Usage:
NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS5596" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
October 31, 1999Problem
Certain G3508, G3512, G3516 Engines have been operating so quitely as to trip false 318-01 and 319-01 (no detonation sensor signal) diagnostics on EIS control resulting in engine shutdown.
Affected Product
Model & Identification Number
G3516 (4EK1-Up)
G3508 (4WD1-Up)
G3508 (9TG1-Up)
G3512 (5JD1-Up 7NJ1-Up )
G3516 (8LD1-Up)
Parts Needed
Dealers will also need 1 set of Tools for this procedure. The tools are Re-usable.
Action Required
See the attached Rework Procedure.
Service Claim Allowances
NOTE: This is a 1-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
- (1-Rework Procedure)
Rework Procedure
1. Please read all of the instructions before replacing the chip.
2. Disconnect power from the system and REMOVE the EIS control from the engine.
3. Run a self test on EIS control. If it fails the self test, scrap it. If it passes the self test, follow the following procedure to replace the chip.
4. Thoroughly clean the software access cover and surrounding area (See Figure 1).
5. Perform this procedure on a flat surface with the connector pointed away from you (See Figure 1). Ideally this procedure should be performed in a low humidity environment
Figure 1
6. Remove the security wire from the EIS software access cover and remove the access cover (See Figure 1).
7. Carefully cut the existing chip restraining tie wrap at both ends with a side cutter (See Figure 2). Do not damage any components on the circuit board. Do not attempt to remove the tie wrap from beneath the chip socket
Figure 2
8. Mark the chip in the EIS control with a permanent marker, paint pen, etc, This is to help make sure that this chip does not get reinserted into the EIS control.
9. Note the direction of the notch in the chip (See Figure 3). Remove the software chip with the puller supplied, grabbing the chip on the notch end (Point A) and the opposite side (Point B) (See Figures 3 & 4). Be careful to grab only the chip and not the socket beneath it (See Figure 4). A gentle rocking motion works well when removing the chip.
Figure 3
Figure 4
10. Immediately after removing the chip, bend the pins over and throw the chip away.
11. Adjust supplied chip installer to the depth shown in Figure 5. This is done by adjusting the set screw that is on the bottom of the installer.
Figure 5
12. The chip is very sensitive to static electricity. To eliminate the hazard of electrostatic discharge (ESD) a person should momentarily touch an unpainted earth grounded metal object (e.g. conduit) prior to handling the chip.
13. Remove the chip from the foam. Place the chip on a hard flat surface with the pins pointing downward. Holding the chip installer body (not the plunger (See Figure 5)), carefully push the chip installer over the chip, being careful not to bend any of the pins. Make sure that the chip is centered in the installer. (See Figure 6)
Figure 6
14. Orient the EIS control with its connector pointed up or away from you (See Figure 7). When installing the new chip, the notch in the chip should point to the left.
NOTE: There is one hole in the socket for every pin on the chip. An empty hole in the socket indicates improper alignment of the chip.
Figure 7
15. Take the chip installer with the chip in it and line the chip up with the socket by making sure the first set of pins are lined up with the first set of holes in the socket. Verify proper orientation (See Figure 7). Gently push down on the plunger of the installer until it stops. Remove the chip installer.
16. Inspect the chip and socket and make sure that there are no empty holes in the socket. If any empty holes are visible, remove the chip (See step 7). Visually inspect the chip for bent or damaged pins. If the pins are not bent or damaged, return to step 10. If bent or damaged pins are found, discard chip. Acquire new chip and return to step 10.
17. If you do not see any empty holes in the socket, the chip is inserted correctly. Gently push down on the chip with your finger to finish seating the chip in the socket
18. Check again to make sure that with the EIS control connector pointed away from you, that the notch in the chip is pointed to the left A new tie wrap will not be installed.
19. Clean the access cover and surrounding area (See Figure 1). Do not allow debris to enter control through access hole.
20. Remove the old o-ring from the access cover and clean the o-ring groove. Lubricate the new o-ring provided with glycerin or similar lubricant and place it in o-ring groove on access cover. DO NOT use petroleum-based lubricant. Place access cover on EIS control. Verify that the o-ring remains in the groove and is not pinched between the access cover and the EIS control housing.
21. Install new bolts provided and torque to 2.25 ± 0.25 N·m (20 ± 2 in/LB). Install the two security seals provided (one at each end of the cover).
22. Using an engraving tool, engrave "w/JUN98 SW" on the control in the area of the part number.
23. Reinstall the EIS on the engine and power the system. Scroll through the Digital Diagnostic Tool (DDT) and make sure the DDT behaves normally. If the DDT is working normally on the engine, the engine is ready to start.
24. If the DDT will not scroll to the proper screens, remove the EIS from the engine and run a self-test on the EIS control. If the EIS passes the self-test, refer to the EIS troubleshooting manual.
25. If the EIS fails the self-test, Scrap it.