LPG FUEL SYSTEM

GM 2.4L ENGINE
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]

PART NO. 1580506 900 SRM 1124

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
LPG Fuel System Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Hoses Replacement ............................................................................................................................................ 1
LPG Tank Replacement..................................................................................................................................... 1
Remove ........................................................................................................................................................... 1
Install ............................................................................................................................................................. 3
Fuel Filter Unit Repair...................................................................................................................................... 4
Fuel Filter Element ....................................................................................................................................... 4
Remove....................................................................................................................................................... 4
Clean/Inspect ............................................................................................................................................. 4
Install ......................................................................................................................................................... 4
Fuel Filter Housing ....................................................................................................................................... 5
Remove....................................................................................................................................................... 5
Disassemble ............................................................................................................................................... 5
Assemble .................................................................................................................................................... 6
Install ......................................................................................................................................................... 6
Electronic Throttle Body Repair ....................................................................................................................... 6
Electronic Throttle Body ............................................................................................................................... 6
Remove....................................................................................................................................................... 6
Install ......................................................................................................................................................... 6
Electronic Throttle Body Adapter Plate ....................................................................................................... 7
Remove....................................................................................................................................................... 7
Install ......................................................................................................................................................... 7
Fuel Injector Repair ........................................................................................................................................... 8
Fuel Rail......................................................................................................................................................... 8
Remove....................................................................................................................................................... 8
Install ......................................................................................................................................................... 8
Fuel Injector................................................................................................................................................... 9
Remove....................................................................................................................................................... 9
Clean .......................................................................................................................................................... 10
Install ......................................................................................................................................................... 10
Fuel Injector Adapters................................................................................................................................... 11
Remove....................................................................................................................................................... 11
Install ......................................................................................................................................................... 11
LPG Regulator Repair ....................................................................................................................................... 12
LPG Regulator ............................................................................................................................................... 12
Remove....................................................................................................................................................... 12
Install ......................................................................................................................................................... 13
LPG Regulator Fuel Filter ............................................................................................................................ 14
Remove....................................................................................................................................................... 14
Install ......................................................................................................................................................... 14
Lock-Off Solenoid and Cartridge .................................................................................................................. 15
Remove....................................................................................................................................................... 15
Install ......................................................................................................................................................... 15
Control System................................................................................................................................................... 16
Electronic Control Unit (ECU)...................................................................................................................... 16
Remove....................................................................................................................................................... 16
Install ......................................................................................................................................................... 16
Power Latch Relay......................................................................................................................................... 17
Remove....................................................................................................................................................... 17
Install ......................................................................................................................................................... 18
Injector Driver Module .................................................................................................................................. 18

©2006 HYSTER COMPANY i

Table of Contents LPG Fuel System

TABLE OF CONTENTS (Continued)

Remove....................................................................................................................................................... 18
Install ......................................................................................................................................................... 19
Camshaft Position (CMP) Sensor ................................................................................................................. 19
Remove....................................................................................................................................................... 19
Install ......................................................................................................................................................... 19
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor ......................................... 20
Remove....................................................................................................................................................... 20
Install ......................................................................................................................................................... 20
Engine Coolant Temperature (ECT) Sensor................................................................................................. 20
Remove....................................................................................................................................................... 20
Install ......................................................................................................................................................... 20
Oxygen Sensor ............................................................................................................................................... 21
Remove....................................................................................................................................................... 21
Install ......................................................................................................................................................... 21

This section is for the following models:

S2.0-3.5FT (S40-70FT, S55FTS ) [F187];

H2.0-3.5FT (H40-70FT) [L177]

ii
900 SRM 1124 LPG Tank Replacement

General
This section has the repair procedures for the parts of the LPG fuel system used on the GM 2.4 liter engines.

Hoses Replacement
The hoses installed on LPG systems are special. When replacing the hose to the quick-disconnect
Hoses that are made for use with hydraulic oil are fitting, make sure it is the same length as the hose
damaged by LPG. When replacing the LPG hoses, it replaces. A longer hose permits the tank to be
make sure to use only Hyster Approved LPG installed in an incorrect position. If a fuel hose has
hoses. Make sure to use the correct size of hose. a restriction, it is coldest around the restriction.

LPG Tank Replacement

REMOVE the supply hose from the LPG tank where it en-
ters the filter unit. Permit the pressure in the
WARNING fuel system to decrease slowly. Fuel leaving
the fitting removes heat. To avoid personal in-
LPG can cause an explosion. Do not cause
jury, wear safety glasses and protective gloves.
sparks or permit flammable material near the
Also use a cloth to further protect your hands
LPG system. LPG fuel systems can be discon-
from the cold fitting.
nected indoors only if the lift truck is at least
8 m (26 ft) from any open flame, motor vehicles, NOTE: The LPG tank bracket used on this line
electrical equipment, or ignition source. of trucks to mount the LPG tank onto the coun-
terweight comes in two styles. One style of
LPG is heavier than air. LPG can stay in low
bracket swings out to the side of the truck and
places and cause an explosion when a spark oc-
the other swings out to the side and drops down
curs.
(EZ-Xchange™). See Figure 1.
DO NOT overfill the LPG tank. Vapor is ex-
1. LPG tanks can be removed and replaced indoors
pelled from the indicator when the bottle has
only if the lift truck is at least 8 m (26 ft) from
reached the 80 percent full point. At this point,
any flame or ignition source. Move the lift truck
the bottle filling operation must be halted. Fill-
to an the area where LPG tanks are changed.
ing the bottle to 80 percent allows the appro-
priate expansion volume within the bottle. The 2. Turn the shutoff valve clockwise until the valve
tank relief valve is installed in the tank to allow is completely closed.
for pressure relief if the bottle is overfilled or
if exposed to high temperatures. 3. Run the engine until it stops. If truck is equipped
with a key switch, turn the key switch to the
Close the shutoff valve on the LPG tank before OFF position. If truck is equipped with a Power
any part of the engine fuel system is discon- ON/OFF button, press the Power ON/OFF but-
nected. Run the engine until the fuel in the sys- ton to turn power off.
tem is used and the engine stops.
4. Disconnect the quick-disconnect fitting on the
If the engine will not run, close the shutoff LPG tank. See Figure 1.
valve on the LPG tank. Loosen the fitting on

1
LPG Tank Replacement 900 SRM 1124

A. SWING-OUT LPG BRACKET B. SWING-OUT AND DROP-DOWN LPG BRACKET

(EZ-XCHANGE™)
1. LPG TANK 7. STOP PIN
2. TANK STRAP 8. BRACKET HANDLE
3. QUICK DISCONNECT FITTING 9. BRACKET PIVOT
4. HYDROSTATIC RELIEF VALVE 10. GAS SPRING (DROP-DOWN BRACKET ONLY)
5. MANIFOLD BLOCK 11. BRACKET RELEASE PIN (BUTTON)
6. ALIGNMENT PIN

Figure 1. LPG Tank and Bracket

2
900 SRM 1124 LPG Tank Replacement

5. Push in the bracket release pin, grab the bracket truck has the swing-out and drop-down bracket
handle, and swing the tank and bracket out (EZ-Xchange™), position the bracket in the
to the side of the lift truck. If your truck is drop-down position.
equipped with a swing-out and drop-down LPG
tank bracket (EZ-Xchange™), drop the tank
WARNING
down to the side of the truck for ease of removal.
See Figure 2. When closing the LPG tank strap, do not wrap
your fingers around the strap handle. The
6. Unlatch the tank strap and remove the LPG tank strap can close quickly and with enough force
from the bracket. to cause injury to the fingers and hand.

1. Place the LPG tank into the bracket. Secure the

tank strap around the tank and close the strap.

2. Pull the stop pin (see Figure 1) and swing the

LPG tank bracket into the resting position on the
counterweight. Be sure that the bracket locks
into position.

3. Connect the hose to the LPG fuel lock-off connec-

tion on the LPG regulator. See Figure 2.

4. Connect the quick-disconnect fitting on the LPG

tank. See Figure 1.

5. Turn the fuel valve counterclockwise to open the

fuel valve.

6. Inspect the fuel system for leaks when the fuel

valve is open. There are four methods used to
inspect the fuel system for leaks:

a. Sound - Listen for sound of LPG escaping

from a tank fitting or hose connection.

b. Smell - LPG has a very distinctive odor. If

1. QUICK-DISCONNECT CONNECTION you smell LPG, DO NOT start the engine.
2. HOSE ASSEMBLY
3. CAPSCREW c. Soapy Water - This method is used in con-
4. LPG TANK junction with Step b above. If the odor of LPG
5. HOSE ASSEMBLY TO LPG is present, but escaping fuel cannot be heard,
REGULATOR/LOCK-OFF apply soapy water to the fittings and observe
6. LPG REGULATOR CONNECTION for bubbles.
7. LPG REGULATOR
d. Frost - If the amount of LPG escaping is suf-
Figure 2. LPG Tank Hose Connections
ficient, frost may appear on the fittings.
INSTALL
NOTE: The LPG bracket must be in the swing-out
position to install the LPG tank. If your lift

3
Fuel Filter Unit Repair 900 SRM 1124

Fuel Filter Unit Repair

FUEL FILTER ELEMENT
Remove

WARNING
LPG can cause an explosion. Do not permit any
sparks or open flames in the work area.

1. Close fuel valve on tank. Run engine until it

stops.

2. Disconnect negative battery cable.

WARNING
A small amount of fuel may still be present in
the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues
to flow from the connections when loosened,
check to make sure the manual valve is fully
closed.

3. Remove the bolt and seal washer from the fuel

filter housing top section. Discard seal washer.
See Figure 3.
1. BOLT*
4. Remove fuel filter housing top section from fuel 2. SEAL WASHER
filter housing bottom section. 3. FUEL FILTER HOUSING TOP SECTION*
4. FUEL FILTER
5. Remove and discard housing O-ring. 5. FUEL FILTER O-RING
6. HOUSING O-RING
6. Remove and discard fuel filter and fuel filter 7. FUEL FILTER HOUSING BOTTOM SECTION*
O-ring.
*NOT SERVICED SEPARATELY
Clean/Inspect
Figure 3. Fuel Filter Removal/Installation
1. Clean and inspect the fuel filter housing top sec-
4. Install bolt and new seal washer. Tighten bolt to
tion for contamination or damage. If damaged,
13 N•m (115 lbf in).
replace the housing.
NOTE: Opening the fuel valve too quickly can cause
2. Clean and inspect the fuel filter housing bottom
the internal excess flow valve to close, restricting the
section for contamination or damage. If dam-
flow of fuel. If this happens, close the fuel valve, wait
aged, replace the housing.
a few seconds, and then slowly open the fuel valve
Install again. This will reset the excess flow valve.

1. Install the new fuel filter and fuel filter O-ring. 5. Slowly open the fuel valve on tank.
See Figure 3. 6. Connect the negative battery cable.
2. Install new housing O-ring. 7. Turn the key to the ON position and back to
3. Install fuel filter housing top section onto fuel the OFF position to pressurize the fuel system.
filter housing bottom section. Check for leaks.

4
900 SRM 1124 Fuel Filter Unit Repair

8. Check for leaks at connections by using soapy Legend for Figure 4

solution or electron leak detector. If leaks are
detected, make proper repairs. 1. FUEL FILTER ASSEMBLY
2. MOUNTING BRACKET
3. SOCKET HEAD CAPSCREWS
FUEL FILTER HOUSING
5. Remove the socket head capscrews and fuel filter
Remove housing from the mounting bracket. Remove fuel
filter assembly. See Figure 4.
WARNING
LPG can cause an explosion. Do not permit any Disassemble
sparks or open flames in the work area. 1. Remove the fuel filter. See Fuel Filter Element,
1. Close fuel valve on tank. Run engine until it Remove.
stops. 2. Remove the low pressure switch from the low
2. Disconnect negative battery cable. pressure switch fitting. See Figure 5.

3. Remove the inlet fitting from the fuel filter hous-

WARNING ing bottom section.
A small amount of fuel may still be present in
the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues
to flow from the connections when loosened,
check to make sure the manual valve is fully
closed.

3. Slowly loosen and disconnect inlet and outlet fit-

tings.

4. Disconnect low pressure switch from engine wire

harness. See Figure 5.

1. BOLT*
2. SEAL WASHER
3. FUEL FILTER HOUSING TOP SECTION*
4. FUEL FILTER
5. HOUSING O-RING
6. INLET FITTING*
7. LOW PRESSURE SWITCH
8. LOW PRESSURE SWITCH FITTING*
9. LOW PRESSURE SWITCH ADAPTER*
10. FUEL FILTER HOUSING BOTTOM SECTION*
11. O-RING*
12. OUTLET ADAPTER FITTING*
13. OUTLET ELBOW FITTING*
14. FUEL FILTER O-RING
Figure 4. Fuel Filter Assembly Removal/
Installation *NOT SERVICED SEPARATELY

Figure 5. Fuel Filter Assembly

5
Electronic Throttle Body Repair 900 SRM 1124

4. Remove the low pressure switch fitting from the Install

low pressure switch adapter.
1. Place the fuel filter assembly in position on the
5. Remove the outlet elbow fitting from the outlet mounting bracket.
adapter fitting.
2. Install the socket head capscrews to attach the
Assemble fuel filter housing to the mounting bracket.
Tighten socket head capscrews to 6 N•m
(53 lbf in).
CAUTION
Do not use Teflon tape on any fuel fitting. Use 3. Connect engine wire harness to the low pressure
a liquid pipe thread sealant when installing fit- switch.
tings.
4. Connect the inlet and outlet fuel lines.
1. Apply pipe thread sealant (Hyster Part No.
0246108) to the threads of the outlet elbow NOTE: Opening the fuel valve too quickly can cause
fitting and install the outlet elbow fitting and the internal excess flow valve to close, restricting the
O-ring. flow of fuel. If this happens, close the fuel valve, wait
a few seconds, and then slowly open the fuel valve
2. Apply pipe thread sealant (Hyster Part No. again. This will reset the excess flow valve.
0246108) on the threads of the low pressure
switch fitting. Install the low pressure switch 5. Slowly open the fuel valve on tank.
fitting onto the low pressure switch adapter.
6. Connect the negative battery cable.
3. Apply pipe thread sealant (Hyster Part No.
7. Turn the key to the ON position and back to
0246108) on the threads of the low pressure
the OFF position to pressurize the fuel system.
switch. Install the low pressure switch onto the
Check for leaks.
low pressure switch fitting.
8. Check for leaks at connections by using soapy
4. Apply pipe thread sealant (Hyster Part No.
solution or electron leak detector. If leaks are
0246108) on the threads of the inlet fitting and
detected, make proper repairs.
install the inlet fitting.

5. Install the fuel filter. See Fuel Filter Element,

Install.

Electronic Throttle Body Repair

ELECTRONIC THROTTLE BODY 5. Remove the throttle body and gasket. Discard
gasket.
Remove
Install
1. Disconnect the negative battery cable.
1. Clean the mating surfaces of the adapter plate
2. Remove the clean air tube from the throttle body and the throttle body.
to the air filter assembly.
2. Place the new gasket and throttle body in posi-
3. Disconnect the electrical connector from the tion on the adapter plate.
throttle body.
3. Install the lockwashers and socket head cap-
4. Remove the socket head capscrews and lock- screws. Tighten the socket head capscrews to
washers retaining the throttle body to the 10 N•m (88.5 lbf in).
adapter plate. See Figure 6.

6
900 SRM 1124 Electronic Throttle Body Repair

ELECTRONIC THROTTLE BODY ADAPTER

PLATE
Remove
1. Remove the throttle body. See Electronic Throt-
tle Body, Remove.

2. Remove the socket head capscrews and lock-

washers retaining the adapter plate to the
intake manifold. See Figure 7.

1. ADAPTER PLATE
2. GASKET
3. ELECTRONIC THROTTLE BODY
4. SOCKET HEAD CAPSCREWS
5. LOCKWASHER

Figure 6. Electronic Throttle Body

4. Install the clean air tube.

5. Connect the battery negative cable. 1. INTAKE MANIFOLD

2. GASKET
6. Key ON the vehicle and with the PC service tool 3. ADAPTER PLATE
4. SOCKET HEAD CAPSCREWS
send a "Restore ECU Defaults" command via the 5. LOCKWASHER
CAN communication bus.
Figure 7. Electronic Throttle Body
7. Key OFF the vehicle and wait 30 seconds.
3. Remove the adapter plate and gasket.
8. Connect the electrical connector to the throttle
body. Verify that the connector clicks/locks into Install
place.
1. Clean the mating surfaces of the adapter plate
WARNING and the intake manifold.
Do not insert fingers or foreign objects into the 2. Place the new gasket and adapter plate in posi-
throttle body. tion on the intake manifold.
9. Start the vehicle and check for proper operation 3. Install the lockwashers and socket head cap-
of the throttle body and the ECU by exercising screws. Tighten the socket head capscrews to
the accelerator pedal with the vehicle in neutral. 10 N•m (88.5 lbf in).
The engine should idle at 775 to 825 rpm with no
pedal to the governor speed of 2675 to 2725 rpm 4. Install the throttle body. See Electronic Throttle
at full pedal. Body, Install.

7
Fuel Injector Repair 900 SRM 1124

Fuel Injector Repair

FUEL RAIL
Remove

WARNING
LPG can cause an explosion. Do not permit any
sparks or open flames in the work area.

1. Close fuel valve on tank. Run engine until it

stops.

2. Disconnect negative battery cable.

3. Disconnect the fuel line from the fuel rail.

4. Disconnect the four electrical connectors from

the fuel injectors. See Figure 8.

1. CAPSCREW 3. FUEL RAIL

2. LOCKWASHER

Figure 9. Fuel Rail Capscrews

CAUTION
When cutting the clamps, use caution not to cut
the hoses or the fuel rail barbs.

8. Carefully cut the clamps holding the hoses to the

fuel rail barbs. See Figure 10.

9. Disconnect each hose from the fuel rail by work-

ing each hose back and forth while pulling the
hose outward, away from the fuel rail.

Install
1. ELECTRICAL CONNECTORS
2. FUEL INJECTORS 1. Place the fuel rail in position on the mounting
bracket.
Figure 8. Fuel Injector Electrical Connectors
2. Install two capscrews and washers to retain the
5. Disconnect the two hoses from the positive fuel rail to the mounting bracket. Tighten cap-
crankcase ventilation (PCV) valve. screws to 10 N•m (88.5 lbf in).
6. Remove the two capscrews and lockwashers re- 3. Place new screw-type clamps over each of the
taining the fuel rail to the mounting bracket. See hoses. Push the hoses onto the fuel rail barbs.
Figure 9.

7. Move the fuel rail away from the injectors.

8
900 SRM 1124 Fuel Injector Repair

FUEL INJECTOR
Remove

CAUTION
The fuel injectors are held in place with an
internal "C" ring. When removing the fuel in-
jectors, pull the injectors straight out. Do not
pry the injectors with a screwdriver or prybar,
as this can damage the injectors or injector
adapters.

NOTE: Do not cut the clamps for the hoses attaching

the fuel injectors to the fuel rail. Remove the fuel
injectors and fuel rail as an assembly.

1. Remove the fuel rail with the injectors attached

by pulling the injectors straight out of the
adapters. See Fuel Rail, Remove, Step 1 through
Step 6, and Figure 11.

1. HOSE 3. FUEL RAIL

2. CLAMP

Figure 10. Fuel Rail Hose Clamp

4. Verify that all fuel hoses are in correct position

and not kinked. Tighten each clamp screw to 2.45
to 2.77 N•m (22 to 25 lbf in).

5. Connect the four electrical connectors to the fuel

injectors. Verify that the connectors click/lock
into place.

6. Connect the two hoses to the PCV valve.

7. Connect the fuel line to the fuel rail.

8. Connect the negative battery cable.

NOTE: Opening the fuel valve too quickly can cause

the internal excess flow valve to close, restricting the
flow of fuel. If this happens, close the fuel valve, wait 1. FUEL RAIL
2. FUEL INJECTOR
a few seconds, and then slowly open the fuel valve 3. CLAMP
again. This will reset the excess flow valve. 4. HOSE
9. Slowly open the fuel valve on tank. Figure 11. Fuel Injectors and Fuel Rail
10. Turn the key to the ON position and back to
the OFF position to pressurize the fuel system. CAUTION
Check for leaks. When cutting the clamps, use caution not to cut
the hoses or the fuel injector barbs.
11. Check for leaks at connections by using soapy
solution or electron leak detector. If leaks are 2. Carefully cut the clamps holding the hoses to the
detected, make proper repairs. fuel injector barbs.

9
Fuel Injector Repair 900 SRM 1124

3. Disconnect hoses from the fuel injectors by hold-

ing hose and rotating fuel injector back and forth
while pulling the fuel injector outward, away
from the hose.

4. Remove O-rings from fuel injectors and discard.

Clean

WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.

CAUTION
Do not use any solvents or cleaners when clean- 1. ADAPTERS
ing the fuel injectors. 2. FUEL INJECTORS

Remove any debris on the open end (outlet toward Figure 12. Fuel Injectors and Adapters
engine) of the fuel injector. Cleaning is only done by
carefully inserting a pick type tool into the passage 6. Verify that all fuel hoses are in correct position
and scraping out debris. Only use compressed air for and not kinked. Tighten each clamp screw to 2.45
blowing away any loose particles. to 2.77 N•m (40 to 45 lbf in).

7. Connect the four electrical connectors to the fuel

Install injectors. Verify that the connectors click/lock
1. Install new O-rings on fuel injectors. into place.

8. Connect the two PCV hoses.

CAUTION
9. Connect the fuel line to the fuel rail.
When installing the fuel injectors, install using
hand pressure only. Do not use an object or 10. Connect the negative battery cable.
tool to hit the injectors to force them into the
adapters. NOTE: Opening the fuel valve too quickly can cause
the internal excess flow valve to close, restricting the
2. Install the fuel injectors into the fuel injector flow of fuel. If this happens, close the fuel valve, wait
adapters. Push the injectors into the adapters a few seconds, and then slowly open the fuel valve
using hand pressure only. See Figure 12. again. This will reset the excess flow valve.
3. Place the fuel rail in position on the mounting 11. Slowly open the fuel valve on tank.
bracket.
12. Turn the key to the ON position and back to
4. Install two capscrews and washers to retain the the OFF position to pressurize the fuel system.
fuel rail to the mounting bracket. Tighten cap- Check for leaks.
screws to 10 N•m (88.5 lbf in).
13. Check for leaks at connections by using soapy
5. Place new screw-type clamps over each of the solution or electron leak detector. If leaks are
hoses. Insert the hoses onto the fuel injector detected, make proper repairs.
barbs.

10
900 SRM 1124 Fuel Injector Repair

FUEL INJECTOR ADAPTERS Legend for Figure 13

Remove 1. RETAINING PLATE

2. CAPSCREWS
3. LOCKWASHERS
CAUTION
3. Remove the fuel injector adapters by using a
The fuel injectors are held in place with an
slight twisting motion to pull the adapters out of
internal "C" ring. When removing the fuel in-
the intake manifold. See Figure 14.
jectors, pull the injectors straight out. Do not
pry the injectors with a screwdriver or prybar,
as this can damage the injectors or injector
adapters.

NOTE: Do not cut the clamps for the hoses attaching

the fuel injectors to the fuel rail. Remove the fuel
injectors and fuel rail as an assembly.

1. Remove the fuel rail with the injectors attached

by pulling the injectors straight out of the
adapters. See Fuel Rail, Remove, Step 1 through
Step 6, and Figure 11.

2. Remove the two capscrews and lockwashers re-

taining the fuel injector adapter retaining plate
and remove retaining plate. See Figure 13.

1. FUEL INJECTOR ADAPTERS

2. INTAKE MANIFOLD

Figure 14. Fuel Injector Adapters

4. Remove the O-rings from the adapters and dis-

card O-rings. See Figure 15.

Install
1. Install new O-rings on adapters.

2. Lubricate the O-rings on the adapters with clean

engine oil and install the adapters into the intake
manifold. See Figure 14.

Figure 13. Fuel Injector Adapter Retaining

Plate

11
LPG Regulator Repair 900 SRM 1124

3. Place the fuel injector adapter retaining plate

in position on the intake manifold. Install the
two capscrews and lockwashers. Tighten the cap-
screws to 20 N•m (14.75 lbf ft).

4. Install the fuel injectors and fuel injector rail.

See Fuel Injector, Install.

1. FUEL INJECTOR ADAPTER

2. O-RING

Figure 15. Fuel Injector Adapter and O-ring

LPG Regulator Repair

LPG REGULATOR WARNING
A small amount of fuel may still be present in
Remove
the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues
WARNING to flow from the connections when loosened,
LPG can cause an explosion. Do not permit any check to make sure the manual valve is fully
sparks or open flames in the work area. closed.

1. Close fuel valve on tank. Run engine until it 4. Slowly disconnect fuel line fitting from fuel filter
stops. assembly to LPG Regulator. See Figure 16.

2. Disconnect negative battery cable. 5. Disconnect the fuel line from LPG Regulator to
fuel rail.
WARNING 6. Tag and disconnect coolant hoses from LPG Reg-
DO NOT remove the radiator cap from the radi- ulator. Cap coolant hoses.
ator when the engine is hot. When the radiator
cap is removed, the pressure is released from 7. Disconnect balance line from LPG Regulator.
the system. If the system is hot, the steam and
boiling coolant can cause burns. 8. Disconnect electrical connector from lock-off so-
lenoid.
3. Put a drain pan under drain valve for radiator.
Open drain valve so coolant drains into pan. Re- 9. Remove capscrew and LPG Regulator from
move radiator cap. mounting bracket. See Figure 17.

12
900 SRM 1124 LPG Regulator Repair

7. Fill the cooling system. Refer to the section Pe-

riodic Maintenance 8000 SRM 1150.

8. Install radiator cap.

9. Connect negative battery cable.

NOTE: Opening the fuel valve too quickly can cause

the internal excess flow valve to close, restricting the
flow of fuel. If this happens, close the fuel valve, wait
a few seconds, and then slowly open the fuel valve
again. This will reset the excess flow valve.

10. Slowly open the fuel valve on tank.

11. Turn the key to the ON position and back to

the OFF position to pressurize the fuel system.
Check for leaks.

12. Check for leaks at connections by using soapy

1. FUEL FILTER TO FUEL TANK FUEL LINE solution or electron leak detector. If leaks are
2. FUEL FILTER ASSEMBLY detected, make proper repairs.
3. FUEL FILTER TO LPG REGULATOR FUEL LINE
4. LOCK-OFF SOLENOID
5. MOUNTING BRACKET
6. LPG REGULATOR
7. BALANCE LINE
8. COOLANT HOSE
9. COOLANT HOSE
10. LPG REGULATOR TO FUEL RAIL FUEL LINE

Figure 16. LPG Regulator and Hose Assembly

Install
1. Place the LPG Regulator in position on mounting
bracket and install capscrew. Tighten capscrew
to 20 N•m (14.75 lbf ft).

2. Connect electrical connector to lock-off solenoid.

See Figure 16.

3. Connect balance line to LPG Regulator.

4. Remove caps from coolant hoses and connect 1. MOUNTING BRACKET

coolant hoses to LPG Regulator as tagged during 2. CAPSCREW
removal. 3. LPG REGULATOR

5. Connect the fuel line to LPG Regulator from fuel Figure 17. LPG Regulator Mounting Bracket
rail.

6. Connect fuel line fitting from filter unit to LPG

Regulator.

13
LPG Regulator Repair 900 SRM 1124

LPG REGULATOR FUEL FILTER 7. Connect the negative battery cable.

Remove NOTE: Opening the fuel valve too quickly can cause
the internal excess flow valve to close, restricting the
flow of fuel. If this happens, close the fuel valve, wait
WARNING
a few seconds, and then slowly open the fuel valve
LPG can cause an explosion. Do not permit any again. This will reset the excess flow valve.
sparks or open flames in the work area.
8. Slowly open the fuel valve on tank.
1. Close fuel valve on tank. Run engine until it
stops. 9. Turn the key to the ON position and back to
the OFF position to pressurize the fuel system.
2. Disconnect the negative battery cable. Check for leaks.

WARNING 10. Check for leaks at connections by using soapy

solution or electron leak detector. If leaks are
A small amount of fuel may still be present in
detected, make proper repairs.
the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues
to flow from the connections when loosened,
check to make sure the manual valve is fully
closed.

3. Disconnect the fuel inlet and outlet lines from the

LPG Regulator. See Figure 16.

4. Remove the fuel inlet fitting and O-ring. See Fig-

ure 18.

5. Remove the plastic body, foam filter, paper filter

element, and filter gasket.

6. Remove the screws fuel outlet fitting O-ring, and

filter. Discard O-ring and filter.

Install
1. Install new filter in port for fuel outlet fitting. 1. LPG REGULATOR
See Figure 18. 2. OUTLET FILTER
3. O-RING
2. Install new O-ring and fuel outlet fitting. 4. FUEL OUTLET FITTING
5. SCREW
6. FILTER GASKET
3. Install retaining screws for fuel outlet fit- 7. PAPER FILTER ELEMENT
ting. Tighten screws to 2 to 3 N•m (17.7 to 8. FOAM FILTER
26.55 lbf in). 9. PLASTIC BODY
10. O-RING
4. Install the filter gasket, new paper filter element, 11. FUEL INLET FITTING
new foam filter, and plastic body.
Figure 18. LPG Regulator Fuel Filter
5. Install the fuel inlet fitting and O-ring. Tighten
to 18 to 20 N•m (13.3 to 14.75 lbf ft).

6. Connect the fuel inlet line to the LPG Regulator.

See Figure 16.

14
900 SRM 1124 LPG Regulator Repair

LOCK-OFF SOLENOID AND CARTRIDGE a few seconds, and then slowly open the fuel valve
again. This will reset the excess flow valve.
Remove
5. Slowly open the fuel valve on tank.
WARNING 6. Turn the key to the ON position and back to
LPG can cause an explosion. Do not permit any the OFF position to pressurize the fuel system.
sparks or open flames in the work area. Check for leaks.
1. Close fuel valve on tank. Run engine until it 7. Check for leaks at connections by using soapy
stops. solution or electron leak detector. If leaks are
detected, make proper repairs.
2. Disconnect the negative battery cable.

3. Disconnect the electrical connector from the lock-

off solenoid.

WARNING
A small amount of fuel may still be present in
the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues
to flow from the connections when loosened,
check to make sure the manual valve is fully
closed.

4. Remove the nut and solenoid from the cartridge.

See Figure 19.

5. Remove the cartridge from the LPG Regulator.

Install
1. Install new cartridge into LPG Regulator.
Tighten cartridge to 16 to 24 N•m (11.8 to
17.7 lbf ft).

2. Install solenoid and nut onto cartridge. Tighten

nut to 7.85 N•m (69.5 lbf in).

3. Connect electrical connector to solenoid. 1. LPG REGULATOR

2. CARTRIDGE
4. Connect the negative battery cable. 3. COIL
4. NUT
NOTE: Opening the fuel valve too quickly can cause
the internal excess flow valve to close, restricting the Figure 19. Lock-Off Solenoid
flow of fuel. If this happens, close the fuel valve, wait

15
Control System 900 SRM 1124

Control System
ELECTRONIC CONTROL UNIT (ECU) 8. Remove the capscrews and nuts holding the ECU
to the mounting bracket. See Figure 21.
Remove
1. Disconnect the negative battery cable.

2. Disconnect the throttle body electrical connector.

3. Remove the capscrews holding the air filter

mounting bracket to the ECU mounting bracket.
See Figure 20.

1. MOUNTING BRACKET
2. CAPSCREW
3. NUTS
4. ECU

Figure 21. ECU Mounting Bracket

9. Disconnect the electrical connectors from the

ECU. Rotate the locking tabs on each connector
to unlock the electrical connectors. Disconnect
the connector closest to the fan assembly first.
Disconnect the center connector second. Dis-
1. CAPSCREW connect the third connector. Remove ECU. See
2. AIR FILTER MOUNTING BRACKET Figure 22.
3. ECU MOUNTING BRACKET
4. WIRE HARNESS CLAMP Install
Figure 20. Air Filter Mounting Bracket and 1. Connect the electrical connectors to the ECU.
ECU Mounting Bracket Connect the electrical connector furthest from
the fan assembly first. Connect the center con-
4. Lower the ECU and mounting bracket assembly
nector second. Connect the connector closest to
down toward the frame.
the fan assembly last. Rotate the locking tabs to
5. Disconnect the hoses from the air filter assembly. lock the electrical connectors in position.

6. Remove the three bolts that attach the air filter 2. Place the ECU in position on the mounting
assembly mounting bracket to the frame and re- bracket. Install the capscrews and nuts. Tighten
move air filter assembly with mounting bracket. capscrews to 10 N•m (88.5 lbf in).

7. Remove capscrew retaining wire harness clamp

to ECU mounting bracket.

16
900 SRM 1124 Control System

POWER LATCH RELAY

Remove
1. Disconnect the negative battery cable.

2. Remove the capscrews holding the air filter

mounting bracket to the ECU mounting bracket.
See Figure 20.

3. Lower the ECU and mounting bracket assembly

down toward the frame.

4. Disconnect the hoses from the air filter assembly.

5. Remove the three bolts that attach the air filter

assembly mounting bracket to the frame and re-
1. MOUNTING BRACKET
2. LOCKING TAB move air filter assembly with mounting bracket.
3. ECU
4. ELECTRICAL CONNECTORS 6. Remove the capscrews and nuts retaining the
power latch relay to the ECU mounting bracket.
Figure 22. ECU and Electrical Connectors See Figure 23.

3. Position the wire harness and wire harness 7. Disconnect the electrical connector from the
clamp on the ECU mounting bracket. Install power latch relay.
the capscrew to retain the wire harness clamp.
Tighten capscrew to 10 N•m (88.5 lbf in).

4. Place the air filter assembly with mounting

bracket in position on the frame. Install bolts
and tighten to 20 N•m (14.75 lbf ft).

5. Connect the hoses to the air filter assembly.

6. Slide the ECU and mounting bracket assembly

into position on the air filter mounting bracket.

7. Install the capscrews to retain the ECU mount-

ing bracket to the air filter mounting bracket.
Tighten capscrews to 20 N•m (14.75 lbf ft).

8. Connect the negative battery cable.

9. Key ON the vehicle and with the PC service tool

send a "Restore ECU Defaults" command via the
CAN communication bus.
1. CAPSCREWS
10. Key OFF the vehicle and wait 30 seconds. 2. POWER LATCH RELAY
3. ELECTRICAL CONNECTOR
11. Connect the throttle body electrical connector. 4. ECU MOUNTING BRACKET
5. NUTS
12. Start the vehicle and check for proper operation
of the throttle body and the ECU by exercising Figure 23. Power Latch Relay
the accelerator pedal with the vehicle in neutral.
The engine should idle at 775 to 825 rpm with no
pedal to the governed speed of 2675 to 2725 rpm
at full pedal.

17
Control System 900 SRM 1124

Install
1. Connect the electrical connector from the power
latch relay.

2. Place the power latch relay in position on the

ECU mounting bracket.

3. Install capscrews and nuts to retain the power

latch relay to the ECU mounting bracket.
Tighten capscrews to 10 N•m (88.5 lbf in).

4. Place the air filter assembly with mounting

bracket in position on the frame. Install bolts
and tighten to 20 N•m (14.75 lbf ft).

5. Connect the hoses to the air filter assembly.

1. CAPSCREW
6. Slide the ECU and mounting bracket assembly 2. NUT
into position on the air filter mounting bracket. 3. INJECTOR DRIVER MODULE

7. Install the capscrews to retain the ECU mount- Figure 24. Injector Driver Module
ing bracket to the air filter mounting bracket.
Tighten capscrews to 20 N•m (14.75 lbf ft).

8. Connect the negative battery cable.

INJECTOR DRIVER MODULE

Remove
1. Disconnect the negative battery cable.

2. Remove the capscrews holding the air filter

mounting bracket to the ECU mounting bracket.
See Figure 20.

3. Lower the ECU and mounting bracket assembly

down toward the frame.

4. Disconnect the hoses from the air filter assembly.

5. Remove the three bolts that attach the air filter

assembly mounting bracket to the frame and re- 1. ELECTRICAL CONNECTOR
move air filter assembly with mounting bracket. 2. INJECTOR DRIVER MODULE

6. Remove the capscrew and nut retaining the injec- Figure 25. Injector Driver Module Electrical
tor driver module to the mounting bracket. See Connector
Figure 24.

7. Disconnect the electrical connector from the in-

jector driver module. See Figure 25.

18
900 SRM 1124 Control System

Install 3. Remove harness clamp from CMP sensor support

plate.
1. Connect the electrical connector to the injector
driver module. 4. Remove the screw and lockwasher retaining the
CMP sensor. See Figure 27.
2. Place the injector driver module in position on
the mounting bracket.

3. Install the capscrew and nut to retain the injector

driver module to the mounting bracket. Tighten
the capscrew to 10 N•m (88.5 lbf in).

4. Place the air filter assembly with mounting

bracket in position on the frame. Install bolts
and tighten to 20 N•m (14.75 lbf ft).

5. Connect the hoses to the air filter assembly.

6. Slide the ECU and mounting bracket assembly

into position on the air filter mounting bracket.

7. Install the capscrews to retain the ECU mount-

ing bracket to the air filter mounting bracket.
Tighten capscrews to 20 N•m (14.75 lbf ft).

8. Connect the negative battery cable.

1. SCREW
CAMSHAFT POSITION (CMP) SENSOR 2. LOCKWASHER
3. CMP SENSOR
Remove 4. O-RING
5. CMP SENSOR SUPPORT PLATE
1. Disconnect the negative battery cable.
Figure 27. CMP Sensor
2. Disconnect the CMP sensor electrical connector.
See Figure 26. 5. Remove the CMP sensor and O-ring.

6. Remove O-ring from CMP sensor and discard.

Install
1. Install new O-ring on CMP sensor.

2. Lubricate O-ring with clean engine oil.

3. Install the CMP sensor into the CMP sensor sup-

port plate.

NOTE: Before installing retaining screw, verify the

CMP sensor is fully seated.

4. Install retaining screw and lockwasher. Tighten

retaining screw to 6 N•m (53 lbf in).

5. Connect the electrical connectors. Verify that the

1. CMP SENSOR connectors click/lock into place.
2. WIRE HARNESS CLAMP
3. ELECTRICAL CONNECTORS 6. Install harness clamp to CMP sensor support
plate.
Figure 26. CMP Sensor Electrical Connector

19
Control System 900 SRM 1124

MANIFOLD ABSOLUTE PRESSURE ENGINE COOLANT TEMPERATURE (ECT)

(MAP)/MANIFOLD AIR TEMPERATURE SENSOR
(MAT) SENSOR
Remove
Remove
1. Disconnect the negative battery cable.
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector from the ECT
2. Disconnect the electrical connector from the sensor. See Figure 29.
MAP/MAT sensor. See Figure 28.
3. Remove the ECT sensor and washer.
3. Remove the two screws retaining the MAP/MAT
sensor to the intake manifold. Remove MAP/
MAT sensor.

1. MAP/MAT SENSOR
2. SCREW
3. ELECTRICAL CONNECTOR 1. ELECTRICAL CONNECTOR
2. ECT SENSOR
Figure 28. MAP/MAT Sensor 3. WASHER

Install Figure 29. ECT Sensor

1. Place the MAP/MAT sensor in position on the Install

intake manifold and install the two retaining
screws. Tighten retaining screws to 6 N•m 1. Install the new ECT sensor and washer. Tighten
(53 lbf in). the sensor to 20 N•m (14.75 lbf ft).

2. Connect the electrical connector to the 2. Connect the electrical connector to the ECT sen-
MAP/MAT sensor. Verify that the connector sor.
clicks/locks into place.
3. Connect the negative battery cable.
3. Connect the negative battery cable.

20
900 SRM 1124 Control System

OXYGEN SENSOR 2. Install nut and clip to retain the oxygen sensor
wiring harness and connector to the thermostat
Remove housing.

1. Disconnect the negative battery cable. 3. Connect the electrical connectors. Verify that the
connectors click/lock into place.
2. Disconnect the oxygen sensor electrical connec-
tor. See Figure 30. 4. Verify that the wire is pulled up toward the ther-
mostat and away from any hot exhaust compo-
nents.

5. Connect the negative battery cable.

Figure 31. Oxygen Sensor Socket

1. ELECTRICAL CONNECTORS
2. CLIP
3. NUT
4. THERMOSTAT HOUSING

Figure 30. Oxygen Sensor Electrical Connector

3. Remove nut and clip retaining the oxygen sensor

wiring harness and connector to the thermostat
housing.

4. Using a special tool, oxygen sensor socket, re-

move the oxygen sensor. See Figure 31 and Fig-
ure 32.

Install
1. Before installing the sensor, coat sensor spar-
ingly with an antiseize compound, then install
oxygen sensor into exhaust manifold adapter. 1. EXHAUST MANIFOLD ADAPTER
Using a special tool, oxygen sensor socket, 2. OXYGEN SENSOR
tighten oxygen sensor to 40 to 60 N•m (30 to Figure 32. Oxygen Sensor
44 lbf ft). See Figure 31 and Figure 32.

21
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 TECHNICAL PUBLICATIONS

900 SRM 1124 8/06 (5/05)(12/04) Printed in United Kingdom