wcHEVY 8.1L L18 G-CHASSIS with Automatic TransmissionInstallation and Testing

Pg- IOZq.** READ THIS FIRST *****

At this time GM does not include the PCM calibrations in the OEM programmingthat are required for the High ldle feature to function! Gurrently chassis must beprogrammed by a GM dealer according to the instructions in Upfitter Integration Bulletin# 46 Rev. 1 or higher. This bulletin is available and should be downloided from theInternet at https://www.g3gp!l$r.cem/secure/publicaUbull/bull46re.pdf. The dealer isonly required to reflash feprogramlfr-e PCM to load the newTalibraffi and change thefast idle engine speed parameters. There are 3 of these parameters that should be set tothe customer's requirements for fast idle RPM: "PTO Max. Engine Speed', "PTOStandhy Speed' &"PTO Max. Engage Speed'. The recommended engine speed is 1200RPM. This may be changed to meet the customer's needs. The dealer should NOTinstall any of the wiring, switches or relays shown in Ul Bulletin # 46 because these areused for manual only operation and are not required. The installation of the PennTexHigh ldler kit includes all of the wiring and hardware for automatic & manual High ldleroperation.

INSTALLATION:NOTES: The air cleaner has air flow sensors mounted in it that feed information to the PCM. The engine

will not run properly without the air cleaner and all air intake ducts connected to the throttle body!Chassis that are not yet equipped with brake lights will not high idle because the voltage on thebrake circuit will rise to around 5 volts causing the PCM and High ldler to disengage. LED brakelights may also cause a similar problem if not properly designed.DTCs (Diagnostic Trouble Codes) set in the PCM may also prevent the PCM from going into Highldle mode.lf after High ldler installation the Yellow LED on the GM 8.1 L ldler Adapter P/N: Pl-0426 (moduleattached to the middle of the harness under the dash, not the black ldle Controller box mounted onthe dash) stays illuminated constantly and the engine will not high idle, then the PCM may not havebeen programmed with the correct calibration.Modifications to chassis and idler may be necessary in some applications.

"**** D/SCO N N ECT TH E G RO U N D CAB LE FROM ALL BATT ERI ES. ******

1. Mount the idle controller (inside the vehicle) in a location that is both easily accessible to driver and within wiringharnesses reach.

2. Connect the red wire from the idler to a source that provides +12 volts when the ignition switch is in the'RUN"position (ex. brown wire from fuse # 18 (circuit #441), also found at the "TCC/Brake Switch" cavity D).

3. Connect the green wire from the idler to a white wire (circuit # 17) from the "TCC/Brake Switch" cavity F. Thiswire should pullto +12 volts when the brake pedal is pressed. This wire is also available at position number E4 inthe "Convenience Center" (GM terminology for connector C202).

4. Gonnect the yellow wire from the idler to a light green wire (circuit #275) from the "TCC/Brake Switch" cavity B.This wire should pull to +12 volts when the ignition switch is in the "RUN" position and the gear selector(automatic transmission) is in the "PARK" position.

5. Connect the black wire from idler to a known gooda good ground.

chassis ground. Do not just assume any screw in the dash is

Idler Kit # PI-1029

Toatl0-9-2001

_7A96 PENNTEX HIGH IDLER

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PD-00182

Idler Kit #Pl-1029

6. Remove the air cleaner assembly (2 bolts 1Omm drive, 2 connectors, hose clamp 8mm).l0-9-2001

7. Drill a 112 inch hole through the fire wall under the drive/s side of the dash for the harness to be routed to thePCM (Powertrain Control Module). Be careful not to drill through harnesses, hose etc.

Feed harness through to grommet. Be sure gronitnffSEatS properly in hole.

Fasten and secure the Adapter module and any loose wires or harness away from sharp edges and moving partsthat could cause damage.

Route the idler harness over to the PCM. Secure the harness away from heat sources, sharp edges or movingparts.

Install the purple wire and terminal into the upper PCM connector at J1-31:a. Remove the upper connector J1 from the PCM by unscrewing the center bolt (9/32' drive). The front

(terminal side) of this connector has two blue terminal retainers or TPA (Terminal Position Assurance).b. The gray plastic wire cover has two pieces. Remove the side piece by sliding it off. To remove the main

part of the cover you must cut the zip tie & carefully release 6 clips. Start at the opposite end from theharness. Squeeze the clip tabs toward each other and pull the cover away from the connector. Whilemaintaining the pulling force release the 2 center clips using a small screw driver. Finally release theclips at the harness end and remove.

c. Remove the blue TPA for cavity #31 by releasing the retaining tabs at either end.d. Carefully insert the terminal on the purple wire into cavity'31" with enough force to break through the

rubber terminal seal tower. The terminal should lock into place. To avoid PCM damage double check toinsure that the purple wire is inserted into cavity "31" in connector J1 with the blue TPAs.

e. Reassemble the connector and carefully reconnect it to the PCM.

lnstall the white wire and terminal into the lower PGM connector at J244.a. Remove the lower connector J2 from the PCM by unscrewing the center bolt (9/32' drive). The front

(terminal side) of this connector has two red terminal retainers or TPA (Terminal Position Assurance).b. The gray plastic wire cover has two pieces. Remove the side piece by sliding it off. To remove the main

part of the cover you must cut the zip tie & carefully release 6 clips. Start at the opposite end from theharness. Squeeze the clip tabs toward each other and pull the cover away from the connector. Whilemaintaining the pulling force release the 2 center clips using a small screw driver. Finally release theclips at the harness end and remove,

c. Remove the red TPA for cavity #44 by releasing the retaining tabs at either end.d. Carefully insert the terminal on the white wire into cavity "44" with enough force to break through the

rubber terminal seal tower. The terminal should lock into place. To avoid PCM damage double check toinsure that the white wire is inserted into cavity "44' in connector J2 with the red TPAs.

e. Reassemble the connector and carefully reconnect it to the PCM.

Secure ALL loose wires away from heat sources, sharp edges or moving parts.

Reinstall the air cleaner assembly and reconnect all battery ground cables.

brake). Turn ignition switch to run position, but DO NOT START ENGINE. The"LO\N' battery indicator (red) should be lit. After 10 seconds the "HIGH IDLE' indicator (yellow) should light up.

Press the brake pedal. The "HIGH IDLE" indicator (yellow) should turn off. Release the brake and it shouldcome back on with no delay.

!Press the brake pedal and move the gear shift to 'DRIVE.. Release the brake pedal. The "HIGH IDLE" indicator(yellow) should not be lit. Put the shifter in "PARK'. The "HIGH IDLE" indicator should light.

The "HIGH IDLE" indicator (yellow) should light up.

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TESTING AND ADJ U STMENT:

4. Start the engine and press the "MANUAL ENGAGE'button.

fntl. 0 PD-00182

Idler Kit # PI-1029 l0-9-2001At the same time that the "HIGH IDLE" indicator lights up, the green LED on the Adapter should flash once. TheAdapter is the module in the harness under the dash, not the ldle Controller black box. This green LED indicatesthat the Adapter is sending instructions to the PCM telling it to go into High ldle mode. Then the yellow LED onthe Adapter should turn on. This indicates that the PCM received the message and switched into high idle mode.The engine should increase it's RPM to the level programmed by the dealerwith the Tech ll scan tool. Therecommended RPM is 1200.

5. Press the brake to insure idle speed returns to normal.

6. Installationcomplete.

TROUBLESHOOTING:lf the engine fails to high idle and the status indicator (yellow) on the ADAPTER stays on continuously then the PCMmay not have been reflashed with the correct calibration or the PCM may not have accepted the attempted reflashcalibration.Several additional things can prevent the engine from going into high idle mode:

a. Any DTCs that are set in the PCM for malfunctions of engine sensors.b. Incorrect wiring or PCM connector terminal installation.c. False PCM brake signal sense. The PCM senses the brake pedaldepression from the main lamp circuit

#17 which goes to +12 volts when the pedal is pressed. lf no brake lamps are installed or LED brakelamps this circuit voltage will rise to approximately 5 volts and trick the PCM into thinking the brake isbeing pressed.

d, The PCM also senses the brake through a redundant circuit # 420. This circuit uses a normally closedswitch to send 12 volts to the PCM when the brake pedal is NOT pressed. This works opposite fromcircuit #1 7 listed above.

e. The PCM monitors the DTR (DigitalTransmission Range) signal from the "ParUNeutral Position (PNP)"switch. A malfunction could cause the PCM to think the vehicle was in gear and prevent high idle.

f. Future calibrations that get reflashed during vehicle maintenance could remove the high idle function.Periodically calibrations are chariged and added to fix bugs and improve performance. In the past wehave seen vehicles that suddenly stop high idling after the dealer serviced them. This happened whenthe PCM had been reflashed with newer software that for some reason disabled the fast idle function.

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UI BULLETIN # 46 Rev. 1

SUBJECT: G Van High ld le

MODELS AFFECTED: G Ful l 'Bodied Vans andCutaways w/ 8.1L Engine (RPO L18)

MODEL YEAR(S): 2001

DATE: 3/16/2001

REVISION DATE: 612012001

PAGE: 1 ot 12

ADVISORY

This is a revis ion to Upf i t rer Integrat ion bul let in number 46, dated 3/16/01, to

advise of a change to the wir ing schematic of the high id le switch, the operat ion

of the high id le ano tn" procedure to adjust rPm sPeed of the high id le '

The purpose of this bulletin is to provide upfitters and Special Vehicle Manufacturers (sVMs)

with information regarding high idle availability. This bulletin also provides installation in-

structions to interface with the new high idle calibrations now available.

Upfitter Integration suggests the following procedures !e followed carefully if your applica- -tion requires a high idte feature for any ZOCif C Van or Cutaway equipped with the 8.1L (RPO

118) engine.

Condit ionSome Upfitters and SVMs are requesting high idle capabilities for 2001 G vans or Cutaways

equipped with the 8.1L engine, High idle refers to the increase in engine rpm to values higher

than normal base idle speed, High idle historically has been provided through additional

mechanical hardware to regulate an increased engine rpm speed.

CauseThe high idle calibrations were

2001. The 2001 model Year Gsors. Various engine functions,means due to the incorPorationcontrolled throttle.

not included in the original production PCM calibrations for

Vans equipped with the 8,1L engine differ from their predeces-

including idle speed, are now controlled through electronic

of an electronically controlled throttle versus a mechanically

Correct ionThe new calibration, which includes the high idle feature, can be programmed into the PCM

with a GM Tech 2 scan tool. The GM Tech 2 scan tool connects to the data link connector

under the dash above the driver's foot well area' The Tech 2 scan tool MUST be used to

enable the high idte option and adjust the factory default settings to the desired high idle

rpm.

Ul BULLETIN # 46 Rev.(Gont 'd)

Correction (cont.)A GM dealer will be able to perform the reprogramming of the PCM. A Vehicle ldentificationNumber (VlN) will be required by the dealer to change the calibration. The dealer must callGM Techline Customer Assistance at 800-828-6860 for a VCI authorization number to accessand obtain the calibration. Once the dealer performs the reflash of the PCM, the GM vehiclebuild record will be updated to reflect the new calibration in the vehicle.

Cal ibrat ion Part NumbersThe new calibration part numbers, which include the high idle feature, are as follows:

9373572

9373573

Al l Federal Emission Appl icat ions, Models 05/06/03/32 and Cal i forniaEmission Appl icat ions, Models 03/32

Galifornia Emission Applications, Models 05/06

Normally Open10 to 16 Votts DC20 Amps Maximum

Parts ListUpfitters or SVMs requiring the high idle feature will need to install the following additionalparts to allow the end user to activate the high idle feature:

. Momentary switch, either push button or lever type. Quantity of 1 required.

. Relay, GM part number 12088567 or equivalent*. GM relay is available through serviceparts from a GM dealer. Quantity of 1 required.

. Relay connector (Delphi Packard) part number 12110541. Quantity of 1 required.(recommended if relay is to be mounted under dash). Refer to Delphi PackardHandbook for appropriate mating terminal ends and secondary locks.

. Suitable electrical wire. Length and quantity dependent on switch and relay location.

*Equivalent

Relay Type:Voltage:

Relay Specifications:

Contact Current Rating :

Optional parts if relay is to be installed in the underhood bussed electrical center (BEC):

. Terminal end, part number 12110844 for cavities 87 and A9. Quantity of 2 required.

. Terminal end, part number 12110843 for cavities 89 and A7. Quantity of 2 required.

Note: lf the relay is installed in the underhood BEC, it is recommended that the locationof the high idle relay be noted on the BEC label.

BULLZYS46/Rev.1 2ot12 311612001 / Rev. 1: 612O12001

2001 G VanHigh ld le

Adjustment ProcedureTech 2 Menu Screens

ATTACHMENT 1PAGE 1

UI BULLETIN(Cont 'd)

# 46 Rev. 1

6ot12 311612001 / Rev. 1: 612012001

Ul BULLETIN # 46 Rev. 1(Cont 'd)

ATTACHMENT 1PAGE 2

Tech 2 Main Menu Screen

Main Menu

F0: Diagnostics *

F1: Service Programming SYstemF2: View Captured DataF3: . . .F4: . . .

* Selection

Tech 2 Vehicle lD Screen

* Selection

Vehicle lD (Model Years)

(3) 2oo3(2) 2002(1) 2001 -(Y) 2000

7 ot12 311612001 / Rev. 1: 6120120O1

UI BULLETIN # 46(Cont 'd)

Rev. 1

Tech 2 System Selection Screen

System Selection Menu

(1) 2001 LD Truck

F0: Powertrain *

F1: BodyF2: ChassisF3: Diagnostic Circuit Check

ATTACHMENT 1PAGE 3

Tech 2Vehicle lD Screen

Vehicle ldentification

Passenger CarLD Truck, MPV, Incomplete *

Medium Duty TruckSaturn

* Selection

8ot12

* Selection

311612001 / Rev, 1: 612012001

UI BULLETIN(Cont 'd)

ATTACHMENT 1PAGE 4

Tech 2 Vehicle lD Screen

Vehicle lDSelect one of the following

LD Truck Engine tYPes

(1) V8 LB7 Diesel(G)V8118 8. ' ,1 L.(G)V8 118 3500HD

* Selection

Tech 2 Vehicle lD Screen

Vehicle ldentificationSelect one of the following Transmissions

5 Speed Automatic Trans (M74)4 Speed Automatic Trans (MT1) .

ManualTrans (MLO)Other

# 46 Rev. 1

9of12

* Selection

311612001 / Rev. 1: 612O120O1

* Selection

Tech 2 Special Functions Screen

UI BULLETIN(Cont 'd)

ATTACHMENT 1PAGE 5

Tech 2 Powertrain Screen

Powertrain

F0: . . .F1: Data DisplayF2: Special Funclions *

F3: SnapshotF4: . . .F5: . . .

Special Functions

F1: . . .F2: . . .F3: . . .F4'. ...F5: . . .F6: Service Bay TestF7: PTO Options *

F8: Engine ShutdownF9: . . .

* Selection

# 46 Rev. 1

10 of 12 311612001 / Rev. 1: 612012001

ATTACHMENT 1PAGE 6

Fast ldle Mode Settings DisPlaY

UI BULLETIN # 46(Gont 'd)

Rev. 1

Nl]te:

No changes can be made to this screen'Press change options to get to the nextmenu

* Selection

PTO Operating Modes Screen

PTO Option

F0; Fast ldle .

F1: Preset PTO SPeed Control

F2: Variable PTO SPeed Control

PTO Option

PTO Fast ldle Option Fast ldlePTO Max. Engine SPeed XXXX RPMPTO Standby Speed* XXXX RPMPTO Max. Engage SPeed XXXXRPMPTO Engine Shutdown (No)PTO Engage Relay (No)PTO Feedbacr (No)

BULLZYS46/Rev.1 11 of 12

* Selection

311612001 / Rev. 1: 612O120O1

UI BULLETIN # 46(Cont 'd)

ATTACHMENT 1PAGE 7

Fast ldle Mode Settings Update Screen

PTO OPtions

PTO Fast ldle OptionPTO Max. Engine SpeedPTO Standby Speed*PTO Max. Engage SpeedPTO Engine ShutdownPTO Engage RelayPTO Feedback

Press [Reprogram Options] when done

Fast ldleXXXX RPMXXXX RPMXXXX RPM(No)(No)(No)

Rev. 1

* SelectionThen scroll Decrease/l ncreaseto change high idle rpm setting @@ffi

12ot12 311612001 / Rev. 1: 612012OO1