

CKP Sensor Low

LGN/BE

Feedback

CKP Sensor High

GY/W

LGN/O

Actuator

Exhaust

Actuator

IAC A High

GN/W

Ground

(HDI)

IAC B Low

GY/O

R/GN

System Power

IAC A Low

BK/GN

GND 2

IAC B High

LGN/O

Ground

LGN/V

Active Intake

AIS

(HDI)

Ground

GN/O

R/GN

System Power

[178B] [178A]

[78A-2] [78B-2]

GY/W

B Low

GN/W

B High

IAC

GND 1

GY/O

A Low

GN/O

A High

[87B] [87A]

Figure 6-31. Active Exhaust Actuator and AIS Circuit

DTC P0506, P0507

1. IAC Operational Test

1. While watching the IAC pintle for movement turn IGN OFF,

PART NUMBER

TOOL NAME

ON, then OFF.

HD-41199-3

IAC TEST LIGHT

2. Did pintle move?

HD-41404

HARNESS CONNECTOR TEST KIT

a. Yes. IAC system operating properly. Check for

HD-50390-1

BREAKOUT BOX

improperly adjusted throttle stop, vacuum leaks, cyl-

inder misfire, contaminated fuel, leaking injectors and

HD-50390-4

ECM CABLE

engine mechanical failure.

HD-50390-4-P

ECM OVERLAY

b. No. Go to Test 2.

Table 6-48. DTC P0506, P0507 Diagnostic Faults

2. Connector Test

1. Disconnect IAC [87].

POSSIBLE CAUSES

2. Connect IAC TEST LIGHT (Part No. HD-41199-3) to [87B].

IAC malfunction

Short to voltage in circuits

3. Turn IGN ON.

Short to ground in circuits

4. While observing test light, turn IGN OFF.

Open in system power circuit

5. Did both IAC test lights flash alternately?

Short between IAC circuits

a. Yes. Replace IAC.

Open circuits

b. No. Go to Test 3.

Vacuum/air leaks

Fuel system problems

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4. Circuits Shorted to Ground Test

Table 6-49. IAC, Wire Color, ECM

1. Test continuity on each IAC wire between BOB and

IAC [87B]

WIRE COLOR

ECM [78-2]

ground. Refer to Table 6-49.

GY/W

2. Is continuity present on any circuits?

GN/W

a. Yes. Repair short to ground on appropriate circuit.

GY/O

b. No. Go to Test 5.

GN/O

5. Circuits Short to Voltage Test

3. Circuits Open Test

1. Turn IGN ON.

1. Turn IGN OFF.

2. Test voltage between BOB and ground on each IAC wire.

2. Remove test light.

Refer to Table 6-49.

3. Connect BREAKOUT BOX (Part No. HD-50390-1) and

3. Is voltage present on any circuit?

ECM CABLE (Part No. HD-50390-4) to wiring harness

a. Yes. Repair short to voltage in appropriate circuit.

[78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2]

disconnected. See 1.2 DIAGNOSTIC TOOLS.

b. No. Go to Test 6.

4. Verify ECM OVERLAY (Part No. HD-50390-4-P) is in

6. Short Between Circuits Test

position on BOB.

1. Turn IGN OFF.

5. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), test continuity on each IAC wire between BOB

2. Test continuity between each IAC circuit and the other

and [87B]. Refer to Table 6-49.

IAC circuits.

6. Is continuity present on all circuits?

3. Is continuity present between any two IAC circuits?

a. Yes. Go to Test 4.

a. Yes. Repair short between IAC circuits.

b. No. Repair open in appropriate circuit.

b. No. Replace ECM.

2013 Softail Diagnostics: Engine Management 6-59

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DTC P0603,

P0605

6.16

DESCRIPTION AND OPERATION

ed03469

See Figure 6-32 and Figure 6-33. The DTCs listed indicate a

failure which requires replacement of the ECM. Refer to

Table 6-50.

NOTE

After replacing ECM, perform password learning procedure

and clear DTCs using odometer self-diagnostics. See 2.1 INI-

TIAL DIAGNOSTICS, Odometer Self-Diagnostics.

Table 6-50. Code Description

DTC

DESCRIPTION

P0603

ECM EEPROM memory error

P0605

ECM flash memory error

1. ECM [78-1]

2. ECM [78-2]

DTC P0603 Test

3. Retaining clips

1. Clear DTCs.

Figure 6-32. ECM [78-1] and [78-2]: Except FXSB

2. Turn IGN ON.

3. Check DTCs.

ed03462

4. Did DTC reset?

a. Yes. Replace ECM.

b. No. System operating properly.

DTC P0605 Test

1. Clear DTCs.

2. Attempt to program ECM using correct calibration.

3. Start engine.

4. Check DTCs.

5. Did DTC reset?

a. Yes. Replace ECM.

b. No. System operating properly.

1. ECM

2. ECM [78-2]

3. ECM [78-1]

4. Purge solenoid [95] (back side of purge

solenoid)

5. Security siren

6. BCM

7. BCM [242] (back side of BCM)

8. Security siren [142]

9. Rear WSS [168]

10. ABS [166]

11. ABS ECU

Figure 6-33. Electrical Panel: FXSB

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DTC P0641

6.17

DESCRIPTION AND OPERATION

Connector Information

See Figure 6-34, Figure 6-35 and Figure 6-36. The ECM sup-

For additional information about the connectors in the following

plies 5V to the VSS, MAP, TPS and JSS from [78-2] terminal

diagram(s) and diagnostic procedure(s), including the color of

9. These sensors may have individual codes along with this

the harness test kit terminal probes, see B.1 CONNECTORS.

code since they all share the 5V ref circuit. If the ECM sees a

voltage of less than 4V or greater than 6V on the 5V ref circuit,

ed03304

P0641 will be set.

ed03338

1. VSS

2. Oil tank

3. Starter

Figure 6-35. VSS

ed03292

1. Rear fuel injector [85]

2. IAC [87]

3. Front fuel injector [84]

4. Active intake solenoid [178]

5. TPS [88]

6. IAT sensor [89]

7. MAP sensor [80]

Figure 6-34. Between Cylinders Right Side

Table 6-51. Code Description

Voltage regulator to stator [47]

DTC

DESCRIPTION

Front HO2 sensor [138]

Voltage regulator [77]

P0641

5V Vref out of range

JSS [133]

Any of these conditions will set a DTC P0641:

CKP sensor [79]

•

Short to ground on the 5V sensor power circuit.

Figure 6-36. Under Voltage Regulator

•

Short to voltage on the 5V sensor power circuit.

•

VSS fault or malfunction.

•

MAP sensor fault or malfunction.

•

TPS fault or malfunction.

•

JSS (HDI) fault or malfunction.

•

ECM fault or malfunction.

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em00996

5V Sensor Power

R/W

VSS

VSS Input

LGN/Y

Ground

BK/GN

[65A] [65B]

5V Sensor Ground

BK/W

MAP

MAP Input

Sensor

5V Sensor Power

R/W

To BCM

[80A] [80B]

5V Sensor Power

R/W

TPS

5V Sensor Ground

BK/W

TPS

GN/V

[88A] [88B]

System Power

R/GN

Rear HO2

Rear O2 Heater Ground

BK/PK

Sensor

Rear O2 Sensor

GY/BN

5V Sensor Ground

BK/W

[138B] [138A]

5V Sensor Ground

R/W

JSS

JSS Signal

LGN/GY

(HDI)

Sensor Ground

BK/GN

[133A] [133B]

System Power

R/GN

Front HO2

Front O2 Heater Ground

BK/O

Sensor

Front O2 Sensor

GN/BN

5V Sensor Ground

BK/W

[138B] [138A]

IAT

GN/GY

IAT

Sensor

5V Sensor Ground

BK/W

[89A] [89B]

ET Sensor

Sensor

5V Sensor Ground

BK/W

[90A] [90B]

GND 1

[78B-1]

[78B-2]

[78A-1]

[78A-2]

ECM

Figure 6-37. Sensor Circuit

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DTC P0641

3. MAP Power Circuit Below Range Test

1. Turn IGN OFF.

PART NUMBER

TOOL NAME

2. Disconnect MAP sensor [80].

HD-41404

HARNESS CONNECTOR TEST KIT

3. Turn IGN ON.

HD-50390-1

BREAKOUT BOX

4. Test voltage between BOB [78-2] terminals 9 and 10.

HD-50390-4

ECM CABLE

HD-50390-4-P

ECM OVERLAY

5. Is voltage less than 4V?

a. Yes. Go to Test 4.

Table 6-52. DTC P0641 Diagnostic Faults

b. No. Replace MAP sensor.

POSSIBLE CAUSES

4. VSS Circuit Below Range Test

Short to ground on the 5V sensor power circuit

1. Turn IGN OFF.

Short to voltage on the 5V sensor power circuit

2. Disconnect VSS [65].

VSS fault or malfunction

3. Turn IGN ON.

MAP sensor fault or malfunction

4. Test voltage between BOB [78-2] terminals 9 and 10.

TPS fault or malfunction

5. Is voltage less than 4V?

JSS (HDI) fault or malfunction

a. Yes, with JSS. Go to Test 5.

1. 5V Sensor Short to Voltage Test

b. Yes, without JSS. Go to Test 6.

1. Turn IGN OFF.

c. No. Replace VSS.

2. Connect BREAKOUT BOX (Part No. HD-50390-1) and

ECM CABLE (Part No. HD-50390-4) between wiring har-

5. JSS Circuit Below Range Test

ness [78B-1] and [78B-2] and ECM [78A-1] and [78A-2].

1. Turn IGN OFF.

See 1.2 DIAGNOSTIC TOOLS.

2. Disconnect JSS [133].

3. Verify ECM OVERLAY (Part No. HD-50390-4-P) is in

position on BOB.

3. Turn IGN ON.

4. Turn IGN ON.

4. Test voltage between BOB [78-2] terminals 9 and 10.

5. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

5. Is voltage less than 4V?

41404), test voltage between BOB [78-2] terminal 9 and

a. Yes. Go to Test 6.

ground.

b. No. Replace JSS.

6. Is voltage between 4-6V?

a. Yes. Concern is intermittent. See 1.3 DIAGNOSTICS

6. Circuit Short to Ground Test

AND TROUBLESHOOTING, Wiggle Test.

1. Disconnect ECM from breakout box.

b. No. Greater than 6V. Repair short to voltage on

2. Test continuity between BOB [78-2] terminal 9 and ground.

(R/W) wire.

3. Is continuity present?

c. No. Less than 4V. Go to Test 2.

a. Yes. Repair short to ground in (R/W) wire.

2. TPS Circuit Below Range Test

b. No. Go to Test 7.

1. Turn IGN OFF.

7. Circuit Shorted to Sensor Ground Circuit

2. Disconnect TPS [88].

Test

3. Turn IGN ON.

1. Test continuity between BOB [78-2] terminals 9 and 7.

4. Test voltage between BOB [78-2] terminals 9 and 10.

2. Is continuity present?

5. Is voltage less than 4V?

a. Yes. Repair short between (R/W) and (BK/W) wires.

a. Yes. Go to Test 3.

b. No. Replace ECM.

b. No. Replace TPS.

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DTC P0661,

P0662

6.18

DESCRIPTION AND OPERATION

ed03354

Active intake solenoid (AIS) is included on HDI vehicles only.

See Figure 6-39. The AIS regulates the amount of air entering

the air cleaner. The AIS opens when vehicle speed exceeds

45 mph (70 km/h) with 50% or greater throttle opening. Once

open, active intake will close when vehicle speed falls below

40 mph (65 km/h). The power for the AIS comes from the BCM.

The ECM provides the path to ground to trigger the AIS.

Table 6-53. Code Description

DTC

DESCRIPTION

P0661

AIS low/open

P0662

AIS shorted/high

1. Intake module

2. Intake solenoid connector [178]

3. Air cleaner backing plate

Figure 6-38. Intake Solenoid Connector Location

NOTE

The AIS and active exhaust actuator share the same power

source and function simultaneously.

Connector Information

For additional information about the connectors in the following

diagram(s) and diagnostic procedure(s), including the color of

the harness test kit terminal probes, see B.1 CONNECTORS.

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[78A-1] [78B-1]

ECM

CKP Sensor Low

Sensor Low

CKP

CKP Sensor High

Sensor High

Ground

BK/GN

[79B] [79A]

Main

R/GN

System Power

BCM

Harness

[242B] [242A]

[179B] [179A]

System Power

R/GN

CKP Sensor Low

LGN/BE

Feedback

CKP Sensor High

GY/W

LGN/O

Actuator

Exhaust

Actuator

IAC A High

GN/W

Ground

(HDI)

IAC B Low

GY/O

R/GN

System Power

IAC A Low

BK/GN

GND 2

IAC B High

LGN/O

Ground

LGN/V

Active Intake

AIS

(HDI)

Ground

GN/O

R/GN

System Power

[178B] [178A]

[78A-2] [78B-2]

GY/W

B Low

GN/W

B High

IAC

GND 1

GY/O

A Low

GN/O

A High

[87B] [87A]

Figure 6-39. Active Exhaust Actuator and AIS Circuit

DTC P0661

4. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), jump BOB [78-2] terminals 2 to 10.

PART NUMBER

TOOL NAME

5. Turn IGN ON.

HD-41404

HARNESS CONNECTOR TEST KIT

6. Does AIS activate immediately?

HD-50390-1

BREAKOUT BOX

a. Yes. Replace ECM.

HD-50390-4

ECM CABLE

b. No. Go to Test 2.

HD-50390-4-P

ECM OVERLAY

2. Resistance Test

1. Turn IGN OFF.

Table 6-54. DTC P0661 Diagnostic Faults

2. Disconnect AIS [178].

POSSIBLE CAUSES

3. Test resistance between [178A] terminals 1 and 2.

AIS malfunction

4. Is resistance between 16-20 Ohms?

Active intake shorted low

a. Yes. Go to Test 3.

Open in circuit

b. No. Replace AIS.

1. AIS Test

1. Turn IGN OFF.

3. Open Ground Wire Test

1. Test continuity between BOB [78-2] terminal 2 to AIS

2. Connect BREAKOUT BOX (Part No. HD-50390-1) and

[178B] terminal 2 (LGN/V) wire.

ECM CABLE (Part No. HD-50390-4) to wiring harness

[78B-1] and [78B-2], leaving ECM [78A-1] and [78A-2]

2. Is continuity present?

disconnected. See 1.2 DIAGNOSTIC TOOLS.

a. Yes. Go to Test 4.

3. Verify ECM OVERLAY (Part No. HD-50390-4-P) is in

b. No. Repair open in (LGN/V) wire.

position on BOB.

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2. Disconnect AIS [178].

4. Low Short to Ground Test

1. Test continuity between BOB [78-2] terminal 2 and ground.

3. Using HARNESS CONNECTOR TEST KIT (Part No. HD-

41404), test resistance between [178A] terminals 1 and

2. Is continuity present?

a. Yes. Repair short to ground on (LGN/V) wire.

4. Is resistance between 16-20 Ohms?

b. No. Go to Test 5.

a. Yes. Go to Test 2.

5. Open Supply Wire Test

b. No. Replace AIS.

1. Test continuity between [78B-2] terminal 2 and [178B]

2. Short to Voltage Test

terminal 1 (R/GN) wire.

1. Turn IGN ON.

2. Is continuity present?

2. Test voltage between [178B] terminal 2 and ground.

a. Yes. Replace ECM.

3. Is voltage greater than 5.0V?

b. No. Repair open in (R/GN) wire.

a. Yes. Repair short to voltage on (LGN/V) wire

DTC P0662

b. No. Replace ECM.

PART NUMBER

TOOL NAME

HD-41404

HARNESS CONNECTOR TEST KIT

Table 6-55. DTC P0662 Diagnostic Faults

POSSIBLE CAUSES

Active intake shorted high

1. AIS Resistance Test

1. Turn IGN OFF.

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DTC P1009

6.19

GENERAL

ed03462

PART NUMBER

TOOL NAME

HD-48650

DIGITAL TECHNICIAN II

Password Problem

The ECM and BCM exchange passwords during operation. An

incorrect password will set a DTC. If any U-codes exist,

troubleshoot the higher priority codes prior to performing the

tests in this section. Refer to Table 2-1.

NOTE

Vehicle will not start if BCM is disconnected.

Table 6-56. Code Description

DTC

DESCRIPTION

P1009

Incorrect password

ed03310

ECM

ECM [78-2]

ECM [78-1]

Purge solenoid [95] (back side of purge

solenoid)

Security siren

BCM

BCM [242] (back side of BCM)

Security siren [142]

Rear WSS [168]

10. ABS [166]

11. ABS ECU

Figure 6-41. Electrical Panel: FXSB

BCM battery power [259]

BCM [242]

Rear WSS [168]

Diagnostic Tips

Rear tire

This code will usually appear after replacing the ECM or BCM.

Figure 6-40. BCM [242]: Except FXSB

New modules must be programmed using DIGITAL TECHNI-

CIAN II (Part No. HD-48650). After parts are programmed and

matched correctly for specific vehicle, clear codes.

DTC P1009

PART NUMBER

TOOL NAME

HD-48650

DIGITAL TECHNICIAN II

Table 6-57. DTC P1009 Diagnostic Faults

POSSIBLE CAUSES

ECM malfunction

BCM malfunction

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