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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 960 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 6.6L (LLY) - DTC P0401 TO DTC P2510)DTC P0540CIRCUIT/SYSTEM TESTING
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Circuit/System Testing

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Circuit/System Testing
WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2007 GMC Savana Special, 2007 GMC Savana Camper Special, 2007 GMC Savana, 2007 Chevrolet RV Cutaway, and 2007 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Perform the Circuit/System Verification before proceeding with Circuit/System Testing.
  1. Probe the battery positive circuit at the IAH with a test lamp connected to ground, and observe that the test lamp illuminates.
    • If the test lamp does not illuminate, test the battery positive circuit for an open, a short to ground, or high resistance.
  2. Observe that the IA Heater Driver Ground parameter displays OK with a scan tool.
    • If the IA Heater Driver Ground displays fault, inspect that the IAH is grounded properly to the air intake tubes, or for a faulty IAH.
  3. Test the following circuits for an open, a short to ground, or a short to voltage:
    • The IAH temperature signal circuit
    • The IAH command 1 circuit
    • The IAH command 2 circuit
    • The IAH current signal circuit
    • The IAH voltage signal circuit
    • The IAH feedback signal circuit

      Repair any circuit, as necessary.

  4. Connect any circuits that were disconnected. With the ignition ON and the engine OFF, observe that the scan tool displays the IA Heater Driver Shorted Open parameter as OK.
    • If the IA Heater Driver Shorted Open parameter displays Fault, replace the intake air heater.
  5. With the ignition ON and the engine OFF, observe that the scan tool displays the Glow Plug Driver Shorted Open parameter as OK.
    • If the Glow Plug Driver Shorted Open parameter displays Fault, replace the Glow Plug Control Module.
  6. With the ignition ON and the engine OFF, observe the GPCM data display with a scan tool.
    • If the glow plug undervoltage displays Fault, and the IA heater undervoltage displays OK, replace the GPCM.
    • If the glow plug overvoltage displays Fault, and the IA heater overvoltage as OK, replace the GPCM.
    • If the glow plug undervoltage displays OK, and the IA heater undervoltage displays Fault, replace the IAH.
    • If the scan tool displays the glow plug overvoltage as OK, and the IAH overvoltage as Fault, replace the IAH.
  7. Disconnect the IAH and measure between the temperature circuit on the IAH and a good ground for 15,000-18,000 ohms with a DMM.
    • If the DMM does not measure between 15,000-18,000 ohms, replace the IAH.
  8. Turn ON the ignition and measure between the temperature circuit on the harness side and a good ground for 2-3 volts with a DMM.
    • If the DMM does not measure between 2-3 volts ohms, replace the GPCM.
    9. IMPORTANT: Set the DMM to the 4 v AC hertz scale.
  9. With a DMM measure between command 2 circuit and a good ground on the harness side of the connector for 0.78-1.1 Hz.
    • If the DMM does not measure between 0.78-1.1 Hz ohms, replace the GPCM.
    10. IMPORTANT:
    • Do not install the jumper wire between 12 volts and the command circuit for more the 20 seconds.
    • Set the DMM to the 4 v AC hertz scale.
  10. Turn OFF the ignition. Install a jumper wires between the IAH and the IAH harness for the temperature signal circuit and command 2 circuit. Install a jumper wire between 12 volts and the command 1 terminal on the IAH. Turn ON the ignition. With a DMM measure for 1 hertz on the following circuits:
    • Current signal
    • Voltage signal
    • Feedback signal
  • If the DMM measures 0.7-1.1 hertz for all 3 circuits, replace the GPCM.
  • If the DMM does not measure 0.7-1.1 hertz for any of the 3 circuits, replace the IAH.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.