Action

Complete a customer questionnaire and the check sheets to help assist in the identification of a drivability/stalling issue. The questionnaire and check sheet is a 3-page document; 1-page customer questionnaire and a 2-page Workshop Procedure/diagnostic check sheet. A copy of the forms are shown in this bulletin. The following information take the technician through the check sheet in more detail by section.

It is vital that the customer is lead through the questionnaire with the service advisor and that the dealer technician completes every stage of the diagnostic check sheet.

Note:
If the dealer technician finds a fault/error in the early stages of the check sheet, it is mandatory that the remainder of the check sheet be completed.

1. Connect the WDS to the vehicle's DLC and select the PCM data read application. Select the tab with the car with the wrench. From the Vehicle Configuration Main Menu, select Special Applications, then select Powertrain control module data read application.





1.2 Record value 0x094d, as shown in Illustration 1.





1.2 Record value 0x094e, as shown in Illustration 2.

2. In the luggage compartment:





2.1 Check battery lead to rear body ground point fixing bolt, as shown in Illustration 3. (Torque tighten to 12 Nm +/- 1.8 Nm).





2.2 Check mega fuse, as shown in illustration 4. (Torque tighten to 12 Nm +/- 1.8 Nm).





2.3 Check fuse box power lead, as shown in illustration 5. (Torque tighten to 12 Nm +/- 1.8 Nm).

3. Vehicle interior:





3.1 Check that all connections at secondary junction box are pushed fully home and are not damaged i.e. bent/backed-out (Illustration 6). Where available, utilize opposing pins from the harness repair kit and insert into populated pins to ensure a good/tight fit is achieved.





3.1 Check secondary junction box power lead connections as shown in Illustration 7. (Torque tighten to 4.1 Nm +/- 0.7 Nm).





3.2 Check inertia switch connections are pushed fully home and are not damaged i.e. bent/backed-out. Where available, utilize opposing pins from the harness repair kit and insert into populated pins to ensure a good/tight fit is achieved (Illustration 8). On vehicles prior to VIN L63474 check that the harness is not pulled tight, putting strain on the inertia switch connector.

3.3 Check the PCM for signs of water entry. Ensure that leak paths are rectified if signs of water ingress are evident.

Caution:
Do not open the case to check for internal water entry, as this will invalidate the warranty.

Note:
Replace the PCM only if it can be proven that it is faulty.





3.4 Check primary junction box connections (located in right-hand side A-post fuse box), as shown in Illustration 9. (Torque tighten to 3.2 Nm +/- 0.5 Nm) Wiggle block connectors to ensure they are sufficiently clamped to fuse box i.e. tight.





3.4 Check primary junction box connections (located in right-side A-post fuse box) are pushed fully home and are not damaged i.e. bent/backed-out. Where available, utilize opposing pins from the harness repair kit and insert into populated pins to ensure a good/tight fit is achieved (Illustration 10).








3.7 After removing the jet pump assembly from the left side of the fuel tank (Illustration 11), drain the fuel and feel inside that the disk is present and secure in the float level valve (Illustration 12). The valve is welded into the tank and cannot be viewed directly. Loose components may be floating on the surface on the fuel.

3.7 Illustration 12 shows complete and defective float level valves. A defective valve can result in stalling immediately after the fuel tank has been fully filled. Under these conditions, fuel can saturate the charcoal canisters which causes an overly rich condition when the PCM attempts to purge the canisters.

4. Under the hood:





4.1 Record the Mass Air Flow Sensor (MAFS) date stamp code, as shown in Illustration 13.





4.2 Check for chafing of the engine harness on the injector pressure sensor bracket, as shown in Illustration 14.





4.3 Check PCM connectors, as shown in Illustration 15. (Torque tighten to 4.8 Nm +/- 0.8 Nm). Wiggle block connectors to ensure they are sufficiently clamped to PCM i.e. tight.

Note:
Removal of pollen filter housing allows easier access to PCM connectors.





4.4 Check engine harness to body harness connectors P146 and P12 for signs of water entry. Ensure the connectors are pushed fully home and are not damaged i.e. bent/backed-out. Where available, utilize opposing pins from the harness repair kit and insert into populated pins to ensure a good/tight fit is achieved (Illustration 16).





4.5 Measure spark plug resistance between the spark electrode and the coil end of the plug, using a standard ohmmeter (Illustration 17).

4.5.1 Check the spark plugs, wells and coils for signs of water ingress. If signs of water ingress are visible, clean and dry the affected area. (For V8 vehicles only, if signs of water ingress are visible, replace coil covers).





4.6 Check in-line connector from engine harness to injector harness for signs of water ingress (Illustration 18). Ensure the connectors are pushed fully home and are not damaged i.e. bent/backed-out. Where available, utilize opposing pins from the harness repair kit and insert into populated pins to ensure a good/tight fit is achieved.





4.7 Check that the air cleaner lid securing clips are secure, as shown in Illustration 19. If the clips are loose, check the air cleaner (intake to engine side) for dirt ingress. Clean/replace as necessary and re-install lid ensuring that the securing clips are fastened correctly.





4.8 Check the engine compartment fuse box power lead, as shown in Illustration 20. (Torque tighten to 12 Nm +/- 1.8 Nm).





4.9 Check the PCM relay base connections (relays number 4 and 14 in engine compartment fuse box) are pushed fully home and are not damaged i.e. bent/backed-out. Where available, utilize opposing pins from the harness repair kit and insert into populated pins to ensure a good/tight fit is achieved (Illustration 21).





4.9.1 Remove the harness-retaining clip (1, Illustration 22) from FH42 ground point. Check that the FH42 grounding point securing nut (2, Illustration 22) is tight (torque tighten to 12 Nm +/- 1.8 Nm). Reinstall harness-retaining clip.

5. Under the vehicle:





5.1 Check ground point FH049 (located under front passenger side wheel arch liner), as shown in Illustration 23. (Torque tighten to 12 Nm +/- 1.8 Nm).





5.2 Check power lead connection B03/B04 (located under front right-hand wheel arch liner), as shown in Illustration 24 (Torque tighten to 12 Nm +/- 1.8 Nm).

5.3 Check the crank position sensor and its connector/wiring (P140) for signs of water/oil ingress. Ensure the connectors are pushed fully home and are not damaged i.e. bent/backed-out. Where available, utilize opposing pins from the harness repair kit and insert into populated pins to ensure a good/tight fit is achieved. The crank position sensor can be found at the rear of the engine for V8 vehicles and at the front of the engine for V6 vehicles.

Note:
If after completing the Questionnaire and Check Sheet the problem is still present, contact Technical Hotline for further assistance.