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DTC P0107, P0108

5.21

GENERAL

f1939x9x

MAP Sensor
See Figure 5-51. The manifold absolute pressure sensor
(MAP sensor) is supplied 5 volts from the ECM (Pin 14) and
sends a signal back to the ECM (Pin 25). This signal varies in
accordance with engine vacuum and atmospheric barometric
pressure. Changes in barometric pressure are influenced by
weather and altitude.

Table 5-31. Code Description


DTC

LAMP
CODE

P0107

12

MAP sensor open/low

P0108

12

MAP sensor high

DESCRIPTION

MAP Sensor

Figure 5-51. Induction Module (Top View)

Diagnostic Notes

DIAGNOSTICS

1.

These codes will set if the MAP sensor signal is out of


range. Code P0108 can only be detected with the engine
running.

Connect BREAKOUT BOX (Part No. HD-43876)


between wire harness and ECM. See Section 5.7 BREAKOUT BOX: EFI.

2.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), gray pin probes and patch cords.

With the MAP sensor disconnected, the ECM and Scanalyzer should recognize a low voltage. If low voltage is
observed, the ECM and harness are not at fault unless
there is a short to ground.

Scanalyzer Notes

Diagnostic Tips

The reference numbers below correlate with the circled numbers on the Test 5.21 flow charts.

Gently place a jumper wire across MAP sensor connector [80B] Terminals B and C using HARNESS CONNECTOR TEST KIT (Part No. HD-41404), gray male probes
and patch cord. With the jumper in place, the ECM and
Scanalyzer should recognize a high voltage.

MAP sensor output check. Using the VACUUM PUMP


(Part No. HD-23738), apply a vacuum to the pressure
port of the MAP sensor. The signal voltage should lower
as the vacuum is applied.

The MAP and TP sensors are connected to the same


reference line (+5V Vref). If the reference line goes to
ground or open, multiple codes will be set (DTC P0107,
P0108, P0122, P0123).

The Scanalyzer icon appears at those points in the flow chart


where the Scanalyzer can be used.
1.

Press F1 key on Scanalyzer to view volts.

2003 Touring: Engine Management (EFI)

5-73

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f1743q9s

MAP
Sensor

25

26

R/W

To TP
Sensor

BK/W

To TP, ET &
IAT Sensors

V/W

A B C

R/W

[80B]

V/W

A B C

BK/W

[80A]

[78B]
[78A]

14
ECM
Figure 5-52. MAP Sensor Circuit

Table 5-32. Wire Harness Connectors in Figure 5-52.


DESCRIPTION

NO.

5-74

TYPE

LOCATION

[78]

ECM

36-Place Packard

Under Right Side Cover

[80]

MAP Sensor

3-Place Packard

Top of Induction Module

2003 Touring: Engine Management (EFI)

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Test 5.21 (Part 1 of 2)


MAP SENSOR: DTC P0107, P0108

USING BREAKOUT BOX

USING SCANALYZER

Connect Breakout Box. With ignition ON,


measure voltage between Terminals 25
and 26 on Breakout Box.

With engine running, observe


Scanalyzer MAP voltage values.
1

With key ON, engine OFF, voltage must be


between 3.5 and 5.0 volts.
With key ON, engine running, voltage must
be between 1.5-3.0 volts at hot idle.
Does voltage fit specifications?

YES

NO

Perform 5.8 WIGGLE TEST


to check for intermittents.
Intermittents present?

STOP
Go to Test 5.21 (Part 2 of 2).

YES

NO

To the source of intermittents, start


with box marked by Bold Asterisk
under Test 5.21 (Part 2 of 2). Wiggle
harness while watching DVOM.

Replace MAP sensor. Clear codes if a


Scanalyzer is available and road test. Did
check engine lamp illuminate and set DTC
P0107 or P0108?

7620

YES

NO

Install original MAP sensor.


Replace ECM (reprogram,
relearn) and road test again
to verify.

System
now OK.
7630

7625

At some point in the flow chart you


may be instructed to jump directly
to the box marked by a bold asterisk. Disregard the asterisk (but not
the instruction box) if your normal
progression through the chart
brings you to this location.

Clear codes and confirm proper


operation with no check engine
lamp.

2003 Touring: Engine Management (EFI)

5-75

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Test 5.21 (Part 2 of 2)


MAP SENSOR: DTC P0107, P0108

Continued from
Test 5.21 (Part 1 of 2).
Check the 5 volt reference supply
at Connector [80B]. With
ignition ON, measure voltage between
Sockets C (R/W) and A (BK/W).
Voltage approximately 5.0 volts?

YES

NO.
Greater
than 6V.

Connect Breakout Box to Connector [78B]


leaving ECM disconnected.
OPEN CHECK: Measure resistance
between Socket B of Connector [80B]
and Terminal 25 of Breakout Box.
Resistance less than 1 ohm?

NO.
Less
than 4.5V.

Locate short to 12 volts


on R/W wire. Repair
as necessary.

7635

YES

NO

SHORT CHECK: Measure


resistance between Socket B
of Connector [80B] and
chassis ground. Resistance
greater than 1 megohm?

Locate and repair


open on V/W wire.
7645

YES

NO

Replace
MAP sensor.

Connect Breakout Box to


Connector [78B] leaving ECM
disconnected. Check continuity
between Socket C of Connector [80B]
and Terminal 14 of Breakout Box.
Then measure continuity between
Socket A of Connector [80B] and
Terminal 26 of Breakout Box.
Continuity less than 1 ohm?

Locate and repair


grounded V/W wire.

7650

YES

NO

Check resistance between


Socket C of Connector
[80B] and Terminal 26 of
Breakout Box.
Resistance greater than
1 megohm?

Locate and repair


open wire.

YES

NO

Replace ECM.
Reprogram and learn
password.

Locate and repair


short between
R/W and BK/W
wires.

7640

7655

7641
7642

At some point in the flow chart you


may be instructed to jump directly
to the box marked by a bold asterisk. Disregard the asterisk (but not
the instruction box) if your normal
progression through the chart
brings you to this location.

5-76

2003 Touring: Engine Management (EFI)

Clear codes and confirm proper


operation with no check engine
lamp.

HOME

DTC P0112, P0113

5.22

GENERAL

DIAGNOSTICS

IAT Sensor

Diagnostic Tips

The ECM supplies and monitors a voltage signal (Pin 7) to


one side of the intake air temperature sensor (IAT sensor).
The other side of the IAT sensor is connected to a common
sensor ground, which is also connected to the ECM (Pin 26).
The IAT sensor is a thermistor device, meaning that at a specific temperature, it will have a specific resistance across its
terminals. As this resistance varies, so does the voltage on
Pin 7.

At high temperatures, the resistance of the sensor is very


low, which effectively lowers the signal voltage on Pin 7.

At low temperatures, the resistance is very high, allowing


the voltage to rise close to 5 volts.

The Scanalyzer displays intake air temperature in degrees, or


by pressing the F1 key, in volts. An intermittent may be
caused by a poor connection, rubbed through wire insulation
or a wire broken inside the insulation. Check the following
conditions:

Poor connection: Inspect ECM and harness connector


[78] for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor terminal-to-wire connection and damaged harness.

See Section 5.8 WIGGLE TEST to locate intermittents: If connections and harness are OK, use the Scanalyzer to check the intake air temperature reading while
moving related connectors and wiring harness. If failure
is induced, the intake air temperature display will change.

Shifted sensor: See Table 5-34. Use table to test the


intake air temperature sensor at various temperature levels in order to evaluate the possibility of a shifted (out-ofcalibration) sensor which can result in driveability problems.

The ECM monitors this voltage to compensate for various


operating conditions.

NOTE

Table 5-33. Code Description


DTC

LAMP
CODE

P0112

15

IAT sensor voltage low

P0113

15

IAT sensor open/high

All voltage and resistance values are approximate (20%).


Measure IAT sensor resistance between ECM Terminal 7 and
system ground (ECM Terminal 26).

DESCRIPTION

Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 5.22 flow charts.

Table 5-34. IAT Sensor Table


TEMP C

RESISTANCE

VOLTAGE

TEMP F

-40

100950

4.9

-40

-30

53100

4.8

-22

-20

29121

4.7

-4

-10

16599

4.5

14

9750

4.2

32

10

5970

3.8

50

20

3747

3.3

68

25

3000

3.0

77

30

2417

2.7

86

40

1598

2.2

104

50

1080

1.8

122

60

746

1.4

140

70

526

1.0

158

1.

Connect BREAKOUT BOX (Part No. HD-43876) to EFI


wire harness only (leave ECM disconnected). See Section 5.7 BREAKOUT BOX: EFI.

2.

If the engine has not been operated for 1 hour, the measured resistance should be very close to the measured
resistance across the ET sensor which is Pins 6 and 26
on the Breakout Box. Scanalyzer values (using Data
Monitor Mode) will be approximately the same if code is
historic. Current code will read default value.

3.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), gray pin probes and patch cords.

4.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), gray socket probes and patch cords.

5.

See INTAKE AIR TEMPERATURE SENSOR, REMOVAL/INSTALLATION, in the 2003 Touring Models Service Manual (Part Number 99483-03).

Scanalyzer Notes
The Scanalyzer icon appears at those points in the flow chart
where the Scanalyzer can be used.

2003 Touring: Engine Management (EFI)

5-77

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f1743r9s

IAT
Sensor

A B

[78B]
[78A]

BK/W

To TP, ET &
MAP Sensors

Lt GN/Y

Lt GN/Y

[89B]

A B

BK/W

[89A]

26

ECM

Figure 5-53. IAT Sensor Circuit

Table 5-35. Wire Harness Connectors in Figure 5-53.


DESCRIPTION

NO.

5-78

TYPE

LOCATION

[78]

ECM

36-Place Packard

Under Right Side Cover

[89]

IAT Sensor

2-Place Packard

Below Fuel Tank (Right Side)

2003 Touring: Engine Management (EFI)

HOME

Test 5.22 (Part 1 of 2)


IAT SENSOR: DTC P0112, P0113

Connect Breakout Box to Connector [78B]


leaving ECM disconnected. With engine at room
temperature (60-90 F or 16-32 C), use a DVOM
to measure resistance across Terminals 7
and 26 on Breakout Box.
Resistance between 1.4k ohms and 6.9k ohms?

1
2

YES

NO

Connect ECM to Breakout Box.


Perform 5.8 WIGGLE TEST to check for
intermittents. Intermittents present?

STOP
Go to Test 5.22 (Part 2 of 2).

YES

NO

While wiggling harness, perform


steps marked by BOLD ASTERISKS under Test 5.22 (Part 2 of 2).
Repair as necessary.

Disconnect Connector [89]. Turn


ignition ON. Using a DVOM,
measure the voltage between
Terminals 7 (positive) and 26
(negative) on Breakout Box.
Voltage approximately 5 volts?

7715

YES

Replace IAT sensor, clear codes if


Scanalyzer is available and road test.
Did check engine lamp illuminate and
set DTC P0112 or P0113?

NO.
Less than
4.7 volts.

NO.
Greater than
5.3 volts.

With IAT sensor disconnected,


disconnect ECM from breakout box.
Measure resistance between
Breakout Box Pin 7 and Pins 10 or 28.
Resistance less than 1 megohm?

Unplug ECM leaving Breakout Box


connected at vehicle harness.
Measure voltage between
Breakout Box Pin 7 and Pins 10 or 28.
Voltage 0 volts?

YES

NO

YES

NO

YES

NO

Install original IAT


sensor. Replace
ECM. Reprogram
and learn password.
Road test.

System
OK.

Locate and repair


short to ground on
Lt GN/Y wire.

Replace ECM.
Reprogram and
learn password.

Replace ECM.
Reprogram and
learn password.

Examine IAT signal wire (Lt GN/Y)


for short to voltage and repair.

7725
7730

7735

7740
7745

7720

Clear codes and confirm proper


operation with no check engine
lamp.

At some point in the flow chart you


may be instructed to jump directly
to the box marked by a bold asterisk. Disregard the asterisk (but not
the instruction box) if your normal
progression through the chart
brings you to this location.

2003 Touring: Engine Management (EFI)

5-79

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Test 5.22 (Part 2 of 2)


IAT SENSOR: DTC P0112, P0113

Continued from
Test 5.22 (Part 1 of 2).
Disconnect Connector [89] and examine
for damage. Connector OK?

YES

NO

Using a DVOM, measure the resistance


between Socket A of Connector [89B]
and Terminal 7 on Breakout Box.
Resistance less than 1.0 ohm?

Repair
connector.
7750

YES

NO

Using a DVOM, measure the resistance


between Socket B of Connector [89B]
and Terminal 26 on Breakout Box.
Resistance less than 1.0 ohm?

Locate and repair open


on Lt GN/Y wire.

YES

NO

Using a DVOM, measure the resistance


between Terminals 7 and 26 on
Breakout Box. Resistance greater
than 1.0 megohm?

Locate and repair


open on BK/W wire.

YES

NO

Using a DVOM, measure the resistance


between Terminal 7 on Breakout Box
and ground. Resistance greater
than 1.0 megohm?

Locate and repair


short between Lt GN/Y
and BK/W wires.

7750

7750

7750

YES

NO

Remove IAT sensor and measure


resistance across Pins in Connector
[89A]. With sensor at room temperature
(60-90 F or 16-32 C), is resistance
between 1.4k ohms and 6.9k ohms?

Locate and repair


short to ground
7750

YES

At some point in the flow chart you


may be instructed to jump directly
to the box marked by a bold asterisk. Disregard the asterisk (but not
the instruction box) if your normal
progression through the chart
brings you to this location.

NO

Perform 5.8 WIGGLE TEST on steps


marked with a BOLD ASTERISK above to
locate intermittents. Repair as necessary.

Replace
IAT sensor.
7760

7755

5-80

2003 Touring: Engine Management (EFI)

Clear codes and confirm proper


operation with no check engine
lamp.

HOME

DTC P0117, P0118

5.23

GENERAL

DIAGNOSTICS

ET Sensor

Diagnostic Tips

The ECM supplies and monitors a voltage signal (Pin 6) to


one side of the engine temperature sensor (ET sensor). The
other side of the ET sensor is connected to a common sensor
ground, which is also connected to the ECM (Pin 26).
The ET sensor is a thermistor device, which means that at a
specific temperature it will have a specific resistance across
its terminals. As this resistance varies, so does the voltage on
Pin 6.

At high temperatures, the resistance of the sensor is very


low, which effectively lowers the signal voltage on Pin 6.

The Scanalyzer displays engine temperature in degrees, or


by pressing the F1 key, in volts. After the engine is started,
the temperature should rise steadily.
An intermittent may be caused by a poor connection, rubbed
through wire insulation or a wire broken inside the insulation.
Check the following conditions:

Poor connection: Inspect ECM and harness connector


[78] for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor terminal-to-wire connection and damaged harness.

See Section 5.8 WIGGLE TEST to locate intermittents: If connections and harness are OK, use the Scanalyzer to check the intake air temperature reading while
moving related connectors and wiring harness. If failure
is induced, the intake air temperature display will change.

Shifted sensor: See Table 5-37. Use table to test the


engine temperature sensor at various temperature levels
in order to evaluate the possibility of a shifted (out-of-calibration) sensor which can result in driveability problems.

At low temperatures, the resistance is very high, allowing


the voltage to rise close to 5 volts.

The ECM monitors this voltage to compensate for various


operating conditions. The ECM also uses the sensor input as
a reference for determining IAC pintle position.

Table 5-36. Code Description


DTC

LAMP
CODE

P0117

14

ET sensor voltage low

P0118

14

ET sensor open/high

NOTE
All voltage and resistance values are approximate (20%).
Measure ET sensor resistance between ECM Terminal 6 and
system ground (ECM Terminal 26).

DESCRIPTION

Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 5.23 flow charts.

Table 5-37. ET Sensor Table


TEMP C

RESISTANCE

VOLTAGE

TEMP F

-10

16599

4.5

14

9750

4.1

32

10

5970

3.8

50

20

3747

3.3

68

25

3000

3.0

77

30

2417

2.7

86

40

1598

2.2

104

50

1080

1.8

122

60

746

1.4

140

70

526

1.0

158

80

377

0.8

176

90

275

0.6

194

100

204

0.5

212

110

153

0.4

230

1.

Connect BREAKOUT BOX (Part No. HD-43876) to EFI


wire harness only (leave ECM disconnected). See Section 5.7 BREAKOUT BOX: EFI.

2.

If engine has not been operated for 1 hour, the measured


resistance should be very close to the measured resistance across the IAT sensor which is Pins 7 and 26 on
the Breakout Box. Scanalyzer values (using Data Monitor Mode) will be approximately the same if code is historic. Current code will read default value.

3.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), gray pin probes and patch cords.

4.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), gray socket probes and patch cords.

5.

See ENGINE TEMPERATURE SENSOR, REMOVAL/


INSTALLATION, in the 2003 Touring Models Service
Manual (Part Number 99483-03).

Scanalyzer Notes
The Scanalyzer icon appears at those points in the flow chart
where the Scanalyzer can be used.

2003 Touring: Engine Management (EFI)

5-81

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f1743s9s

ET
Sensor

[90B]

A B

PK/Y

A B

BK/W

[90A]

BK/W

[78B]
[78A]

PK/Y

To TP, IAT &


MAP Sensors

26

ECM

Figure 5-54. ET Sensor Circuit

Table 5-38. Wire Harness Connectors in Figure 5-54.


NO.

5-82

DESCRIPTION

TYPE

LOCATION

[78]

ECM

36-Place Packard

Under Right Side Cover

[90]

ET Sensor

2-Place Packard

Back of Front Cylinder (Left Side)

2003 Touring: Engine Management (EFI)

HOME

Test 5.23 (Part 1 of 2)


ET SENSOR: DTC P0117, P0118

1
2

Connect Breakout Box to Connector [78B]


leaving ECM disconnected. With engine at
room temperature (60-90 F or 16-32 C),
use a DVOM to measure resistance across
Terminals 6 and 26 on Breakout Box. Resistance between 1.4k ohms and 6.9k ohms?

YES

NO

Connect ECM to Breakout Box.


Perform 5.8 WIGGLE TEST to check for
intermittents. Intermittents present?

STOP
Go to Test 5.23 (Part 2 of 2).

YES

NO

While wiggling harness, perform


steps marked by BOLD ASTERISKS under Test 5.23 (Part 2 of 2).
Repair as necessary.

Disconnect Connector [90]. Turn


ignition ON. Using a DVOM,
measure the voltage between
Terminals 6 (positive) and
26 (negative) on Breakout Box.
Voltage approximately 5 volts?

7660

YES

Replace ET sensor, clear codes if


Scanalyzer is available and road test.
Did check engine lamp illuminate and
set DTC P0117 or P0118?

YES

NO

Install original
ET sensor and replace
ECM. Reprogram and
learn password.
Road test.

System
OK.

7665

7670

NO.
Less than
4.7 volts.

NO.
Greater than
5.3 volts.

With ET sensor disconnected,


disconnect Connector [78B].
Measure resistance between
Pin 6 and Pins 10 or 28.
Resistance less than 1 megohm?

Unplug ECM leaving Breakout Box


connected at vehicle harness.
Measure voltage between
Pin 6 and Pins 10 or 28.
Voltage 0 volts?

YES

NO

YES

NO

Locate and repair


short to ground
on PK/Y wire.

Replace ECM.
Reprogram and
learn password.

Replace ECM.
Reprogram and
learn password.

Examine ET
signal wire (PK/Y)
for short to voltage
and repair.

7675

7680

7685
7690

Clear codes and confirm proper


operation with no check engine
lamp.

At some point in the flow chart you


may be instructed to jump directly
to the box marked by a bold asterisk. Disregard the asterisk (but not
the instruction box) if your normal
progression through the chart
brings you to this location.

2003 Touring: Engine Management (EFI)

5-83

HOME

Test 5.23 (Part 2 of 2)


ET SENSOR: DTC P0117, P0118

Continued from
Test 5.23 (Part 1 of 2).
Disconnect Connector [90B] and
examine for damage. Connector OK?

YES

NO

Using a DVOM, measure resistance


between Socket A of Connector [90B]
and Terminal 6 on Breakout Box.
Resistance less than 1.0 ohm?

Repair
connector.
7695

YES

NO

Using a DVOM, measure resistance


between Socket B of Connector [90B]
and Terminal 26 on Breakout Box.
Resistance less than 1.0 ohm?

Locate and repair


open on PK/Y wire.

YES

NO

Using a DVOM, measure the resistance


between Terminals 6 and 26 on
Breakout Box. Resistance greater
than 1.0 megohm?

Locate and repair


open on BK/W wire.

YES

NO

Using a DVOM, measure the resistance


between Terminal 6 on Breakout Box
and ground. Resistance greater
than 1.0 megohm?

Locate and repair


short between PK/Y
and BK/W wires.

YES

NO

Remove ET sensor and measure


resistance across Pins of Connector [90B].
With sensor at room temperature (60-90 F
or 16-32 C), is resistance between
1.4k ohms and 6.9k ohms?

Locate and repair


short to ground.

YES

NO

Perform 5.8 WIGGLE TEST on steps


marked with a BOLD ASTERISK above to
locate intermittents. Repair as necessary.

7695

7695

7695

7695

Replace
ET sensor.
7710

7705

5-84

2003 Touring: Engine Management (EFI)

Clear codes and confirm proper


operation with no check engine
lamp.

At some point in the flow chart you


may be instructed to jump directly
to the box marked by a bold asterisk. Disregard the asterisk (but not
the instruction box) if your normal
progression through the chart
brings you to this location.

HOME

DTC P0122, P0123


GENERAL

5.24
Check for the following conditions:

Poor Connection: Inspect ECM and harness connector


[78B] for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor terminal-to-wire connection and damaged harness.

Perform 5.8 WIGGLE TEST to locate intermittents: If


connections and harness check out OK, monitor TP sensor voltage using a Scanalyzer or DVOM while moving
related connectors and wiring harness. If the failure is
induced, the TP sensor display will also change in data
monitor mode.

TP sensor scaling: Observe the TP sensor voltage display while opening the throttle with engine stopped and
ignition key ON. Display should vary from closed throttle
TP sensor voltage (when throttle is closed) to greater
than 4.5 volts (when throttle is held wide open). As the
throttle is slowly moved, the voltage should change
gradually without spikes or low voltages being observed.

TP Sensor
The ECM supplies a 5 volt signal (Pin 14) to the throttle position sensor (TP sensor). The TP sensor sends a signal back
to the ECM (Pin 24). The returned signal varies in voltage
according to throttle position.

At idle (closed throttle), the signal is typically in the range


of 0.20-0.60 volts.

At wide open throttle, the signal is normally 4.6-4.9 volts.

A code P0122 or P0123 will set if the TP sensor voltage signal does not fall within the acceptable range.

If TPS sensor is greater than 90%, then the system is in


clear flood mode and engine will not start. While spark
will be present, fuel is shut off (injectors disabled). Problem can be mechanical, such as throttle/throttle cables
stuck.

Table 5-39. Code Description


DTC

LAMP
CODE

P0122

11

TP sensor open/low

P0123

11

TP sensor high

DESCRIPTION

Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 5.24 flow charts.
1.

DIAGNOSTICS
Diagnostic Tips
The Scanalyzer or DVOM reads throttle position in volts, or by
pressing the F1 key, as a percentage of throttle opening. Voltage should increase at a steady rate as the throttle is moved
from idle to wide open. A short to ground or open on the GY/
V or R/W wires also will result in a DTC P0122. A short to
ground or open on the R/W wire (+5v REF) sets multiple
codes as described below.
NOTE
The MAP and TP sensors are both connected to the same
reference line (+5v Vref). If the line goes to ground or open,
multiple trouble codes will be set, that is, diagnostic trouble
codes P0107, P0108 and P0122 or P0123. Start with the
trouble code having the lowest ranking value.

Connect a BREAKOUT BOX (Part No. HD-43876)


between EFI wire harness and ECM before measuring
voltage. See Section 5.7 BREAKOUT BOX: EFI.
a.

If using a DVOM to measure voltage, take reading


across Pin 24 (positive lead) and Pin 26 (negative
lead) on Breakout Box.

b.

If using Scanalyzer to measure voltage, consult


Data Monitor Mode. See Section 5.5 SCANALYZER: EFI for more information.

2.

See THROTTLE POSITION SENSOR, REMOVAL/


INSTALLATION, in the 2003 Touring Models Service
Manual (Part Number 99483-03).

3.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), gray pin probes and patch cords.

Scanalyzer Notes
The Scanalyzer icon appears at those points in the flow chart
where the Scanalyzer can be used.

2003 Touring: Engine Management (EFI)

5-85

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s0452x9x

TP
sensor

A B C
R/W

[88B]

To MAP, ET &
IAT sensors

GY/V

A B C

BK/W

[88A]

GY/V

BK/W

[78B]
[78A]

R/W

To MAP
sensor

14

24

26

ECM

Figure 5-55. TP Sensor Circuit

Table 5-40. Wire Harness Connectors in Figure 5-55.


NO.

5-86

DESCRIPTION

TYPE

LOCATION

[78]

ECM

36-Place Packard

Under Right Side Cover

[88]

TP Sensor

3-Place Packard

Below Fuel Tank (Right Side)

2003 Touring: Engine Management (EFI)

HOME

Test 5.24 (Part 1 of 2)


TP SENSOR: DTC P0122, P0123

With ignition key ON, measure TP sensor voltage while


gradually opening throttle. Does voltage increase steadily
with no spikes or low voltages from 0.2-0.6 volts at idle
(closed throttle) to 4.6-4.9 volts at wide open throttle?

YES

NO.
But voltage is
greater than
4.95 volts.

Check engine lamp ON


continuously and
DTC P0122 or P0123
the only one set?

NO.
Low voltage
or spikes
observed.

Unplug Connector [88B] and


measure voltage between
Sockets B (+) and A (-) with
ignition ON.
Is reading 4.8-5.0 volts?

STOP
Go to Test 5.24 (Part 2 of 2).

YES

NO

YES

NO

Replace ECM.
Reprogram and
learn password.

Perform 5.8 WIGGLE TEST


to check for intermittents.
Intermittents present?

Measure resistance
between Terminal
24 on Breakout Box
and chassis ground.
Greater than 1
megohm?

Measure
resistance between
Socket B of Connector [88B] and Terminal
14 on Breakout Box.
Less than 1.0 ohm?

7555

YES

NO

While wiggling harness,


start with the first step of
Test 5.24 (Part 2 of 2)
(marked by BOLD ASTERISK). Repair as necessary.

Replace TP sensor,
clear codes if Scanalyzer is
available and road test.
Did check engine lamp
illuminate and set
DTC P0122 or P0123?

YES

NO

Replace
TP sensor.

Locate and repair


short to ground
on GY/V signal
wire.

7560

YES

NO

Install original
TP sensor, replace ECM
(reprogram and learn
password) and road test.

System
OK.

7595

7605

YES

NO

Locate and repair


open in
BK/W wire.

Locate and
repair open in
R/W wire.

7610

7570

7615

7565

Clear codes and confirm proper


operation with no check engine
lamp.

At some point in the flow chart you


may be instructed to jump directly
to the box marked by a bold asterisk. Disregard the asterisk (but not
the instruction box) if your normal
progression through the chart
brings you to this location.

2003 Touring: Engine Management (EFI)

5-87

HOME

Test 5.24 (Part 2 of 2)


TP SENSOR: DTC P0122, P0123

Continued from Test 5.24 (Part 1 of 2).


With ignition key OFF, disconnect Connector [78B].
Turn ignition key ON. Voltage greater than 0 volts across
Terminals 24 and 26 on Breakout Box?

YES

NO

Locate and repair


short between
GY/V signal wire
and 12 volts.

Measure resistance between


Terminal 24 on Breakout Box and
Socket C of Connector [88B].
Less than 0.5 ohm?

7575

YES

NO

Measure resistance
between Sockets C and B
on Connector [88B].
Less than 1.0 megohm?

Locate and repair


open on GY/V
signal wire.

YES

NO

Locate and repair


short between R/W
and GY/V signal
wires.

Replace
TP sensor.
7590

7585

Clear codes and confirm proper


operation with no check engine
lamp.

5-88

2003 Touring: Engine Management (EFI)

At some point in the flow chart you


may be instructed to jump directly
to the box marked by a bold asterisk. Disregard the asterisk (but not
the instruction box) if your normal
progression through the chart
brings you to this location.

7580

HOME

DTC P0261, P0262, P0263, P0264


GENERAL

5.25

s0472x9x

Fuel Injectors
The fuel injectors are solenoids that allow pressurized fuel
into the intake tract. The injectors are timed to the engine
cycle and triggered sequentially. The power for the injectors
comes from the system relay. The system relay also provides
power for the fuel pump and the ignition coil. The ECM provides the path to ground to trigger the injectors.
NOTE
ECM power fuse and EFI system relay failures or wiring harness problems will cause 12 volt power to be lost to both
injectors, ignition coils and fuel pump.

Figure 5-56. Fuel Injector Connector

HD34730-2C

Table 5-41. Code Description


DTC

LAMP
CODE

P0261

23

Front injector open/low

P0262

23

Front injector high

P0263

32

Rear injector open/low

P0264

32

Rear injector high

DESCRIPTION

Figure 5-57. Fuel Injector Test Lamp


(Part No. HD-34730-2C)

DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 5.25 flow charts.
1.

See FUEL INJECTORS, REMOVAL/INSTALLATION, in


the 2003 Touring Models Service Manual (Part Number
99483-03).

2.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), purple pin probe and patch cord.

3.

Connect a BREAKOUT BOX (Part No. HD-43876)


between EFI wire harness and ECM. See Section 5.7
BREAKOUT BOX: EFI.

4.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), gray socket probe and patch cord.

2003 Touring: Engine Management (EFI)

5-89

HOME

[62B]

f1973k9s

System
relay
[62B]

Y/GN

O/GY

[141B] [141A]

BK

AB

AB

W/BK

Y/BE
BE/O

C D

GY/BE

C D

[85B] [85A]

A B

Y/BE

A B

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Ignition
coil

[83B] [83A]

W/BK
BE/GY

GN/GY

15 amp
ECM fuse

W/Y

GY/BE
BE/O

12
11
10
9
8
7
6
5
4
3
2
1

Battery
R

W/BK
BK

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Y/GN

BE/GY

Coil F

Ion

[84B] [84A]

3 4

Inj. F

W/Y

15 amp
fuel pump
fuse

3 4

Inj. R

Y/GN

GN/O
AB

ECM

Fuel pump

[13A] [13B]

AB

Coil R

30 85 86

GN/O
W/BK

87A

BE/GY

87

Q C P R

[78B]

Y/GN

[78A]

12
11
10
9
8
7
6
5
4
3
2
1

BK

R/BK

BK

I BA

15 amp
IGN fuse
GY

Main circuit
breaker

[33B]
[33A]

Ignition
switch

W/BK
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

[8B] [8A]

[22A]
[22B]

BK

12-Place on
FLHP-I Only
BK
BK

Engine stop
switch

Figure 5-58. Battery Voltage Circuit Diagram (FLHR/C-I, FLHP-I)

Table 5-42. Wire Harness Connectors in Figure 5-58.

5-90

NO.

DESCRIPTION

TYPE

LOCATION

[8]

Ignition (Main to EFI Harness)

12-Place Deutsch (Gray)

Under Right Side Cover

[22]

Right Handlebar Switches

12-Place Deutsch (Black)

Inside Headlamp Nacelle

[33]

Ignition/Light Key Switch

3-Place Packard

Under Left Side Cover

[78]

ECM

36-Place Packard

Under Right Side Cover

[83]

Ignition Coil

4-Place Packard

Below Fuel Tank (Left Side)

[84]

Front Injector

2-Place Packard

Below Fuel Tank (Left Side)

[85]

Rear Injector

2-Place Packard

Below Fuel Tank (Left Side)

2003 Touring: Engine Management (EFI)

HOME

[62B]

f1973a9s

System relay

BE/GY
GN/O
W/BK

Y/GN

O/GY

[84B] [84A]

15 amp
fuel pump
fuse

W/Y

[141B] [141A]

BK
Y/GN

AB

AB

W/BK

Y/BE
BE/O

C D

GY/BE

C D

[85B] [85A]

A B

Y/BE

A B

Ignition
coil

[83B] [83A]

W/BK
BE/GY

GN/GY

15 amp
ECM fuse

W/Y

BK

GY/BE

BE/GY
BE/O

12
11
10
9
8
7
6
5
4
3
2
1

12
11
10
9
8
7
6
5
4
3
2
1

Battery
R

W/BK

Coil F

Y/GN

GN/O
AB

Ion

Fuel pump

[13A] [13B]

AB

Inj. F

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Inj. R

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

ECM

1 2 3 4 5 6 7

1 2 3 4 5 6 7
Coil R

87A
87
30 85 86

[78B]

I Q C P R

Y/GN

[78A]

BK

R/BK

BK

Main circuit
breaker

DCBA

[33B]
[33A]

15 amp
IGN fuse

Ignition
switch

GY
W/BK

12 11 10 9 8 7 6 5 4 3 2 1

BK

BK

[1B]
[1A]

12 11 10 9 8 7 6 5 4 3 2 1

[8B] [8A]

BK

[22A]
[22B]

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

Engine stop
switch
Figure 5-59. Battery Voltage Circuit Diagram (FLTR-I, FLHTC/U-I)

Table 5-43. Wire Harness Connectors in Figure 5-59.


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)

[33]

Ignition/Light Key Switch

4-Place Packard

Inner Fairing (Top Fork Bracket)

[78]

ECM

36-Place Packard

Under Right Side Cover

[83]

Ignition Coil

4-Place Packard

Below Fuel Tank (Left Side)

[84]

Front Injector

2-Place Packard

Below Fuel Tank (Left Side)

[85]

Rear Injector

2-Place Packard

Below Fuel Tank (Left Side)

2003 Touring: Engine Management (EFI)

5-91

HOME

Test 5.25 (Part 1 of 3)


FUEL INJECTORS: DTC P0261, P0262, P0263, P0264

Is wire bail on connector securely


attached to the fuel injector?

YES

NO

See Figure 5-57. Using Fuel


Injector Test Lamp, crank
engine. Does lamp flash?

Reconnect.
7785

YES

NO

Recheck connections.
Perform 5.8 WIGGLE TEST
to check for intermittents.
Intermittents present?

Check Socket A (Y/GN wire)


on Connector [84B]/[85B] to
ground. Voltage equivalent to
battery voltage for 2 seconds
after key ON?

YES

NO

Repair
intermittent.

7790

Measure resistance
of suspect injector
across injector
terminals. Is resistance
10-25 ohms?

YES

NO

STOP

Check for 12 volts at Terminal 87


of system relay during first 2
seconds after key ON.
Correct voltage present?

Go to Test 5.25 (Part 2 of 3).

YES

NO
YES

Check for loose


or corroded terminals
in harness.

NO

Replace
injector.
System relay OK. Measure
resistance between Terminal 87 of
system relay and Socket A
(Y/GN wire) of Connector [84B]/[85B].
Resistance less than 0.5 ohm?

7795
7790

YES

NO

Perform 5.8 WIGGLE TEST


to check for intermittents.
Repair as necessary.

Locate and repair


bad connection
or open wire.

7820

STOP
Go to Test 5.25
(Part 3 of 3).

7825

Clear codes and confirm proper


operation with no check engine
lamp.

5-92

2003 Touring: Engine Management (EFI)

HOME

Test 5.25 (Part 2 of 3)


FUEL INJECTORS: DTC P0261, P0262, P0263, P0264

2
3

FRONT INJECTOR: DTC P0261 or P0262.

REAR INJECTOR: DTC P0263 or P0264.

Measure resistance between Socket B of


Connector [84B] and Terminal 21 (W/Y wire)
on Breakout Box.

Measure resistance between Socket B of


Connector [85B] and Terminal 19 (GN/GY wire)
on Breakout Box.

2
3

Resistance
less than 0.5 ohm?

YES

NO

Check for continuity between


Terminal 10 on Breakout Box
and ground.

Locate and repair


open or poor
connection.
7805

Continuity present?

YES

NO

Front injector code: Check for


continuity between Terminals 10 and
21 on Breakout Box.
Rear injector code: Check for
continuity between Terminals 10 and
19 on Breakout Box.

Locate and
repair open.
7808

Continuity present?

YES

NO

Locate and
repair short
to ground.

With key on, check for voltage


to ground (Terminal 10 on
Breakout Box).

7808

Front injector code: Terminal 21


on Breakout Box.
Rear injector code: Terminal 19
on Breakout Box.
Voltage present after two seconds?

Clear codes and confirm proper


operation with no check engine
lamp.

YES

NO

Locate and
repair short
to voltage.

Replace ECM.
Reprogram and
learn password.

7809

7815

2003 Touring: Engine Management (EFI)

5-93

HOME

Test 5.25 (Part 3 of 3)


FUEL INJECTORS: DTC P0261, P0262, P0263, P0264

Continued from Test 5.25 (Part 1 of 3).


Check for 12 volts at Terminal 30 of system relay.
Correct voltage present?

YES

NO

Check for 12 volts at Terminal


86 of system relay.
Correct voltage present?

Locate and repair


open between
fuse and system relay.
7830

YES

NO

Measure resistance between


Terminal 86 of system
relay and Terminal 13 on
Breakout Box.
Resistance less than 0.5 ohm?

See Section 5.13 NO


ECM POWER.

YES

NO

Measure resistance between


Terminal 85 of system relay
and Terminal 4 on Breakout
Box.

Locate and
repair open on
W/BK wire.
7835

YES

NO

Install known good relay.


Does fuel pump run for first
2 seconds after key ON?

Locate and
repair open on
GN/O wire.
7840

YES

NO

Replace
system relay.

Reinstall original relay.

7845

Replace ECM. Reprogram


and learn password.
7850

Clear codes and confirm proper


operation with no check engine
lamp.

5-94

2003 Touring: Engine Management (EFI)

HOME

DTC P0373, P0374


GENERAL

5.26
f1692x8x

CKP Sensor
If the crank position sensor (CKP sensor) signal is weak or
absent, diagnostic trouble codes P0373 or P0374 will be set.
NOTE
If signal is not detected or cannot synchronize (DTC P0374),
engine will not start.

Table 5-44. Code Description


DTC

LAMP
CODE

P0373

41

CKP sensor intermittent

P0374

41

CKP sensor synch error

DESCRIPTION
Figure 5-60. CKP Sensor

f1916x9x

DIAGNOSTICS
Diagnostic Tips

Engine must be cranked for more than five seconds without CKP signal to set code.

With a fully charged battery and vehicle at room temperature, the Scanalyzer should display RPM in Data Monitor Mode while cranking. (A low voltage during cranking
may cause the Scanalyzer to reset). If RPM is present,
problem is intermittent.

Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 5.26 flow chart.
1.

Connect BREAKOUT BOX (Part No. HD-43876) to ECM


wire harness only (leave ECM disconnected). See Section 5.7 BREAKOUT BOX: EFI.

2.

One megohm is very high resistance. Some meters will


read , OL, etc.

3.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), brown socket probes and patch cords.

4.

For testing purposes, install sensor without running wiring along normal path. Disconnect and route wiring properly if system is now OK.

Crankshaft Position
Sensor [79]

Oil Pressure
Sending Unit [140]

Figure 5-61. CKP Sensor Connector Location

2003 Touring: Engine Management (EFI)

5-95

HOME

s0453x9x

[78B]
[78A]

BK

BK

BK

[79A]
[79B]

BK

CKP
sensor

10

12

28

30

ECM

Figure 5-62. CKP Circuit

Table 5-45. Wire Harness Connectors in Figure 5-62.


NO.

5-96

DESCRIPTION

[78]

ECM

[79]

CKP Sensor

2003 Touring: Engine Management (EFI)

TYPE

LOCATION

36-Place Packard

Under Right Side Cover

2-Place Mini-Deutsch

Under Right Side Cover

HOME

Test 5.26
CKP SENSOR: DTC P0373, P0374

1
2

Connect Breakout Box to harness only


leaving ECM disconnected. Measure resistance
between Terminals 30 and 28 and between
Terminals 12 and 28 on Breakout Box.
Resistance more than 1 megohm?

YES

NO

Check for intermittent connection, pinched


or damaged wires, and loose or missing
CKP sensor fastener. Conditions found?

Disconnect Connector [79]. Leaving


ECM disconnected, measure resistance
between Terminals 12 and 28 and
between Terminals 30 and 28 on Breakout Box. Continuity to ground
(less than 1 megohm resistance)?

YES

NO

Repair as
necessary.

Connect DVOM to Pins 12 and 30


on Breakout Box.
Set DVOM to AC volts and crank engine.
Does DVOM read 1 VAC minimum
during cranking?

7980

YES

YES

NO

Repair short to
ground on R or
BK wire between
Connectors [78B]
and [79B].

Replace
CKP sensor.

NO

With DVOM or Scanalyzer still


connected, check for intermittents
using 5.8 WIGGLE TEST.
Intermittents present?

YES

7981

7980

Connect DVOM at
Pins 1 and 2 of Connector [79A].
Does DVOM read 1 VAC
minimum while cranking?

NO

Repair as
necessary.

7982

Install known good CKP


sensor. Clear codes
and retest. DTC P0373
or P0374 set?

YES

NO

Reinstall original
CKP sensor. Replace
ECM. Reprogram
and learn password.

Replace
CKP sensor.

7983

7984

YES

NO

Check for continuity between


Socket 1 of Connector [79B]
and Terminal 30 on
Breakout Box.
Continuity present?

Replace
CKP sensor.
7985

YES

NO

Repair open on BK wire


between Socket 2 of
Connector [79B] and
Terminal 12 on Breakout Box.

Repair open on R wire


between Socket 1 of
Connector [79B] and
Terminal 30 on Breakout Box.

7986

7987

Clear codes and confirm proper


operation with no check engine
lamp.

2003 Touring: Engine Management (EFI)

5-97

HOME

DTC P0501, P0502

5.27

GENERAL
7951

Vehicle Speed Sensor


See Figure 5-63. The vehicle speed sensor is powered and
monitored by the speedometer. The speedometer sends a
vehicle speed signal (9000 pulses/mile) to the ECM. The
ECM processes the vehicle speed signal and transmits this
signal to the TSM/TSSM through the serial data line.
NOTE
When the vehicle speed signal is greater than 0, the idle
speed control is inhibited.

Table 5-46. Code Description


DTC

LAMP
CODE

P0501

43

VSS sensor low

P0502

43

VSS sensor high

DESCRIPTION

Figure 5-63. Speedometer Speed Sensor

HD41354

DIAGNOSTICS
Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 5.27 flow charts.
1.

The speedometer has a built-in diagnostic mode.


a.

To enter diagnostic mode, depress odometer reset


switch and turn ignition switch to IGN.

b.

To clear codes, depress odometer reset switch and


hold for ten seconds.

c.

2.

3.

See Figure 5-64. Check system using SPEEDOMETER


TESTER (Part No. HD-41354). Enter the number 70 to
simulate 3 MPH. If tester is not available, elevate the rear
wheel and spin briskly while looking for a voltage drop.

4.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), black pin probe and patch cord.

To return speedometer to normal operating mode,


cycle ignition switch.

Connect BREAKOUT BOX (Part No. HD-43876)


between wire harness and ECM. See Section 5.7 BREAKOUT BOX: EFI.

5-98

Figure 5-64. Speedometer Tester

2003 Touring: Engine Management (EFI)

HOME

f1973c9s

Radio

23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

[2A]
[2B]

12 11 10 9 8 7 6 5 4 3 2 1

Speedometer

[27A]
[27B]

W/GN

12 11 10 9 8 7 6 5 4 3 2 1

[39A]
[39B]

Speedometer
sensor

11

10

C
D
E
F
G

Cruise Control
Module

BK

BK

W/GN

[8A]
[8B]

[17B] [17A]

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

W/GN

[65A] [65B]

[78B]
[78A]

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

ECM

Figure 5-65. Vehicle Speed Sensor Circuit (FLTR-I, FLHTC/U-I)

Table 5-47. Wire Harness Connectors in Figure 5-65.


NO.

DESCRIPTION

MODEL

TYPE

LOCATION

[2]

Main to Interconnect Harness

All

12-Place Deutsch
(Gray)

Inner Fairing (Right Radio Support


Bracket)

[8]

Ignition (Main to EFI Harness)

All

12-Place Deutsch
(Gray)

Under Right Side Cover

[17]

Cruise Control Module

All

10-Place Packard

Under Left Side Cover

[27]

Radio

All

23-Place Amp (Black)

Inner Fairing -Back of Radio (Right Side)

[39]

Speedometer

FLTR-I

12-Place Packard

Under Instrument Bezel


(Back of Speedometer)

FLHTC/U-I

12-Place Packard

Inner Fairing (Back of Speedometer)

[65]

Speedometer Speed Sensor

All

3-Place Deutsch

Upper Frame Crossmember


(Under Seat)

[78]

ECM

All

36-Place Packard

Under Right Side Cover

2003 Touring: Engine Management (EFI)

5-99

HOME

f1973b9s

Speedometer

[39A]
[39B]

Speedometer
sensor

12

C
D
E
F
G
H

BK

BK

J
K

W/GN

[8A]
[8B]

12 11 10 9 8 7 6 5 4 3 2 1

[17B] [17A]

12 11 10 9 8 7 6 5 4 3 2 1

W/GN

[65A] [65B]

Cruise Control
Module

[78B]
[78A]

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

ECM

Figure 5-66. Vehicle Speed Sensor Circuit (FLHR/C-I)

Table 5-48. Wire Harness Connectors in Figure 5-66.


NO.

DESCRIPTION

[8]

Ignition (Main to EFI Harness)

[17]

Cruise Control Module

[39]

Speedometer

[65]
[78]

TYPE

LOCATION

12-Place Deutsch (Gray)

Under Right Side Cover

10-Place Packard

Under Left Side Cover

12-Place Mini-Deutsch

Back of Speedometer (Under Console)

Speedometer Speed Sensor

3-Place Deutsch

Upper Frame Crossmember (Under Seat)

ECM

36-Place Packard

Under Right Side Cover

5-100 2003 Touring: Engine Management (EFI)

HOME

Test 5.27 (Part 1 of 2)


VEHICLE SPEED SENSOR: DTC P0501, P0502

Does speedometer
operate properly?

YES

NO

Place speedometer into diagnostic


mode and clear fault codes. Connect
all circuits and ride motorcycle for
approximately 1 mile (1.6 km). Check
for new logged codes.
Codes present?

See Speedometer Test


2A under Section 2.2
SPEEDOMETER.

YES

NO

See Speedometer Test


2A under Section 2.2
SPEEDOMETER.

2
3

Connect Scanalyzer to Connector [91A].


Place Scanalyzer in Data Monitor Mode.
Jack up rear wheel and rotate faster than 3 MPH.
Is vehicle speed registered on display?

YES

NO

Clear codes. Clear


debris off speedometer
sensor. Retest.

STOP

7954

Clear codes and confirm proper


operation with no check engine
lamp.

Go to Test 5.27 (Part 2 of 2).

At some point in the flow chart you


may be instructed to jump directly
to the box marked by a bold asterisk. Disregard the asterisk (but not
the instruction box) if your normal
progression through the chart
brings you to this location.

2003 Touring: Engine Management (EFI) 5-101

HOME

Test 5.27 (Part 2 of 2)


VEHICLE SPEED SENSOR: DTC P0501, P0502

Continued from Test 5.27 (Part 1 of 2).


Verify that speedometer is connected and ignition switch
is turned to IGNITION. Check for voltage on Terminal 33 of
Breakout Box while rotating tire faster then 3 MPH.
Does voltage match specifications?

Rear wheel rotating: 3-6 volts.


Rear wheel stationary: 9-11 volts.

YES

NO

Disconnect Connector [78]. Inspect


for damaged terminals, terminals
backed out or corrosion. Terminal
problems present?

Disconnect Connector [78]. Inspect


for damaged terminals, terminals
backed out or corrosion. Terminal
problems present?

YES

NO

YES

NO

Repair terminal
damage.

Reconnect. Problem
still exist?

Repair terminal
damage.

Reconnect Connector
[78]. Problem still
exist?

7956

YES

Replace ECM.
Reprogram and learn
password.

7959

NO

YES

NO

Problem
fixed.

Disconnect Connectors
[78] and [39]. Check for continuity
to ground on W/GN wire.
Continuity present?

Problem
fixed.

7958

7957

YES

NO

Locate and repair


short to ground
on W/GN wire.

Check for continuity on W/GN


wire between Connector [39] and
Terminal 33 on Breakout Box.
Continuity present?

7962

YES

NO

Replace
speedometer.

Locate and
repair open.

7963

Clear codes and confirm proper


operation with no check engine
lamp.

5-102 2003 Touring: Engine Management (EFI)

At some point in the flow chart you


may be instructed to jump directly
to the box marked by a bold asterisk. Disregard the asterisk (but not
the instruction box) if your normal
progression through the chart
brings you to this location.

7964

7961

HOME

DTC P0562, P0563

5.28

GENERAL
f2023x9x

Battery Voltage
Battery voltage is constantly monitored by the ECM (Pin 13).
If the battery voltage fails to meet normal operating parameters, a code is set.

Code P0562 is displayed when battery positive voltage is


less than 11.0 volts at 2000 RPM for longer than 5 seconds.

Code P0563 is displayed when battery positive voltage is


greater than 16.0 volts for more than 4 seconds.

NOTES
Warm idle speed will be automatically increased if battery voltage is low at idle.

TSSM problems may also set a code P0562 or P0563.

Table 5-49. Code Description


DTC

LAMP
CODE

P0562

16

Battery voltage low

P0563

16

Battery voltage high

DESCRIPTION

Ignition
Fuse
Figure 5-67. Left Side Cover Removed
(FLTR, FLHT/C)

Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 5.28 flow charts.
1.

Low voltage generally indicates a loose wire, corroded


battery connections and/or a charging system problem.

A high voltage condition may be caused by a shorted


stator (check when hot) or faulty voltage regulator.

Yes. Charge battery.

b.

No. See charging system troubleshooting.

Connect BREAKOUT BOX (Part No. HD-43876)


between wire harness and ECM. See Section 5.7 BREAKOUT BOX: EFI.

3.

Use Scanalyzer Data Monitor Mode to check RPM on


vehicles without tachometers.

4.

This checks for voltage drops in the ignition module circuit.


a.

Place (+) probe to battery positive terminal.

b.

Place (-) probe to W/BK terminal on Breakout Box.

5.

Problem is most likely the ground connection at the


frame.

6.

Connect BREAKOUT BOX (Part No. HD-42682) to Connector [22]. FLHR/C-I models will also need HD-42962
adapters.

Scanalyzer Notes
The Scanalyzer icon appears at those points in the flow chart
where the Scanalyzer can be used.

a.
2.

DIAGNOSTICS
Diagnostic Tips

Was battery allowed to discharge? Was battery drawn


down by a starting problem?

2003 Touring: Engine Management (EFI) 5-103

HOME

f1973d9s

[62B]

BE/GY
GN/O
W/BK

BK

W/BK

Main circuit
breaker

15 amp
ECM fuse

Battery
BK

W/BK

BK

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

GN/O

BK

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

System relay

BE/GY

1 2 3 4 5 6 7

ECM

I Q C P R

[78B]

87A
87
30 85 86

Y/GN

[78A]

12
11
10
9
8
7
6
5
4
3
2
1

12
11
10
9
8
7
6
5
4
3
2
1

R/BK
I BA

15 amp
IGN fuse
GY

[33B]
[33A]

Ignition
switch

W/BK
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

[8B] [8A]

[22A]
[22B]

12-Place on
FLHP-I Only

Engine stop
switch

BK

Figure 5-68. Battery Voltage Circuit Diagram (FLHR/C-I, FLHP-I)

Table 5-50. Wire Harness Connectors in Figure 5-68.


NO.

DESCRIPTION

[8]

Ignition (Main to EFI Harness)

[22]

Right Handlebar Switches

[33]
[78]

TYPE

LOCATION

8-Place Deutsch (Gray)

Under Right Side Cover

12-Place Deutsch (Black)

Inside Headlamp Nacelle

Ignition/Light Key Switch

3-Place Packard

Under Left Side Cover

ECM

36-Place Packard

Under Right Side Cover

5-104 2003 Touring: Engine Management (EFI)

HOME

f1973j9s

[78A]

[78B]
[62B]
87A

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

15 amp
ECM fuse

Battery
BK

W/BK

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

W/BK

BK

BK

BK

System relay

BE/GY

3 4

30 85 86

3 4

Q C P R

GN/O

ECM

BE/GY
GN/O
W/BK

87

Y/GN

12
11
10
9
8
7
6
5
4
3
2
1

12
11
10
9
8
7
6
5
4
3
2
1

Main circuit
breaker

R/BK
DCBA

[33B]
[33A]

15 amp
IGN fuse

Ignition
switch

GY
W/BK

12 11 10 9 8 7 6 5 4 3 2 1

[8B] [8A]

[1B]
[1A]

12 11 10 9 8 7 6 5 4 3 2 1

[22A]
[22B]

12 11 10 9 8 7 6 5 4 3 2 1

BK

12 11 10 9 8 7 6 5 4 3 2 1

Engine stop
switch
Figure 5-69. Battery Voltage Circuit Diagram (FLTR-I, FLHTC/U-I)

Table 5-51. Wire Harness Connectors in Figure 5-69.


NO.

DESCRIPTION

TYPE

LOCATION

[1]

Main to Interconnect Harness

12-Place Deutsch (Black)

Inner Fairing (Right Fairing Bracket)

[8]

Ignition (Main to EFI Harness)

8-Place Deutsch (Gray)

Under Right Side Cover

[22]

Right Handlebar Switches

12-Place Deutsch (Black)

Inner Fairing (Right Fairing Support Brace)

[33]

Ignition/Light Key Switch

4-Place Packard

Inner Fairing (Top Fork Bracket)

[78]

ECM

36-Place Packard

Under Right Side Cover

2003 Touring: Engine Management (EFI) 5-105

HOME

Test 5.28 (Part 1 of 2)


BATTERY VOLTAGE: DTC P0562, P0563

2
3

Perform charging system tests.


Charging system OK?

YES

NO

Connect Breakout Box. With engine


running at 2000 RPM or higher for 10
seconds or longer, measure voltage
between Terminals 13 and 10 and
between Terminals 13 and 28
on Breakout Box.
Is voltage above 11.0 volts?

Repair charging system.


See Section 1 of this manual.

YES

NO

System
OK.

With ignition ON, measure voltage drop


between battery positive (+) terminal
and Terminal 13 (-) on Breakout Box.
Is voltage drop greater than 0.5 volt?

7770

YES

NO

With ignition ON, measure voltage


drop between battery positive (+)
terminal and Terminal 4 (-) on Breakout Box. Is voltage drop greater
than 0.5 volt?

Measure voltage drop between


battery negative (-) terminal and
Terminal 10 (+) on Breakout Box and
between battery negative (-) terminal
and Terminal 28 on Breakout Box. Is
voltage drop greater than 0.5 volt?

YES

NO

With ignition ON, measure voltage drop


between battery positive (+) terminal
and Terminal 3 (-) on Breakout Box.
Is voltage drop greater than 0.5 volt?

Replace W/BK wire


or terminals between
Connectors [22A]
and [78B].

YES

NO

Locate and repair


bad connection.

Problem is intermittent.
Perform 5.8 WIGGLE
TEST. Locate and
repair bad connection.

7775
7776

7310

YES

STOP

NO

Inspect Connector [22] for


corrosion or loose wires. If
conditions are not present,
replace engine stop switch.

Go to Test 5.28 (Part 2 of 2).

5-106 2003 Touring: Engine Management (EFI)

7781

Clear codes and confirm proper


operation with no check engine
lamp.

HOME

Test 5.28 (Part 2 of 2)


BATTERY VOLTAGE: DTC P0562, P0563

Continued from Test 5.28 (Part 1 of 2).


With ignition ON, measure voltage drop between battery positive (+) terminal and GY terminal of 15 amp
ignition fuse (-). Is voltage drop greater than 0.5 volt?

YES

NO

With ignition ON, measure voltage drop


between battery positive (+) terminal and
R/BK terminal of 15 amp ignition fuse. Is
voltage drop greater than 0.5 volt?

Replace GY wire
or terminals.

YES

NO

With ignition ON, measure voltage drop


between battery positive (+) terminal and
silver post of main circuit breaker (-).
Is voltage drop greater than 0.5 volt?

Replace fuse or
fuse terminals.

YES

NO

With ignition ON, measure voltage drop


between battery positive (+) terminal and
copper post of main circuit breaker (-).
Is voltage drop greater than 0.5 volt?

Replace ignition
switch or terminals.

7780

7782

7783

YES

NO

High resistance between 40 amp


circuit breaker and battery. Replace
wire or terminals.

Replace circuit
breaker.
7779

7784

Clear codes and confirm proper


operation with no check engine
lamp.

2003 Touring: Engine Management (EFI) 5-107

HOME

DTC P0603, P0605

5.29

GENERAL

DIAGNOSTICS

ECM Failure

DTC P0603 Test

See Table 5-52. The codes indicate a failure that requires


replacement of the ECM (Job Time Code 7913). See ELECTRONIC CONTROL MODULE, REMOVAL/INSTALLATION,
in the 2003 Touring Models Service Manual (Part Number
99483-03).

Table 5-52. Code Description


DTC

LAMP
CODE

DESCRIPTION

P0603

54

ECM EEPROM error

P0605

53

ECM flash error

5-108 2003 Touring: Engine Management (EFI)

1.

Power down the vehicle.

2.

Clear codes using Scanalyzer.

3.

Replace ECM if codes reappear.

DTC P0605 Test


1.

Power down the vehicle.

2.

Clear codes using Scanalyzer.

3.

Attempt to reprogram ECM using correct calibration.

4.

Restart vehicle. If code reappears, replace ECM.

5.

Perform password learn and code clearing.

HOME

DTC P1009, P1010

5.30

GENERAL

Data Link
Connector [91A]

Password Problem
The ECM and TSM/TSSM exchange passwords during operation. An incorrect password or missing password will set a
diagnostic code.
NOTE
If the TSM/TSSM is not connected to the wiring harness, the
vehicle will not start.

Table 5-53. Code Description


DTC

LAMP
CODE

P1009

99

Incorrect password

P1010

99

Missing password

DESCRIPTION

f1917x9x

Figure 5-70. Right Side Cover Removed

DIAGNOSTICS

7844

Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 5.30 flow charts.
1.

DTC P1009 may be set if a recent ECM or TSM/TSSM


replacement did not follow the correct password assignment procedure. See Section 3.24 TSM/TSSM for
details.

2.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), black socket probes and patch cord.

3.

Connect BREAKOUT BOX (Part No. HD-43876)


between wire harness and ECM. See Section 5.7 BREAKOUT BOX: EFI.

4.

See TURN SIGNAL/SECURITY MODULE, REMOVAL/


INSTALLATION, in the 2003 Touring Models Service
Manual (Part Number 99483-03). If necessary, be sure to
reference the Electrical Diagnostic Manual for the password learn routine (Scanalyzer menu refers to this function as module replacement).

Figure 5-71. TSM/TSSM Module

2003 Touring: Engine Management (EFI) 5-109

HOME

GY/Y

f1973e9s

[30B]
[30A]
[8A]
[8B]

1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

TSM/TSSM
Module

1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

Data Link
Connector
1

LtGN/R
BK
LtGN/V
GY

[91A] [91B]

LtGN/R

LtGN/V

12V

[78B]
[78A]

Scanalyzer

ECM

Figure 5-72. ECM and TSM/TSSM Circuit

Table 5-54. Wire Harness Connectors in Figure 5-72.


NO.

DESCRIPTION

TYPE

LOCATION

[8]

Ignition (Main to EFI Harness)

12-Place Deutsch (Gray)

Under Right Side Cover

[30]

TSM/TSSM

12-Place Deutsch

Cavity in Crossmember
at Rear of Battery Box (Under Seat)

[78]

ECM

36-Place Packard

Under Right Side Cover

[91]

Data Link

4-Place Deutsch

Under Right Side Cover

5-110 2003 Touring: Engine Management (EFI)

HOME

Test 5.30
PASSWORD PROBLEM: DTC P1009, P1010

Which diagnostic trouble


code was set?

1
4

DTC P1009.
Bad password.
Reprogram password.
See Section 3.24 TSM/
TSSM.
DTC P1009 still exist?

DTC P1010.
No password.
Are there any
U-codes set?

YES

YES

NO

Replace TSSM and


relearn password.
System OK?

System
OK.

Troubleshoot
lowest U-code.

Remove Connector [78].


Check for continuity to ground at
Pin 3 of Connector [91A].
Continuity present?

6701

YES

NO

System
OK.

NO

Reinstall original TSSM


and replace ECM.
Reprogram and
relearn password.

4
6702

YES

NO

Locate and repair


short to ground.

Check for battery voltage


on Pin 3 of Connector [91A].
Battery voltage present?

6704

6703

YES

NO

Locate and repair


short to voltage.
6705

Check for continuity between


Pin 3 of Connector [91A]
and Terminal 5 on Breakout Box.
Continuity present?

YES

NO

Replace TSM/TSSM and


relearn password.
System OK?

Inspect terminals
for damage or repair
opens as necessary.

6706

YES

NO

System
OK.
6707

Reinstall original TSSM


and replace ECM.
Reprogram and
relearn password.
6708

2003 Touring: Engine Management (EFI) 5-111

HOME

DTC P1351, P1352, P1354, P1355


GENERAL

5.31

7863

Ignition Coil
Ignition coil codes will set if the ignition coil primary voltage is
out of range. This could occur if there is an open coil or loss of
power to the coil. If front and rear codes are set simultaneously, it is likely a coil power failure or a coil failure.
The coil receives power from the system relay at the same
time that the fuel pump and injectors are activated. The system relay is active for the first 2 seconds after the ignition
switch is turned ON and then shuts off until RPM is detected
from the CKP sensor, at which time it is reactivated. The ECM
is responsible for turning on the system relay by providing the
ground to activate the relay, which in turn powers the coil.
Figure 5-73. Ignition Coil Circuit Test

Table 5-55. Code Description


DTC

LAMP
CODE

P1351

24

Front ignition coil open/low

P1352

24

Front ignition coil high/shorted

P1354

25

Rear ignition coil open/low

P1355

25

Rear ignition coil high/shorted

DESCRIPTION

s0475x9x

D
C
B
A

DIAGNOSTICS
Diagnostic Notes

Figure 5-74. Ignition Coil Connector Terminals

The reference numbers below correlate with the circled numbers on the Test 5.31 flow charts.
1.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), gray pin probes and patch cord.

2.

See Figure 5-73. Plug IGNITION COIL CIRCUIT TEST


ADAPTER (Part No. HD-44687) and FUEL INJECTOR
TEST LAMP (Part No. HD-34730-2C) into Breakout Box.
Note that cranking the engine with test lamp in place of
the ignition coil can sometimes cause a DTC P1351,
P1352, P1354 or P1355. This condition is normal and
does not by itself indicate a malfunction. Clear codes
afterward.

5-112 2003 Touring: Engine Management (EFI)

3.

Connect BREAKOUT BOX (Part No. HD-43876)


between EFI wire harness and ECM. See Section 5.7
BREAKOUT BOX: EFI.

4.

Use HARNESS CONNECTOR TEST KIT (Part No. HD41404), gray socket probes and patch cord.

HOME

[62B]

f1973k9s

System
relay
[62B]

Y/GN

O/GY

[141B] [141A]

BK

AB

AB

W/BK

Y/BE
BE/O

C D

GY/BE

C D

[85B] [85A]

A B

Y/BE

A B

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Ignition
coil

[83B] [83A]

W/BK
BE/GY

GN/GY

15 amp
ECM fuse

W/Y

GY/BE
BE/O

12
11
10
9
8
7
6
5
4
3
2
1

Battery
R

W/BK
BK

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Y/GN

BE/GY

Coil F

Ion

[84B] [84A]

3 4

Inj. F

W/Y

15 amp
fuel pump
fuse

3 4

Inj. R

Y/GN

GN/O
AB

ECM

Fuel pump

[13A] [13B]

AB

Coil R

30 85 86

GN/O
W/BK

87A

BE/GY

87

Q C P R

[78B]

Y/GN

[78A]

12
11
10
9
8
7
6
5
4
3
2
1

BK

R/BK

BK

I BA

15 amp
IGN fuse
GY

Main circuit
breaker

[33B]
[33A]

Ignition
switch

W/BK
12 11 10 9 8 7 6 5 4 3 2 1

[22A]
[22B]

12 11 10 9 8 7 6 5 4 3 2 1

[8B] [8A]

12-Place on
FLHP-I Only
BK

BK

Engine stop
switch

BK

Figure 5-75. Battery Voltage Circuit Diagram (FLHR/C-I, FLHP-I)

Table 5-56. Wire Harness Connectors in Figure 5-75.


NO.

DESCRIPTION

[8]

Ignition (Main to EFI Harness)

[22]

Right Handlebar Switches

[33]

TYPE

LOCATION

8-Place Deutsch (Gray)

Under Right Side Cover

12-Place Deutsch (Black)

Inside Headlamp Nacelle

Ignition/Light Key Switch

3-Place Packard

Under Left Side Cover

[78]

ECM

36-Place Packard

Under Right Side Cover

[83]

Ignition Coil

4-Place Packard

Below Fuel Tank (Left Side)

[84]

Front Injector

2-Place Packard

Below Fuel Tank (Left Side)

[85]

Rear Injector

2-Place Packard

Below Fuel Tank (Left Side)

2003 Touring: Engine Management (EFI) 5-113

HOME

[62B]

f1973a9s

System relay

BE/GY
GN/O
W/BK

Y/GN

O/GY

[84B] [84A]

15 amp
fuel pump
fuse

W/Y

[141B] [141A]

BK
Y/GN

AB

AB

W/BK

Y/BE
BE/O

C D

GY/BE

C D

[85B] [85A]

A B

Y/BE

A B

Ignition
coil

[83B] [83A]

W/BK
BE/GY

GN/GY

15 amp
ECM fuse

W/Y

BK

GY/BE

BE/GY
BE/O

12
11
10
9
8
7
6
5
4
3
2
1

12
11
10
9
8
7
6
5
4
3
2
1

Battery
R

W/BK

Coil F

Y/GN

GN/O
AB

Ion

Fuel pump

[13A] [13B]

AB

Inj. F

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Inj. R

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

ECM

1 2 3 4 5 6 7

1 2 3 4 5 6 7
Coil R

87A
87
30 85 86

[78B]

I Q C P R

Y/GN

[78A]

BK

R/BK

BK

Main circuit
breaker

DCBA

15 amp
IGN fuse

[33B]
[33A]

Ignition
switch

GY
W/BK

12 11 10 9 8 7 6 5 4 3 2 1

[8B] [8A]

BK

BK

[1B]
[1A]

12 11 10 9 8 7 6 5 4 3 2 1

BK

[22A]
[22B]

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

Engine stop
switch
Figure 5-76. Battery Voltage Circuit Diagram (FLTR-I, FLHTC/U-I)

Table 5-57. Wire Harness Connectors in Figure 5-76.


NO.

DESCRIPTION

TYPE

LOCATION

[1]

Main to Interconnect Harness

12-Place Deutsch (Black)

Inner Fairing (Right Fairing Bracket)

[8]

Ignition (Main to EFI Harness)

8-Place Deutsch (Gray)

Under Right Side Cover

[22]

Right Handlebar Switches

12-Place Deutsch (Black)

Inner Fairing (Right Fairing Support Brace)

[33]

Ignition/Light Key Switch

4-Place Packard

Inner Fairing (Top Fork Bracket)

[78]

ECM

36-Place Packard

Under Right Side Cover

[83]

Ignition Coil

4-Place Packard

Below Fuel Tank (Left Side)

[84]

Front Injector

2-Place Packard

Below Fuel Tank (Left Side)

[85]

Rear Injector

2-Place Packard

Below Fuel Tank (Left Side)

5-114 2003 Touring: Engine Management (EFI)

HOME

Test 5.31 (Part 1 of 2)


IGNITION COIL: DTC P1351, P1352, P1354, P1355

Disconnect Connector [83]. Measure


voltage on Socket A of Connector [83B].
Is voltage equal to battery voltage during
first 2 seconds after key ON?

YES

NO

Use Breakout Box and test light


for the next inspection.

Front coil code: Check between


Terminals 29 and 13 on Breakout Box.

STOP
Go to Test 5.31
(Part 2 of 2).

Rear coil code: Check between


Terminals 11 and 13 on Breakout Box.
Does test lamp flash
when engine is cranked?

YES

NO

Measure ignition coil resistance.

Measure voltage at system


relay Terminal 30 during first
2 seconds after key ON?
Voltage equivalent
to battery voltage?

Front coil code: Check between


Pins A and D of Connector [83A].
Rear coil code: Check between
Pins A and C of Connector [83A].
Resistance 0.3-0.5 ohms?

YES

NO

YES

NO

Locate and repair


open wire or connection
on Y/GN wire.

Check for multiple codes.


See MULTIPLE TROUBLE
CODES under Section 5.4
CHECKING FOR TROUBLE
CODES: EFI.

7875

STOP

Replace
ignition coil.

7880

7856

Go to Test 5.31
(Part 2 of 2).

Clear codes and confirm proper


operation with no check engine
lamp.

2003 Touring: Engine Management (EFI) 5-115

HOME

Test 5.31 (Part 2 of 2)


IGNITION COIL: DTC P1351, P1352, P1354, P1355

Continued from Test 5.31 (Part 1 of 2).


Using Breakout Box, measure resistance between
ECM and ignition coil terminals as follows:

1
3

DTC

IGNITION
COIL

BREAKOUT
BOX

P1351/P1352

D
(BE/O wire)

29

P1353/P1354

C
(Y/BE wire)

11

Resistance less than 0.5 ohms?

YES

NO

Perform 5.8 WIGGLE TEST


to check for intermittents.
Intermittents present?

Locate and repair


open wire
or connection.
7860

YES

NO

Locate and repair


intermittent.

Check for continuity to ground.


Front coil code: Check
Terminal 29 on Breakout Box.

7865

Rear coil code: Check


Terminal 11 on Breakout Box.
Continuity present?

YES

NO

Locate and
repair short
to ground.

Check for voltage.


Front coil code: Check
Terminal 29 on Breakout Box.

7853

Rear coil code: Check


Terminal 11 on Breakout Box.
Voltage present?

YES

NO

Locate and
repair short
to voltage.

Replace ECM.
Reprogram and
learn password.

7854

7870

Clear codes and confirm proper


operation with no check engine
lamp.

5-116 2003 Touring: Engine Management (EFI)

HOME

DTC P1653, P1654

5.32

GENERAL
Tachometer
Gauge [108]

Tachometer
Tachometers may be OE installed or as a customer purchased accessory item. Any damage to the tachometers PK
wire could set a code even without an installed tachometer.
NOTE
The system cannot diagnose an open wire. It can only detect
a short high or low.

Table 5-58. Code Description


DTC

LAMP
CODE

P1653

35

Tachometer low

P1654

35

Tachometer high

DESCRIPTION

f2040x8x

DIAGNOSTICS

Figure 5-77. Outer Fairing Removed

Diagnostic Notes
The reference numbers below correlate with the circled numbers on the Test 5.32 flow charts.
1.

Consult the instruction sheet which accompanied the


tachometer kit.

2003 Touring: Engine Management (EFI) 5-117

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15 amp
instruments fuse

f1973g9x

R/BK

To splices
in harness
[108C] [108D] FLHP-I Only

To fuel
gauge

[108A] [108B] FLTR-I, FLHTC/U-I Only


To indicator
lamps

PK
BK

BK

PK

A
[108A]

[108B] [108A]
FLHP-I Only

Tachometer

FLHR/C-I
Only

BK

10

BK

PK

1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

ECM

[8A]
[8B]

[78B]
[78A]

28

Figure 5-78. Tachometer Circuit

Table 5-59. Wire Harness Connectors in Figure 5-78.


NO.

DESCRIPTION

MODEL

TYPE

LOCATION

[8]

Ignition (Main to EFI Harness)

All

12-Place Deutsch (Gray)

Under Right Side Cover

[78]

ECM

All

36-Place Packard

Under Right Side Cover

FLHR/C-I

1-Place Amp

Inside Headlamp Nacelle

FLTR-I

6-Place Packard

Inside Instrument Nacelle


(Back of Tachometer)

FLHTC/U-I

6-Place Packard

Inner Fairing (Back of Tachometer)

[108]

Tachometer

5-118 2003 Touring: Engine Management (EFI)

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Test 5.32
TACHOMETER: DTC P1653, P1654

Install Breakout Box to harness


but leave ECM unplugged. Disconnect
Connector [108]. With ignition ON, measure
voltage across Terminals 3 (+) and 10 (-)
on Breakout Box. Battery voltage present?

YES

NO

Check for continuity


between Sockets 1 and 3
of Connector [108B].
Continuity present?

Check for continuity


between Terminals 3 and 10
on Breakout Box.
Continuity present?

YES

NO

YES

NO

Locate and repair


short to voltage.

Reconnect ECM. Start engine.


With ignition ON, measure voltage
across Terminals 3 (+) and
10 (-) on Breakout Box.
Battery voltage present?

Locate and repair short


to ground on PK wire
between Connectors
[78B] and [108B].

Reconnect Connector
[108]. Check resistance
between Terminals 3 and
10 on Breakout Box.
Resistance less than
5,000 ohms?

7884

YES

NO

Use 5.8 WIGGLE TEST


to locate intermittents.

Replace ECM.
Reprogram and
learn password.

7881

7882

7886

YES

NO

Replace
tachometer.

Disconnect Connector [78].


Inspect for damaged terminals,
terminals backed out or corrosion.
Terminal problems present?

7883

YES

NO

Repair terminal
damage.

Reconnect Connector
[78]. Problem still
exist?

7878

Clear codes and confirm proper


operation with no check engine
lamp.
YES

NO

Replace ECM.
Reprogram and
learn password.

Problem
fixed.
7879

7882

2003 Touring: Engine Management (EFI) 5-119

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DTC U1016, U1064, U1255

5.33

GENERAL
Loss of TSM/TSSM or ECM Serial Data
On fuel injected motorcycles the serial data connector provides a means for the ECM and TSM/TSSM to communicate
their current status. When all operating parameters on the
serial data link are within specifications, a state of health
message is sent between the components. While a DTC
U1016 indicates that the ECM is not receiving this state of
health message, a DTC U1064 indicates that the TSM/TSSM
is not receiving.

Table 5-60. Code Description


DTC

LAMP
CODE

U1064

61

7844

DESCRIPTION
Figure 5-79. TSM/TSSM Module
Loss of TSM/TSSM serial data
6924

DIAGNOSTICS
4

1
5

Diagnostic Notes
3
The reference numbers below correlate with the circled numbers on the Test 5.33 flow chart.
1.

Connect BREAKOUT BOX (Part No. HD-43876)


between wire harness and ECM. See Section 5.7 BREAKOUT BOX: EFI.

2.

Connect BREAKOUT BOX (Part No. HD-42682)


between wire harness and TSM/TSSM. See Section
3.10 BREAKOUT BOX: TSM/TSSM.

1.
2.
3.
4.
5.

Terminal 1: flash pin (Lt GN/R)


Terminal 2: ground (BK)
Terminal 3: serial data (Lt GN/V)
Terminal 4: power (GY)
Protective cap
Figure 5-80. Data Link Connector

5-120 2003 Touring: Engine Management (EFI)

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GY/Y

f1973e9s

[30B]
[30A]
[8A]
[8B]

1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

TSM/TSSM
Module

1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

Data Link
Connector
1

LtGN/R
BK
LtGN/V
GY

[91A] [91B]

LtGN/R

LtGN/V

12V

[78B]
[78A]

Scanalyzer

ECM

Figure 5-81. ECM and TSM/TSSM Circuit

Table 5-61. Wire Harness Connectors in Figure 5-81.


NO.

DESCRIPTION

TYPE

LOCATION

12-Place Deutsch (Gray)

Under Right Side Cover

[8]

Ignition (Main to EFI Harness)

[30]

TSM/TSSM

12-Place Deutsch

Cavity in Crossmember
at Rear of Battery Box (Under Seat)

[78]

ECM

36-Place Packard

Under Right Side Cover

[91]

Data Link

4-Place Deutsch

Under Right Side Cover

2003 Touring: Engine Management (EFI) 5-121

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Test 5.33 (Part 1 of 2)


LOSS OF ECM SERIAL DATA: DTC U1016

Install Breakout Box on TSM/TSSM and ECM.


Check continuity between Terminal 3 of TSM/TSSM
Breakout Box and Terminal 5 of ECM Breakout Box.
Continuity present?

1
2

YES

NO

Intermittent
present?

Locate and
repair open on
Lt. GN/V wire.
6719

YES

NO

Locate and repair


intermittent.

Check for continuity to ground on


Terminal 10 of ECM Breakout Box.
Wiggle harness during continuity
check. Continuity present?

6719

YES

NO

With the Ignition switch ON,


check for battery voltage at
Terminal 13 of ECM Breakout
Box while wiggling harness.
Battery voltage continuously
present?

Locate and
repair open.
6718

YES

NO

Replace ECM.
Reprogram and
learn password.

Locate and
repair open.
6718

6717

Clear codes and confirm proper


operation with no security lamp.

5-122 2003 Touring: Engine Management (EFI)

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Test 5.33 (Part 2 of 2)


LOSS OF TSM/TSSM SERIAL DATA: DTC U1064
DTC U1255

Install Breakout Box on TSM/TSSM and ECM.


Check continuity between Terminal 3 of TSM/TSSM
Breakout Box and Terminal 5 of ECM Breakout Box.
Continuity present?

1
2

YES

NO

Intermittent
present?

Locate and repair


open on
Lt. GN/V wire.
6719

YES

NO

Locate and repair


intermittent.

Check for continuity to ground on


Terminal 12 of TSM/TSSM Breakout
Box. Wiggle harness during
continuity check. Continuity present?

6719

YES

NO

With the Ignition switch ON,


check for battery voltage
at Terminal 1 of TSM/TSSM
Breakout Box while
wiggling harness. Battery
voltage continuously present?

Locate and
repair open.
6718

YES

NO

Replace
TSM/TSSM.
Reprogram and
learn password.

Locate and
repair open.
6718

6717

Clear codes and confirm proper


operation with no security lamp.

2003 Touring: Engine Management (EFI) 5-123

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NOTES

5-124 2003 Touring: Engine Management (EFI)