Service Manual Beta 2LTR Impco Engine Manual

HHI
2007-2009
2009 Emission Certified
LPG & Bi-Fuel
Bi System
2.0L Engine
Service Manual
Revision A/June, 2009
Table of Contents
General Information................................
................................................................................................
.....................................5
An overview of this Service Manual
Maintenance ................................................................................................
................................ ............................................... 11
General maintenance and maintenance interval information
LPG Fuel System ................................................................................................

................................ ....................................... 19
An overview of the LPG fuel system and its components
LPG Fuel System Diagnosis ................................................................

..................................................... 29
How to identify a general problem
LPG Symptom Diagnostics tics................................................................

....................................................... 39
How to correct a specific problem
Gasoline Fuel System................................

................................................................................................
................................ 55
An overview of the Gasoline fuel system (bi-fuel models only) and its components
Gasoline Fuel System Diagnosis................................................................

Diagn .............................................. 63
How to identify a general problem with the Gasoline fuel system bi-fuel fuel models only)
Gasoline Symptom Diagnostics ................................................................

............................................... 71
How to correct a specific problem with the Gasoline fuel system (bi-fuel fuel models
model only)
Electrical Section ................................................................................................

................................ ....................................... 85
Diagnostic Scan Tool ...........................................................................................

................................ ........................... 87
Using the DST for testing and trouble shooting
Wire Schematic................................
................................................................................................
..................................... 121
Engine wiring schematic
Engine Wire Harness Repair................................................................

Repair ................................................ 125
Repairing a wire harness on the vehicle
Diagnosticic Trouble Codes (DTCs) ................................................................

...................................... 129
Application, schematic and DTC specific code information
Servicing the Fuel System ................................................................
........................................................ 457
Step by step instructions on how repair and/or replace fuel related components omponents
Definitions ................................................................................................
................................ .................................................. 475
Definitions of phrases and acronyms used throughout this Service Manual
Tool Kit & Accessories................................

..............................................................................................
.............................. 481
Definitions of phrases and acronyms used throughout this Service Manual
Appendix ................................................................................................
................................ .................................................... 483
Altitude vs. Barometric Pressure & Ignition System Specifications
4
General Information
5
GENERAL INFORMATION
INTRODUCTION ing technician and damage to the vehicle or

components. Service repairs should always
This service manual supplement has been be performed in a safe environment and the
developed to provide the service technician technician should always wear protective
with the basic understanding of the IMPCO clothing to prevent injury.
certified fuel and emission systems for the
2.0L engine. This manual should be used in For parts or labor to be reimbursed under the
conjunction with the base engine manual and IMPCO Technologies Inc. emission warranty,
the OEM service manual when diagnosing only work performed by IMPCO or OEM
fuel or electrical problems. trained technicians using only IMPCO speci-
fied parts will qualify for reimbursement.
HOW TO IDENTIFY THE ENGINE YEAR Refer to the IMPCO Labor Time Guide for ad-
ditional information.
The 2.0L engine blocks have been stamped
with a serial number. The number can be
For parts or labor not reimbursed under war-
found on the left side of the top edge of the
ranty, a repair shop or person of the owner’s
engine block near the exhaust manifold.
choosing may maintain, replace, or repair
emission-control devices and systems. It is
highly recommended that any replacement
parts used for maintenance or for the repair of
emission control systems be new OEM re-
placement parts. The use of other than
genuine IMPCO replacement parts may im-
pair the effectiveness of emission control
systems, therefore, the owner should assure
that such parts are warranted by their manu-
facturer to be equivalent to genuine IMPCO
OEM parts in performance and durability.
FUEL QUALITY
LPG
Note that LPG engines are designed to operate

on HD–5 or HD–10 specification LPG fuel. Fuel
other than HD–5 or HD–10 may cause harm to
the engine’s emission control system and a war-
ranty claim may be denied on this basis if
operators can readily find the proper fuel*.
Engine Identification Number Table
Use of any other fuel may result in your engine no
longer operating in compliance with CARB or
SERVICING YOUR EMISSIONS
EPA emissions requirements.
CERTIFIED ENGINE
*Not Applicable in the state of California.
Any maintenance and repair should be per-
formed by trained and experienced service
technicians. Proper tools and equipment
should be used to prevent injury to the servic-
6
GENERAL INFORMATION
Gasoline
IMPCO recommends the use of name brand

high detergent gasoline. Gasoline is a mixture Do not allow LPG to accumulate in
of many different hydrocarbons, including ole- areas below ground level such as in a
fins, which are heavy, waxy compounds. Over service pit or underground ventilation
time, these deposits can build up and clog the systems. LPG is heavier than air and
fuel injectors. The formation of these deposits can displace oxygen, creating a dan-
is a normal consequence of engine operation, gerous condition
so detergents are added to high quality gaso-
line to help keep the injectors clean. The use
of low quality low detergent gasoline may
cause fuel injectors to fail. Fuel injector re-
placement or cleaning is expensive, and the Do not make repairs to the LPG fuel
cleaning procedure requires special equip- system if you are not familiar with or
ment that may not be practical in the industrial trained to service LPG fuel system.
lift truck market. Speak with your fuel supplier Contact the dealer who sold you the
to verify that the fuel you are supplied con- vehicle to locate a repair facility with
tains the necessary fuel additives to keep trained technicians to repair your fuel
your fuel system clean. IMPCO may deny system
emissions related warranty claims due to the
use of low quality low detergent gasoline. WARNINGS, CAUTIONS AND NOTES
FUEL SYSTEM CAUTIONS This manual contains several different Warn-

ings, Cautions, and Notes that must be
observed to prevent personal injury and or
damage to the vehicle, the fuel system or
personal property.
Do not smoke, carry lighted tobacco or
use a lighted flame of any type when A “WARNING“ is an advisement that by per-
working on or near any fuel related forming a process or procedure listed in this
component. Highly flammable air-fuel manual improperly may result in serious bodi-
mixtures may be present and can be ly injury, death and/or serious damage to the
ignited causing personal injury vehicle or property.
Typical Warning Label:
Do not allow LPG to contact the skin.

LPG is stored in the fuel tank as a liq-
uid. When LPG contacts the Failure to heed instructions could re-
atmosphere, it immediately expands sult in death, injury, or property
into a gas, resulting in a refrigeration damage.
effect that can cause severe burns to
the skin.
A “CAUTION” label or statement is used when
it has been determine that by performing a
process or procedure defined in the manual
improperly a less severe result may occur. It
7
GENERAL INFORMATION
could however, result in serious bodily injury,  The installed IMPCO fuel system has
and or serious damage to the vehicle or prop- been certified with the Environmental Pro-
erty damage. tection Agency (EPA) and the California
Air Resources Board (CARB) and com-
plies with the regulation in effect at the
time of certification. When servicing the
fuel and emission control system you
Less severe than WARNING but has the should follow all the recommended ser-
potential to cause injury or damage. vice and repair procedures to insure the
Also used to notify of situations that fuel and emissions system is operating as
could lead to eventual failure, injury or designed and certified. Purposely or kno-
damage. wingly defeating or disabling any part or
the fuel and emission system may be in
violation of the anti-tampering provision of
This caution label may also appear in area of the EPA’s Clean Air Act.
this manual that applies to service and repair
procedures which could render the fuel and  Tools identified in this manual with the
emissions control system non-compliant. In prefix “J” or “BT” can be procured through
addition it may also be used to indicate a fail- SPX in Warren, Michigan.
ure to observe which may influence the terms
of the warranty.  Tools identified in this manual with a prefix
“ITK” can be acquired through OEM Parts
An “IMPORTANT” statement generally de- Distribution.
notes a situation that requires strict
adherence to the assembly, tightening, or IMPORTANT
service procedure. Failure to observe this It is important to remember that there may be
procedure could result in an unsafe condition a combination of Metric and Imperial fasten-
or improper performance of the vehicle or a ers used in the installation of the IMPCO fuel
component. system. Check to insure proper fit when using
a socket or wrench on any fastener to prevent
A “NOTE” statement applies to a specific item damage to the component being removed or
or procedure that is to be followed during the injury from “slipping off” the fastener.
servicing of the vehicle or its components.
The IMPCO fuels system utilizes fuel lines
PROPER USE OF THIS SERVICE MANUAL, hoses with swivel connections which attach to
TOOLS AND EQUIPMENT fixed mating connectors. You should always
use a wrench of the proper size on both the
To reduce the potential for injury to the tech- swivel and fixed fitting to prevent turning of
nician or others and to reduce damage to the the fixed fitting. Turning of the fixed fitting may
vehicle during service repairs the technician cause a “twisting” or “kinking” of the hose and
should observe the following steps: may result in a restriction of the fuel line or a
leak.
 The service procedures defined in this
manual, when followed, have been found
to be a safe and efficient process to repair
the fuel system. In some cases special
tools may be required to perform the ne-
cessary procedures to safely remove and
replace a failed component.
8
GENERAL INFORMATION
Always leak check any fuel system

connection after servicing! Use an
electronic leak detector and/or a liquid
leak detection solution. Failure to leak
check could result in serious bodily
injury, death, or serious property dam-
age.
9
10
Maintenance
11
MAINTENANCE SERPENTINE BELT SYSTEM
The maintenance of an engine and related com- Serpentine belts utilize a spring-loaded tensioner
ponents are critical to its operating performance to keep the belt properly adjusted. Serpentine
and lifespan. Industrial engines operate in envi- belts should be checked according to the main-
ronments that often include hot and cold tenance schedule in this section.
temperatures and extreme dust. The recom-
mended maintenance schedule is listed in this IMPORTANT:
section, however, environmental operating condi- The use of “belt dressing” or “anti-slipping
tions and additional installed equipment may agents” on belts is not recommended.
require more frequent inspection and servicing.
The owner and/or service agent should review the COOLING SYSTEM
operating conditions of the equipment to deter-
mine the inspection and maintenance intervals. It is important that the cooling system of the en-
gine be maintained properly to ensure proper
performance and longevity.
When performing maintenance on the engine,

turn the ignition OFF and disconnect the bat-
tery negative cable to avoid injury or damage Do not remove the cooling system pressure
to the engine. cap (radiator cap) when the engine is hot.
Allow the engine to cool and then remove the
The engine installed in this equipment uses a ser- cap slowly to allow pressure to vent. Hot
pentine drive belt configuration that drives the coolant under pressure may discharge vio-
water pump, alternator and additional pumps or lently.
devices. It is important to note that the drive belt
is an integral part of the cooling and charging sys- Note that the LPG vaporizer is connected to the
tem and should be inspected according to the cooling system and the fuel system may be ad-
maintenance schedule in this section. When in- versely affected by low coolant levels and
specting the belts check for: restricted or plugged radiator cores. Therefore,
the cooling system must be maintained according
 Cracks to the recommend maintenance schedule in this
 Chunking of the belt section and also include:
 Splits
 Material hanging loose from the belt  The regular removal of dust, dirt and debris
 Glazing, hardening from the radiator core and fan shroud.
 Inspection of coolant hoses and components
If any of these conditions exist the belt should be for leaks, especially at the radiator hose con-
replaced with the recommended OEM replace- nections. Tighten hose clamps if necessary.
ment belt.  Check radiator hoses for swelling, separation,
hardening, cracks or any type of deterioration.
If any of these conditions exist the hose
should be replaced with a recommended OEM
replacement part.
Alcohol or Methanol based anti-freeze or plain  Inspect the radiator cap to ensure proper seal-
water are not recommended for use in the ing.
cooling system at anytime.
12
COOLANT ENGINE CRANKCASE OIL
Check coolant level in coolant recovery tank and OIL RECOMMENDATION

add coolant as required. Add 50/50 mixture of
ethylene glycol antifreeze and distilled water or Select an engine oil that will best match the pre-
coolant per engine manufacturer’s instructions. vailing daytime temperature:
Do not add plain water. Replace coolant per the
recommended schedule.
IMPORTANT:
The manufacturers of the engine and fuel system
do not recommend the use of “stop leak” additives
to repair leaks in the cooling system. If leaks are
present the radiator should be removed and re-
paired or replaced.
ENGINE ELECTRICAL SYSTEM MAINTNANCE
The engine’s electrical system incorporates com-

puters to control various related components. The
electrical system connections and ground circuits
require good connections. Follow the recom-
mended maintenance schedule in this section to
maintain optimum performance. When inspecting
the electrical system check the following:
 Check Positive and Negative cables for corro-

sion, rubbing, chafing, burning and to ensure
tight connections at both ends. Motor oils meeting this spec receive the API
(American Petroleum Institute) starburst symbol:
 Check battery for cracks or damage to the
case and replace if necessary.
 Inspect engine wire harness for rubbing, chaf-
ing, pinching, burning, and cracks or breaks in
the wiring.
 Verify that engine harness connectors are cor-
rectly locked in by pushing in and then pulling
the connector halves outward.
 Inspect primary ignition coil wires for harden-
ing, cracking, arcing, chafing, burning,
separation, split boot covers.
 Check spark plug wires for hardening, crack-
ing, chafing, arcing or burning, separation, and The recommended API classification: Above SG.
split boot covers.
 Replace spark plugs at the required intervals The oil capacity for the 2.0L engine including a
per the recommended maintenance schedule. new filter is 1.1 gallons (4.0L)
 Verify that all electrical components are se-
curely mounted to the engine or chassis. IMPORTANT:
 Verify that any additional electrical services Oils recommended by the engine manufacturer
installed by the owner are properly installed in already contain a balanced additive treatment.
the system. Oils containing “solid” additives, non-detergent
 Verify that the MIL, charging, and oil pressure oils, or low quality oils are not recommended by
lights illuminate momentarily during engine start. the engine manufacturer. The supplemental addi-
tives added to the engine oil are not necessary
and may be harmful. The engine and fuel system
13
supplier do not review, approve or recommend CHANGING THE ENGINE OIL
such products.
IMPORTANT:
SYNTHETIC OILS When changing the oil, always change the oil
filter.
Synthetic oils have been available for use in in-
dustrial engines for a relatively long period of 1. Start the engine and run until it reaches nor-
time and may offer advantages in cold and hot mal operating temperature.
temperatures. However, it is not known if syn-
thetic oils provide operational or economic
benefits over conventional petroleum-based oils
in industrial engines. Use of synthetic oils does
not permit the extension of oil change intervals.
An overfilled crankcase (oil level being too
CHECKING/FILLING ENGINE OIL LEVEL high) can cause an oil leak, a fluctuation or
drop in oil pressure. When overfilled, the en-
IMPORTANT: gine crankshafts splash and agitate the oil,
Care must be taken when checking engine oil lev- causing it to aerate or foam.
el. Oil level must be maintained between the
“ADD” mark and the “FULL” mark on the dipstick. IMPORTANT:
To ensure that you are not getting a false reading, Change oil when engine is warm and the old oil
make sure the following steps are taken before flows more freely.
checking the oil level.
2. Stop engine
1. Stop engine.
2. Allow approximately five minutes for the oil to IMPORTANT:
drain back into the oil pan. Engine oil will be hot. Use protective gloves to
3. Remove the dipstick. Wipe with a clean cloth prevent burns. Engine oil contains chemicals
or paper towel and reinstall. Push the dipstick which may be harmful to your health. Avoid skin
all the way into the dipstick tube. contact.
4. Remove the dipstick and note the amount of
oil on the dipstick. The oil level must be be- 3. Remove drain plug and allow the oil to drain.
tween the “FULL” and “ADD” marks. 4. Remove and discard oil filter and its sealing
ring.
5. Coat sealing ring on the new filter with clean
engine oil, wipe the sealing surface on the
filter mounting surface to remove any dust, dirt
or debris. Tighten filter securely (follow filter
manufacturer’s instructions). Do not over tigh-
ten.
6. Check sealing ring on drain plug for any dam-
Figure 2 Engine Oil Dip tick (Typical) age, replace if necessary, wipe plug with clean
rag, wipe pan sealing surface with clean rag
5. If the oil level is below the “ADD” mark reinstall and re-install plug into the pan. Tighten to
the dipstick into the dipstick tube and proceed 25.3-32.4 ft.lbs (34.3-44.1 Nm).
to Step 6.
6. Remove the oil filler cap from the valve cover. IMPORTANT:
7. Add the required amount of oil to bring the Always use a new drain plug gasket when chang-
level up to, but not over, the “FULL” mark on ing the oil.
the dipstick Reinstall the oil filler cap to the
valve rocker arm cover and wipe any excess 7. Fill crankcase with oil.
oil clean. 8. Start engine and check for oil leaks.
14
9. Dispose of oil and filter in a safe manner. using a soapy solution or an electronic leak
detector and repair if necessary.
FUEL SYSTEM INSPECTION AND  Check to make sure filter is securely mounted.
MAINTENANCE  Check filter housing for external damage or
distortion. If damaged replace fuel filter.
LPG FUEL SYSTEM
REPLACING THE LPG FUEL FILTER:
The LPG fuel system installed on this industrial
engine has been designed to meet the emission 1. Move the equipment to a well ventilated area
standard applicable for the 2007-2009 model and verify that sparks, ignition and any heat
years. To ensure compliance to these standards, sources are not present.
follow the recommended maintenance schedule 2. Start the engine.
contained in this section. 3. Close the LPG tank valve.
INSPECTION AND MAINTENANCE OF THE 4. When the engine stalls when it runs out of
FUEL STORAGE CYLINDER fuel, turn the ignition key to the OFF position
and disconnect the battery negative cable.
The fuel storage cylinder should be inspected
daily or at the beginning of each operational shift IMPORTANT:
for any leaks, external damage, adequate fuel A small amount of fuel may still be present in the
supply and to ensure the manual service valve is fuel line. Use gloves and proper eye protection
open. Fuel storage cylinders should always be to prevent burns. If liquid fuel continues to flow
securely mounted, inspect the securing straps or from the connections when removed, make sure
retaining devices for damage ensure that all lock- the manual valve is fully closed.
ing devices are closed and locked. Check to
ensure that the fuel storage cylinder is positioned 5. Slowly loosen the inlet fitting and disconnect.
with the locating pin in the tank collar on all hori- 6. Slowly loosen the outlet fitting and disconnect.
zontally mounted cylinders this will ensure the 7. Remove the filter housing form the equipment.
proper function of the cylinder relief valve. 8. Check for contamination.
9. Tap the opening of the filter on a clean cloth.
When refueling or exchanging the fuel cylinder, 10. Check for debris.
check the quick fill valve for thread damage. Also 11. Check canister for proper mounting direction.
verify O-ring is in place and inspect for cracks, 12. Reinstall the filter housing to the equipment.
chunking or separation. If damage to the o-ring 13. Tighten the inlet and outlet fittings to specifica-
is found, replace prior to filling. Check the ser- tion.
vice line quick coupler for any thread damage. 14. Open the LPG tank valve.
IMPORTANT: IMPORTANT:
When refueling the fuel cylinder, wipe both the The fuel cylinder manual valve contains an
female and male connection with a clean rag prior Excess Flow Check Valve. Open the valve slowly
to filling to prevent dust, dirt and debris from being to prevent activating the Excess Flow Check
introduced to the fuel cylinder. Valve.
INSPECTION AND REPLACEMENT OF THE 15. Check for leaks at the inlet and outlet fittings,
LPG FUEL FILTER and the filter housing end connection using a
soapy solution or an electronic leak detector, if
The LPG system on this emission certified engine leaks are detected make repairs.
utilizes an in-line replaceable fuel filter element.
This element should be replaced, at the intervals
specified in the recommended maintenance sche-
dule. When inspecting the fuel filter check the
following:
 Check for leaks at the inlet and outlet fittings,

15
ELECTRONIC PRESSURE REGULATOR (EPR) and failure to follow this recommendation may be
MAINTENANCE AND INSPECTION used to deny a warranty claim.
IMPORTANT: IMPORTANT:
The Electronic Pressure Regulator (EPR) com- Draining the regulator when the engine is warm
ponents have been specifically designed and will help the oils to flow freely from the regulator.
calibrated to meet the fuel system requirements
of the emission certified engine. To drain the EPR, follow the steps below:
If the EPR fails to operate or develops a leak, it 1. Move the equipment to a well ventilated area
should be repaired or replaced with the OEM and ensure no external ignition sources are
recommended replacement parts. When inspect- present.
ing the regulator check for the following items: 2. Start the engine.
3. With the engine running close the LPG tank
 Check for any fuel leaks at the inlet and outlet valve.
fittings. 4. When the engine runs out of fuel turn OFF the
 Check for any fuel leaks in the regulator body. key when the engine stops and disconnect the
 Check the inlet and outlet fittings of the coo- negative battery cable.
lant supply lines for water leaks.
 Check the coolant supply lines for hardening, IMPORTANT:
cracking, chafing or splits. If any of these con- A small amount of fuel may still be present in the
ditions exist replace coolant lines. fuel line, use gloves to prevent burns, wear prop-
 Check coolant supply hose clamp connec- er eye protection. If liquid fuels continues to flow
tions, ensure they are tight. from the connections when loosened check to
 Check to ensure the EPR is securely mounted make sure the manual valve is fully closed.
and the mounting bolts are tight.
 Check EPR for external damage. 5. Slowly loosen the inlet fitting and disconnect.
6. Loosen the hose clamp at the outlet hose
 Check EPR electrical connection to ensure the
fitting and remove the hose.
connector is seated and locked.
7. Remove the Retaining Pin in the LPG Tem-
perature Sensor and remove from the EPR
CHECKING/DRAINING OIL BUILD-UP IN THE
8. Remove the EPR mounting bolts.
ELECTRONIC PRESSURE REGULATOR
9. Place a small receptacle in the engine com-
partment.
During the course of normal operation oil or
10. Rotate the EPR to 90° so that the outlet fitting
“heavy ends” may build inside the secondary
is pointing down into the receptacle and drain
chamber of the Electronic Pressure Regulator
the EPR.
(EPR). These oil and heavy ends may be a result
11. Inspect the secondary chamber for any large
of poor fuel quality, contamination of the fuel, or
dried particles and remove.
regional variation of the fuel make up. A signifi-
12. Remove the receptacle and reinstall the EPR
cant build up of oil can affect the performance of
with the two retaining bolts and tighten to
the secondary diaphragm response. The Rec-
specifications.
ommended Maintenance Schedule found in this
13. Reinstall the outlet fitting and secure with the
section recommends that the oil be drained pe-
previously removed Retaining pin.
riodically. This is the minimum requirement to
14. Reconnect the electrical connector (push in
maintain the emission warranty. More frequent
until it clicks and securely locks), then pull on
draining of the EPR is recommended for special
the connector to ensure it is locked.
situation where substandard fuel may be a prob-
15. Connect the vacuum line.
lem. IMPCO recommends the EPR be drained at
16. Reconnect the outlet hose and secure the
every engine oil change if contaminated or subs-
hose clamp.
tandard fuel is suspected or known to have been
17. Reinstall the fuel inlet line and tighten connec-
used or in use with the emission complaint fuel
tion to specification.
system. This is known as special maintenance,
18. Slowly open the LPG tank valve.
16
IMPORTANT: EXHAUST SYSTEM AND CATALYTIC
The fuel cylinder manual valve contains an CONVERTER INSPECTION AND
Excess Flow Check Valve. Open the manual MAINTENANCE
valve slowly to prevent activating the Excess
Flow Check Valve. IMPORTANT:
The exhaust system on this emission certified en-
19. Check for leaks at the inlet and outlet fittings gine contains a Heated Exhaust Gas Oxygen
using a soapy solution or an electronic leak Sensor (HEGO) which provides feed back to the
detector. If leaks are detected make repairs. ECM on the amount of oxygen present in the ex-
Check coolant line connections to ensure no haust stream after combustion.
leaks are present.
20. Start engine recheck for leaks at the regulator. The measurement of oxygen in the exhaust
21. Dispose of any drained material in safe and stream is measured in voltage and sent to the
proper manner. ECM. The ECM then makes corrections to the
fuel air ratio to ensure the proper fuel charge and
AIR FUEL MIXER/THROTTLE CONTROL optimum catalytic performance. Therefore, it is
DEVICE MAINTENANCE AND INSPECTION important that the exhaust connections remain
secured and air tight.
IMPORTANT:
The Air Fuel Mixer components have been IMPORTANT:
specifically designed and calibrated to meet the The HEGO sensor is sensitive to silicone based
fuel system requirements of the emission certified products. Do not use silicone sprays or hoses
engine. The mixer should not be disassembled or which are assembled using silicone lubricants.
rebuilt. If the mixer fails to operate or develops a Silicone contamination can cause severe damage
leak the mixer should be replaced with the OEM to the HEGO.
recommended replacement parts.
When inspecting the Exhaust system check the
When inspecting the mixer check for the following following:
items:
 Exhaust manifold at the cylinder head for
 Leaks at the inlet fitting. leaks and that all retaining bolts and shields (if
 Fuel inlet hose for cracking, splitting or chaff- used) are in place.
ing, replace if any of these condition exist.  Manifold to exhaust pipe fasteners to ensure
 Ensure the mixer is securely mounted. they are tight and that there are no exhaust
 Inspect air inlet hose connection and clamp. leaks repair if necessary.
Also inspect inlet hose for cracking, splitting or  HEGO electrical connector to ensure connec-
chafing. Replace if any of these conditions ex- tor is seated and locked, check wires to
ist. ensure there is no cracking, splits chafing or
 Inspect Air cleaner element according to the “burn through.” Repair if necessary.
Recommended Maintenance Schedule found  Exhaust pipe extension connector for leaks
in this section. tighten if necessary
 Check Fuel lines for cracking, splitting or chaf-  Visually inspect converter to ensure muffler is
ing. Replace if any of these conditions exist. securely mounted and tail pipe is properly
 Verify Throttle Body return action to ensure aimed.
throttle shaft is not sticking. Repair if neces-  Check for any leaks at the inlet and outlet of
sary. the converter.
 Check for leaks at the Throttle Body and in-
take manifold.
17
LPG & BI-FUEL CERTIFIED ENGINE MAINTENANCE REQUIREMENTS
Perform the following maintenance on the engine at the hours indicated and at equivalent hour intervals thereafter.
Interval Hours
Daily 1000 1500 2000 2500 3000 3500 4000 4500 5000
General Maintenance Section
Visual check for fluid leaks X
Check engine oil level X
Check coolant level X
Change engine oil and filter Every 100 hours or 60 days of operation
Check LPG system for leaks Prior to any service or maintenance activity
Inspect accessory drive belts for cracks, breaks, splits or glazing X X X X X
Inspect electrical system wiring for cuts, abrasions or corrosion X X
Inspect all vacuum lines and fittings for cracks, breaks or hardening X X
Engine Coolant Section
Clean debris from radiator core Every 100 hours or 60 days of operation
Change coolant X X X X X
Inspect coolant hoses for cracks, swelling or deterioration X X X X X
Engine Ignition System
Inspect Battery case for leaks or damage X X X X X
Inspect battery cables for damage corrosion or contamination X X X X X
Check all electrical connector retainer locks X X X X X
Replace spark plugs X X
Fuel System Maintenance
Inspect air cleaner Every 200 hours, or every 100 hours in dusty environment
Replace filter element Annually, or Bi-annually in dusty environments
Replace PCV Valve X
Replace inline LPG fuel filter X X X X X
Check LPG shut off solenoid valve function X X
Replace fuel filter (Bi-fuel only) X X X X X
Inspect Shut-off Valve for leaks and closing X X
Leak check fuel lines X X
Check air induction for leaks X X
Check manifold for vacuum leaks X X
Check fuel injector s& rail for leaks (Bi-fuel only) X X
Replace fuel injectors (Bi-fuel only) X
Inspect EPR for coolant leaks Annually or every 2000 hours
Drain EPR oil build up Every 2500 hrs
Engine Exhaust System
Inspect exhaust manifold for leaks X X
Inspect exhaust piping for leaks X X
Check HEGO sensor connector and wires for burns, cuts or damage X X
Inspect catalyst for mechanical damage X X
This maintenance schedule represents the manufacturer’s recommended maintenance intervals to maintain proper en-
gine/equipment function. Federal, State, or Local regulations may require additional or more frequent inspection or maintenance
intervals than those specified above. Check with the authority having jurisdiction for details. Note that LPG engines are designed to
operate on HD–5 or HD–10 specification LPG fuel. Fuel other than HD–5 or HD–10 may cause harm to the engine’s emission
control system and a warranty claim may be denied on this basis if operators can readily find the proper fuel*. Use of any other fuel
may result in your engine no longer operating in compliance with CARB or EPA emissions requirements.
*Not Applicable in the state of California.
18
LPG Fuel System
19
LPG FUEL SYSTEM OPERATION
20
DESCRIPTION AND OPERATION OF THE FUEL
SYSTEMS
LPG FUEL SYSTEM

The primary components of the LPG fuel system
are the Fuel Storage Tank, Electronic Pressure
Regulator (EPR), Fuel Mixer, Throttle Control De- Typical LPG Cylinder
vice, electric Shut-Off Valve, Engine Control
Module (ECM), Oxygen Sensor and a Catalytic 1. Liquid Outage Fill Check Valve
Converter. The system operates at pressures which 2. Pressure Relief Valve
range from 355.60mm (14.0 inches) of water col- 3. Liquid Outage Valve w/quick disconnect coupl-
umn up to 21.5 BAR (312 psi). ing (also referred to as the manual shut-off
valve or MSV).
LPG FUEL TANK 4. Filler Valve
5. Fuel Gauge
LPG is stored in the fuel tank as a liquid. The ap- 6. Vapor Withdrawal Tube (when applicable)
proximate pressure of the fuel in the tank is 8.8 bar 7. 80% Limiter Tube
(130 psi) when the tank is full at an ambient tem- 8. Fuel Level Float
perature of 27° C (81°F). The boiling point, 9. Liquid Withdrawal Tube
(temperature at which the liquid fuel becomes va-
por) is approximately 40° C (-40° F). When the fuel SERVICE LINE
changes from liquid to vapor the fuel expands and
creates pressure inside the tank. When the tank
LPG flows from the fuel tank to the electric LPG
service valve is opened the pressure inside the
Shut-Off Valve via the service line. The service
tank forces the liquid fuel out though the pickup
line is connected to the tank utilizing a quick
tube located near the bottom of the fuel cylinder.
coupler. The other end of the service line is con-
nected to a bulkhead connector mounted on the
equipment sheet metal. This bulkhead connector
allows for a safe means of passing through the
equipments engine compartment sheet metal and
into the engine compartment. If a bulkhead con-
nector is used a pressure relief device is mounted
in the service line or the connector itself to pre-
vent over pressurization. The service line is
made of high pressure hose with special material
Because the LPG is stored under pressure the tank or possibly tubing which is compatible with the
is equipped with a safety valves which are normally LPG fuel and should always be replaced with an
set at 25.8 bar (375 psi) to prevent tank rupture due OEM supplied part.
to over-pressurization of the cylinder. The service
valve mounted in the end of the cylinder controls
the flow of fuel from the tank. By turning the handle
to its “open” position, fuel flows out of the tank and
into the service line. The service valve is also The bulkhead assembly should never be
equipped with a safety feature called an excess removed. Never run a service line through
flow check valve. This feature reduces the flow the sheet metal.
from the service valve in the event of a rupture of
the fuel line or any downstream.
21
FUEL FILTER Voltage to the LPG Shut-Off Valve is controlled by
the engine control module (ECM).
LPG, fuel like all other motor fuels is subject to
contamination from outside sources. Refueling of ELECTRONIC PRESSURE REGULATOR (EPR)
the equipment tank and removal of the tank from
the equipment can inadvertently introduce dirt The EPR is a combination vaporizer and pressure
and other foreign matter into the fuel system. It is regulating device. The EPR functions as a nega-
therefore necessary to filter the fuel prior to enter- tive pressure two stage regulator that is normally
ing the fuel system components downstream of closed with the ability to supply additional fuel by
the tank. An inline fuel filter has been installed in command from the ECM. When the engine is
the fuel system to remove the dirt and foreign cranking or running, a partial vacuum is created
matter from the fuel, which is replaceable as a in the fuel line which connects the regulator to the
unit only. Maintenance of the filter is critical to mixer. This partial vacuum opens the regulator
proper operation of the fuel system and should be permitting fuel to flow to the mixer.
replaced according to the maintenance schedule
or more frequently under severe operating condi- LPG fuel enters the primary port of the EPR and
tions. passes through the primary jet and into the prima-
ry/heat exchanger chamber and expands as it
heats up, creating pressure inside the chamber.
When the pressure increases above 10.34 kPa
(3.5 psi), sufficient pressure is exerted on the
primary diaphragm to cause the diaphragm plate
to pivot and press against the primary valve pin,
thus closing off the flow of fuel. When the engine
is cranking, sufficient vacuum will be introduced
Inline Fuel Filter into the secondary chamber from the mixer draw-
ing the secondary diaphragm down onto the
LPG SHUT-OFF VALVE spring loaded lever and opening the secondary
valve. An increase in vacuum in the secondary
The LPG Shut-Off Valve is an integrated assembly chamber increases the downward action on the
consisting of a 12 volt solenoid and a normally secondary lever, causing it to open wider and
closed valve. When energized, the solenoid opens permitting more fuel flow to the mixer.
the valve and allows the LPG fuel to flow through
the device. The valve opens during cranking and
engine run cycles.
Electronic Pressure Regulator

LPG Shut-Off Valve
22
The EPR is an emission control device The air/fuel mixer is an emission control
and should only be serviced by qualified device. Components inside the mixer are
technicians. specifically calibrated to meet the engine’s
emissions requirements and should never
AIR FUEL MIXER be disassembled or rebuilt. If the mixer
fails to function correctly, replace with an
The air valve mixer is a completely self-contained
OEM replacement part.
air-fuel metering device. The mixer is an air valve
design, utilizing a relatively constant pressure drop
to draw fuel into the mixer from cranking to full load. THROTTLE CONTROL DEVICE—DRIVE BY
The mixer is mounted in the air stream ahead of the WIRE
throttle control device.
Drive By Wire Engine speed control is maintained
When the engine begins to crank it draws in air with by the amount of pressure applied to the foot
the air valve covering the inlet, and negative pres- pedal located in the engine compartment. In a
sure begins to build. This negative pressure signal Drive By Wire (DBW) application, there is no di-
is communicated to the top of the air valve chamber rect connection between the operator pedal and
through 4 vacuum ports in the air valve assembly. the throttle shaft. Speed and load control are de-
A pressure/force imbalance begins to build across termined by the ECM. Defaults programmed into
the air valve diaphragm between the air valve va- the ECM software and throttle position sensors
cuum chamber and the atmospheric pressure allow the ECM to maintain safe operating control
below the diaphragm. The air valve vacuum spring over the engine. In a drive by wire application the
is calibrated to generate from 101.6 mm (4.0 inch- Electronic Throttle Control device or throttle body
es) of water column at start to as high as 355.60 assembly is connected to the intake manifold of
mm (14.0 inches) of water column at full throttle. the engine. The electronic throttle control device
The vacuum being created is referred to as Air utilizes an electric motor connected to the throttle
Valve Vacuum (AVV). As the air valve vacuum shaft. In addition, a Foot Pedal Position sensor
reaches 101.6mm (4.0 inches) of water column, the (FPP) is located in the operator’s compartment.
air valve begins to lift against the air valve spring.
The amount of AVV generated is a direct result of When the engine is running electrical signals are
the throttle position. At low engine speed the air sent from the foot pedal position sensor to the
valve vacuum and the air valve position is low thus engine ECM when the operator depresses or re-
creating a small venturi for the fuel to flow. As the lease the foot pedal. The ECM then sends an
engine speed increases the AVV increases and the electrical signal to the motor on the electronic
air valve is lifted higher thus creating a much larger throttle control to increase or decrease the angle
venturi. This air valve vacuum is communicated of the throttle blade thus increasing or decreasing
from the mixer venturi to the EPR secondary the air/fuel charge to the engine. The electronic
chamber via the low pressure fuel supply hose. As throttle control device incorporates two internal
the AVV increases in the secondary chamber the Throttle Position Sensors (TPS) which provide
secondary diaphragm is drawn further down forcing output signals to the ECM as to the location of the
the secondary valve lever to open wider. throttle shaft and blade. The TPS information is
The mixer is equipped with a low speed mixture used by the ECM to correct for speed and load
adjustment retained in a tamper proof housing. control as well as emission.
The mixer has been preset at the factory and
should not require adjustment. In the event that the
idle adjustment should need to be adjusted refer to
the Fuel System Repair section of this manual.
23
CATALYTIC CONVERTER Oxygen sensor (HEGO) mounted in the exhaust
system. The HEGO sensor sends a voltage sig-
The Catalytic Converter is a component of the nal to the controller which then outputs signals to
emissions system which is designed and cali- the EPR to change the amount of fuel being deli-
brated to meet the emission standards in effect vered from the regulator or mixer to the engine.
for 2007-2009 model year.
The controller also performs diagnostic functions
The exhaust gases pass through the honeycomb on the fuel system and notifies the operator of
catalyst which is coated with a mixture of metals engine malfunctions by turning on a Malfunction
(such as platinum, palladium, and rhodium) to Indicator Light (MIL) mounted in the dash. Mal-
oxidize and reduce CO, HC and NOX emission functions in the system are identified by a
gases. Diagnostic Trouble Code (DTC) number. In addi-
tion to notifying the operator of the malfunction in
the system, the controller also stores the informa-
tion about the malfunction in its memory. A
technician can than utilize a computerized diag-
nostic scan tool to retrieve the stored diagnostic
code and by using the diagnostic charts in this
manual to determine the cause of the malfunc-
tion. In the event a technician does not have the
computerized diagnostic tool, the MIL light can be
used to identify the diagnostic code to activate
the “blink” feature and count the number of blinks
to determine the diagnostic code number to lo-
Catalytic Converter/Muffler cate the fault in the system.
ENGINE CONTROL MODULE HEATED EXHAUST GAS OXYGEN SENSORS
To obtain maximum effect from the catalyst and The Heated Exhaust Gas Oxygen (HEGO) Sen-
accurate control of the air fuel ratio, the emission sors are mounted in the exhaust system, one
certified engine is equipped with an onboard upstream and one downstream of the catalytic
computer or Engine Control Module (ECM). The converter. The HEGO sensors are used to
ECM is a 32 bit controller which receives input measure the amount of oxygen present in the ex-
data from sensors mounted to the engine and fuel haust stream to determine whether the fuel air
system and then outputs various signals to con- ratio is to rich or to lean. It then communicates
trol engine operation. this measurement to the ECM. If the HEGO sen-
sor signal indicates that the exhaust stream is too
rich, the ECM will decrease or lean the fuel mix-
ture during engine operation. If the mixture is too
lean, the ECM will richen the mixture. If the ECM
determines that a rich or lean condition is present
for an extended period of time which cannot be
corrected, the ECM will set a diagnostic code and
turn on the MIL light in the dash.
Engine Control Module (ECM) By monitoring output from the sensor upstream
and the sensor downstream of the catalytic con-
One specific function of the controller is to main- verter, the ECM can determine the performance
tain a closed loop fuel control which is of the converter.
accomplished by use of the Heated Exhaust Gas
24
TMAP SENSOR
T–MAP Sensor
The Heat Exhaust Gas Oxygen (HEGO) Sensor
The Air Temperature/Manifold Absolute Pressure
or TMAP sensor is a combination of two sensors:
1) A variable resistor used to monitor the differ-
ence in pressure between the intake manifold
and outside or atmospheric pressure. The
ECM monitors the resistance of the sensor to
determine engine load (the vacuum drops
when the engine is under load or at wide
open throttle). When the engine is under load,
the computer may alter the fuel mixture to im-
prove performance and emissions.
2) The intake air temperature or IAT sensor is a
variable resistance thermistor located in the air
intake passage which measures the tempera-
HEGO1 (upstream or before the catalytic con- ture of the incoming air. The ECM uses the
verter) and HEGO2 (downstream) voltage resistance value to monitor incoming air tem-
output. perature and calculate the engine’s airflow
requirement. The ECM provides a voltage di-
vider circuit so that when the air is cool, the
signal reads a higher voltage, and lower when
warm. On cold starts, the ECM richens the
fuel/air mixture.
The Heated Exhaust Gas Oxygen Sensor
(HEGO) is an emissions control compo- COOLANT TEMPERATURE SENSOR
nent. In the event of a failure, the HEGO
should only be replaced with the recom-
mended OEM replacement part. The
HEGO is sensitive to silicone based prod-
ucts and can become contaminated.
Avoid using silicone sealers or air or fuel
hoses treated with a silicone based lubri-
cant.
ECT
The Engine Coolant Temperature sensor or ECT

is a variable resistance thermistor that changes
resistance as the engine's coolant temperature
25
changes. The sensor's output is monitored by
the ECM to determine a cold start condition and
to regulate various fuel and emission control
functions via a closed loop emission system.
OIL PRESSURE SENDER/SWITCH
The Oil Pressure Switch is Mounted on the

side of the Engine Block
The Engine Oil Pressure switch or sender is de-

signed to ensure adequate lubrication throughout
the engine. It provides a pressure value for the
oil pressure gauge and is monitored by the ECM.
If the pressure drops, an MIL will occur.
26
LPG Closed Loop Schematic
27
28
LPG System Diagnosis
29
LPG FUEL SYSTEM DIAGNOSIS
The Electronic Pressure Regulator Assembly (EPR), Shown with Port Fittings and Shut-off Valve.
FUEL SYSTEM DESCRIPTION is also generates lift for the mixer air valve and
is commonly referred to as air valve vacuum.
The Engine Control Module (ECM) receives in- Once in the mixer, the fuel is combined with air
formation from various engine sensors in order and is drawn into the engine for combustion.
to control the operation of the Electronic Pres-
sure Regulator (EPR) and Shut-Off Valve. The DIAGNOSTIC AIDS
Shut-Off Valve solenoid prevents fuel flow un-
less the engine is cranking or running. This procedure is intended to diagnose a ve-
hicle operating on LPG. If the vehicle will not
LPG is stored in the tank as a liquid and deli- continue to run on LPG, refer to Hard Start for
vered under pressure of up to 21.5 BAR (312 preliminary checks. Before starting this proce-
psi). At Key ON, the EPR receives a two (2) dure, complete the following tasks to verify that
second prime pulse from the ECM, allowing liquid fuel is being delivered to the EPR:
time for the LPG to flow from the tank through
the fuel filter and fuel lines to the EPR. Inside of  Inspect fuel tank to verify it has a sufficient
the EPR, fuel is vaporized and reduced in pres- amount of fuel.
sure in two stages. The first stage reduces the  Verify manual shut off valve on the LPG
tank pressure to approximately 20.68 kilopas- tank is fully opened.
cals (3.0 psi). The second stage then reduces  Verify that the excess flow valve has not
the pressure to approximately negative 38.1 been activated.
mm (1.5” of water column) when vacuum from  Inspect fuel tank to ensure it is properly
the engine draws in fuel. mounted and rotated to the correct position.
 Inspect the hoses leading from the tank en-
The fuel is then drawn in from the secondary suring they are properly connected and do
chamber of the EPR by the vacuum generated not have any kinks or damage.
by air flowing through the Mixer. This vacuum
30
TOOLS REQUIRED:
 7/16” Open end wrench (for test port plugs)

 Test port adapter
 Straight Blade screw driver
 Needle nose pliers
DST
 Diagnostic Scan Tool (DST)
PRESSURE GAUGES
 0-10” Water Column Gauge

 0-10 PSI Gauge
TEST DESCRIPTION
The numbers below refer to step numbers on

the Diagnostic Table:
1. This step checks the base mechanical EPR

output pressure by disabling all fuel control
devices.
9. This step checks for proper air valve opera-
tion.
12. This determines if fuel is available from the
fuel tank supply system.
31
LPG FUEL SYSTEM DIAGNOSTICS
Step Action Value(s) Yes No
Go to
1 Were you referred to this procedure by a DTC diagnostic Chart? Go to Step 3
Step 2
Connect the Diagnostic Scan Tool (DST) to the ECM Data Link Go to appli-
Go to
2 Connector (DLC) and check for any DTCs. cable DTC
Step 3
Are any DTCs present in the ECM? Table
Perform the following visual and physical preliminary checks:
 Check all ECM system fuses and circuit breakers (refer to
Engine Wiring Schematic).
 Check the ECM grounds for being clean, tight and in their
proper locations (refer to Engine Wiring Schematic).
 Check the vacuum hoses for damage, splits, kinks and prop-
er connections.
 Check the fuel system for any type of leak or restriction from
the supply tank to the mixer.
 Check for air leaks at all mounting areas of the intake mani-
fold sealing surfaces.
 Check for proper installation of the mixer assembly.
 Check for air leaks at the mixer assembly and all intake duct-
Correct the
ing between intake manifold and air cleaner.
faulty condi- Go to
3  Check air cleaner and all vehicle intake ducting for restric-
tion and Go Step 4
tions.
to Step 20
 Check exhaust system for flow obstructions or leaks.
Check the ignition wires for the following conditions:

 Cracking or hardening
 Proper routing
 Bare or shorted wires
 Carbon tracking
Check the wiring harness for the following conditions:

 Proper connections
 Pinches
 Cuts or abrasions
Were any faulty conditions found in the preliminary checks?
Go to
4 Does the vehicle start and run? Go to Step 9
Step 5
Check the fuel system for the following conditions:
 Verify the LPG fuel tank is at least ¼ full.
 Verify the manual fuel shut-off valve is open and operating Correct the
correctly. faulty condi-
Go to
5  Verify the high-flow valve has not tripped. tion and
Step 6
 Verify the quick disconnect is fully engaged and there are no Go to Step
kinks or obstructions in the high pressure LPG supply hose. 20
 Verify the LPG fuel filter is clean and unobstructed.
Were any faulty conditions found in the fuel supply system?
32
If NO
pressure
was indi-
 Connect a calibrated 0-5” PSI pressure gauge to the pri-
cated, Go
mary pressure test port of the EPR.
to Step 14
 Make sure the manual shut-off valve is open and turn the
2.0 – 4.0
6 ignition to ON. Go to Step 7
PSI If LOW or
 Crank the engine and observe the pressure gauge. HIGH
Does the pressure gauge indicate the proper primary fuel pressure
pressure? was indi-
cated, Go
to Step 15
LPG is a gaseous fuel and requires higher secondary ignition
voltages than gasoline fueled engines. Check the ignition
system for proper ignition secondary voltage output with J
26792 or equivalent.
Remove the spark plugs and check for the following: Correct the
 Correct plug type for LPG application. faulty condi-
 Wet electrodes (oil fouling) Go to
7 tion and
Step 8
 Cracks Go to Step
 Wear 20
 Improper gap
 Burned electrodes
 Heavy deposits
Were any faulty conditions found in the ignition system
check?
Repair the
engine as
Perform a leak-down test on the engine. <10% Go to Step
8 necessary
Are all cylinder leak-down test results within specification? leakage 12
and Go to
Step 20
 Turn OFF the manual fuel shut-off valve.
 Start the engine and let it run until it dies.
 Remove the LPG Temperature Sensor from the EPR (DO
NOT disconnect the electrical connector). Go to Step Go to
9
 Inspect the inside of the low-pressure fuel supply hose for 16 Step 10
heavy-end deposits.
Are there any deposits built-up in the low-pressure fuel
supply hose?
33
Step Action Values Yes No
 Insert the Secondary Pressure Test Adapter into the EPR
port from which you removed the LPG Temp Sensor.
 Connect a CALIBRATED 0-10” water column (WC) vacuum
gauge or manometer to the secondary pressure test port of
the EPR.
 Connect the DST to the vehicle DLC connector and open the
GCP Display software.
 Turn the manual shut-off valve ON. Start the engine and
allow it to reach operating temperature.
Compare the gauge secondary pressure reading to the actual +/-0.75” Go to Step Go to
10
pressure on the DST Faults Screen. WC 19 Step 11
(Sample Only – Readings will vary)
Is the gauge secondary pressure within the specified percen-

tage of the actual pressure indicated on the DST Faults Screen?
With the engine still running:
 Disconnect the EPR electrical connector.
NOTE: This action will cause a DTC to be set turning ON the

-1.0” to Go to Step Go to
11 MIL.
-2.0” WC 15 Step 13
 With the engine idling, observe the pressure reading on the
secondary pressure test port gauge.
Is the pressure reading within specifications?
 Turn OFF the manual shut-off valve and let the engine run
until it dies.
 Turn the ignition OFF.
 Remove the Air induction hose from the mixer.
 Crank the engine and observe the air valve for movement Go to Step Go to
12
while the engine is cranking. 14 Step 13
NOTE: At cranking speeds, the air valve movement will be mi-

nimal.
Is there movement in the air valve when the engine is cranking?
Replace the mixer assembly (refer to Fuel Mixer Replacement). Go to Step
13 NA
Is the action complete? 20
 If turned OFF, turn ON the manual shut-off valve.
 Disconnect the Lock-off valve electrical connector.
Above Go to Step Go to
14  Apply 12V to the lock-off valve terminals and observe the 1.0 PSI 17 Step 18
pressure gauge.
Does the pressure gauge indicate pressure?
Repair or replace the EPR (refer to EPR Repair Instructions). Go to Step
15 NA
34
Inspect the following for heavy-end deposits:
 Electronic Pressure Regulator. Inspect, clean and/or repair
as necessary (refer to EPR Repair Instructions).
 Inspect the diaphragm through the Mixer air inlet for any de- Go to Step
16 posits or contaminants. DO NOT disassemble the Mixer. NA
20
The Mixer is calibrated and disassembly may alter its calibra-
tion and adversely affect engine performance and/or
emissions.
Are all actions complete?
Replace the ECM. Go to Step
17 NA
Replace the Lock-off Valve. Go to Step
18 NA
System working correctly at this time. Vehicle may have inter-
mittent electrical connection conditions.
 Return vehicle to original condition (but leave the diagnostic
equipment connected). Go to Step
19 NA
 Start the engine and wiggle test the harness while observing 20
the DST Faults Screen and the pressure gauge readings.
 Repair any conditions encountered.
Is the action complete?
 Clear any active or historic DTCs (DST Service or Faults
Screen).
 Clear Adaptive from memory (DST Service Screen).
 Return the vehicle to original condition.
 Operate the vehicle under all load and driving conditions for
at least 10 minutes.
-15% to Go to Step Go to
20  Park the vehicle with the engine running and connect the +15% 21 Step 24
DST to the vehicle’s DLC connector.
 Open the GCP software and switch to the Faults Screen.
 Let the vehicle idle with no load for at least 30 seconds and
observe the Adaptive 1 fuel correction.
Did the Adaptive 1 fuel correction remain within the specified
values?
With engine still idling, apply a load with the hydraulic system for
at least 10 seconds and observe the Adaptive 1 value. -15% to Go to Step Go to
21
Did the Adaptive 1 fuel correction remain within the specified +15% 22 Step 24
values?
Raise the engine rpms to 75-90% of maximum full governed
speed with no load for at least 10 seconds and observe the
22 Adaptive 1 fuel correction.
+15% 23 Step 24
values?
 With the engine still running at 75-90% of full governed
speed, apply a moderate load with the hydraulic system.
23  Observe the Adaptive 1 fuel correction.
+15% 29 Step 24
values?
Go to Step Go to
24 Was the Adaptive 1 fuel correction less than-15%?
26 Step 25
35
Go to Step
25 Was the Adaptive 1 fuel correction more than +15%? NA
27
Engine is running RICH (system is trying to compensate by de-
creasing the amount of fuel). Check the following for any
condition which may cause the engine to run RICH:
 Ignition system (See Step 7).
Go to Step
26  Air cleaner and intake system (including vehicle intake duct- NA
28
ing) for airflow obstructions.
 Exhaust system for flow obstructions.
 HEGO 1 for correct switching characteristics.
Engine is running LEAN (system is trying to compensate by in-
creasing the amount of fuel). Check the following for any
condition which may cause the engine to run LEAN:
 Intake manifold for leaks.
 All throttle body and mixer gaskets or o-rings for leaks.
 All vacuum hoses and fittings for leaks.
 Exhaust system for leaks Go to Step
27 NA
28
NOTE: Exhaust system leaks allow for excess O2 to dilute the
HEGO sensors giving a false reading. Engine may exhibit signs
of a rich running condition but the Adaptive 1 corrections will
indicate an excessive positive fuel adjustment.
 HEGO 1 for correct switching characteristics.

28 Repeat Step 20. NA NA
 Remove all test equipment except the DST.
 Connect any disconnected components, fuses, etc.
 Using the DST clear DTC information from the ECM.
 Turn the ignition OFF and wait 30 seconds.
 Start the engine and operate the vehicle to full operating
29 temperature NA NA
 Observe the MIL
 Observe engine performance and driveability
Does the engine operate normally with no stored codes?
Remove all diagnostic equipment and return vehicle to original
condition. Return vehicle to customer.
36
ADDITIONAL STEPS

Go to Ap-
1. Perform the On-Board Diagnostic (OBD) System check. plicable Go to
1
Are any DTCs present in the ECM? DTC Ta- Step 2
ble
Go to
Fuel
Go to
2 Has the Fuel system diagnosis been performed? system
Step 3
Diagno-
sis
1. Replace the Engine Control Unit (ECM). Refer to Engine
Go to Go to
3 Control Unit (ECM) replacement.
Step 5 Step 4
Is this action complete?
1. Repair the open or damaged circuit. Go to Go to
4
Is this action complete? Step 5 Step 8
1. Return the fuel system to normal operating condition.
2. Observe the Adaptive 1 fuel correction.
-15 to Go to Go to
5 3. Raise the engine speed to approximately 2500 rpm.
+15 Step 9 Step 6
Is the Adaptive 1 fuel correction within the specified range at
idle and 2500 rpms?
1. Check all vacuum hoses and mixer connections for lea-
Go to Go to
6 kage.
Step 5 Step 7
Was a problem found?
1. Replace Mixer. Go to Go to
7
Is this action complete? Step 5 Step 9
1. The fuel control system is operating normally. Refer to
Symptoms Diagnosis 1. Disconnect all test equipment 2.
System
8 2. If you were sent to this routine by another diagnostic chart,
OK
retune to the previous diagnostic procedure.
1. Disconnect all test equipment
2. Start the engine
System
9 3. Using a liquid leak detection solution leak check any fuel
OK
system repairs made.
37
38
LPG Symptom Diagnostics
39
LPG SYMPTOM DIAGNOSTICS
Checks Action
Before using this section, you should have performed On Board Diagnostic
(OBD) Check and determined that:
1. The ECM and MIL are operating correctly.

Before Using This 2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists
Section but without a MIL.
Several of the following symptom procedures call for a careful visual and
physical check. These checks are very important as they can lead to prompt
diagnosis and correction of a problem.
1. Verify the customer complaint.

2. Locate the correct symptom table.
3. Check the items indicated under that symptom.
4. Operate the vehicle under the conditions the symptom occurs. Verify
LPG Fuel System Check HEGO switching between lean and rich. IMPORTANT! Normal HEGO
switching indicates the LPG fuel system is in closed loop and oper-
ating correctly at that time.
5. Take a data snapshot using the DST under the condition that the symptom
occurs to review at a later time.
 Check all ECM system fuses and circuit breakers.

 Check the ECM ground for being clean, tight and in its proper location.
 Check the vacuum hoses for splits, kinks and proper connections.
 Check thoroughly for any type of leak or restriction.
 Check for air leaks at all the mounting areas of the intake manifold sealing
surfaces.
 Check for proper installation of the mixer assembly.
 Check for air leaks at the mixer assembly.

Visual and Physical
Checks  Cracking
 Hardening
 Proper routing
 Carbon tracking.
 Check the wiring for the following items: proper connections, pinches or
cuts.
 The following symptom tables contain groups of possible causes for each
symptom. The order of these procedures is not important. If the DST read-
ings do not indicate a problem, then proceed in a logical order, easiest to
check or most likely to cause the problem.
40
INTERMITTENT
Checks Action
DEFINITION: The problem may or may not turn ON the (MIL) or store a Diagnostic Trouble Code (DTC).
Do not use the DTC tables. If a fault is an intermittent, the use of the DTC
Preliminary Checks
tables with this condition may result in the replacement of good parts.
Faulty electrical connections or wiring can cause most intermittent problems.

Check the suspected circuit for the following conditions:
 Faulty fuse or circuit breaker, connectors poorly mated, terminals not fully
seated in the connector (backed out). Terminals not properly formed or
damaged.
 Wire terminals poorly connected.
Faulty Electrical Con-
 Terminal tension is insufficient.
nections or Wiring
 Carefully remove all the connector terminals in the problem circuit in or-
der to ensure the proper contact tension.
 If necessary, replace all the connector terminals in the problem circuit in
order to ensure the proper contact tension (except those noted as “Not
Serviceable”). See section Wiring Schematics.
 Checking for poor terminal to wire connections requires removing the
terminal from the connector body.
If a visual and physical check does not locate the cause of the problem, op-
Operational Test erate the vehicle with the DST connected. When the problem occurs, an
abnormal voltage or scan reading indicates a problem circuit.
The following components can cause intermittent MIL and no DTC(s):
 A defective relay.
 Switch that can cause electrical system interference. Normally, the prob-
lem will occur when the faulty component is operating.
Intermittent MIL
 The improper installation of add on electrical devices, such as lights, 2-
Illumination
way radios, electric motors, etc.
 The ignition secondary voltage shorted to a ground.
 The MIL circuit or the Diagnostic Test Terminal intermittently shorted to
ground.
 The MIL wire grounds.
To check for the loss of the DTC Memory:
1. Disconnect the TMAP sensor.

Loss of DTC Memory 2. Idle the engine until the MIL illuminates.
3. The ECM should store a TMAP DTC which should remain in the memory
when the ignition is turned OFF. If the TMAP DTC does not store and
remain, the ECM is faulty.
41
NO START
Checks Action
DEFINITION: The engine cranks OK but does not start.
Preliminary Checks None
Use the DST to :
 Check for proper communication with both the ECM
 Check all system fuses engine fuse holder. Refer to Engine Controls
ECM Checks Schematics.
 Check battery power, ignition power and ground circuits to the ECM. Re-
fer to Engine Control Schematics. Verify voltage and/or continuity for
each.
 Check the TMAP sensor.
Sensor Checks
 Check the cam angle sensor for output (RPM).
Important: A closed LPG manual fuel shut off valve will create a no start
condition.
 Check for air intake system leakage between the mixer and the throttle
Fuel System Checks body. Verify proper operation of the low pressure lock-off solenoids.
 Verify proper operation of the fuel control solenoids.
 Check the fuel system pressures.
 Refer to the LPG Fuel System Diagnosis.
 Check for proper mixer air valve operation.
Note: LPG being a gaseous fuel requires higher secondary ignition system
voltages for the equivalent gasoline operating conditions.
1. Check for the proper ignition voltage output with J 26792 or the equiva-
lent.
2. Verify that the spark plugs are correct for use with LPG.
Check the spark plugs for the following conditions:

Ignition System Checks  Wet plugs.
 Cracks.
 Wear.
 Improper gap.
 Burned electrodes.
 Heavy deposits.
 Check for bare or shorted ignition wires.
 Check for loose primary ignition coil wire connections.
42
NO START
Checks Action
Important: The LPG Fuel system is more sensitive to intake manifold lea-
kage than the gasoline fuel system.
Check for the following:

 Vacuum leaks.
Engine Mechanical
 Improper valve timing.
Checks
 Low compression.
 Improper valve clearance.
 Worn rocker arms.
 Broken or weak valve springs.
Worn camshaft lobes.
Check the exhaust system for a possible restriction:

 Inspect the exhaust system for damaged or collapsed pipes:
Exhaust System  Inspect the muffler for signs of heat distress or for possible internal fail-
ure.
Checks
 Check for possible plugged catalytic converter. Refer to Restricted Ex-
haust System Diagnosis.
43
HARD START
Checks Action
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run,
or may start but immediately dies.
Preliminary Checks Make sure the vehicle’s operator is using the correct starting procedure.
 Check the Engine Coolant Temperature sensor with the DST. Compare
the engine coolant temperature with the ambient air temperature on a
cold engine. If the coolant temperature reading is more than 10 degrees
greater or less than the ambient air temperature on a cold engine, check
Sensor Checks
for high resistance in the coolant sensor circuit. Check the cam angle
sensor.
 Check the Throttle Position (TPS) and Foot Pedal Position (FPP) sensor
connections.
Important: A closed LPG manual fuel shut off valve will create an extended
crank OR no start condition.
 Verify the excess flow valve is not tripped or that the LPG tank valve is
not closed.
Fuel System Checks
Check mixer assembly for proper installation and leakage.
 Verify proper operation of the low pressure lock-off solenoid.
 Verify proper operation of the EPR.
 Check for air intake system leakage between the mixer and the throttle
body. Check the fuel system pressures. Refer to the Fuel System Diag-
nosis.
voltages for the equivalent gasoline operating conditions.
 Check for the proper ignition voltage output with J 26792 or the equiva-
lent.
 Verify that the spark plugs are the correct type and properly gapped.

 Wet plugs.
 Cracks.
 Wear.
Ignition System Checks
 Heavy deposits
 Check for moisture in the distributor cap.
Important:
1. If the engine starts but then immediately stalls, check the cam angle sen-
sor.
2. Check for improper gap, debris or faulty connections.
44
HARD START
Checks Action
kage than the gasoline fuel supply system.

 Vacuum leaks
 Improper valve timing
Engine Mechanical
 Low compression
Checks
 Improper valve clearance.
 Worn rocker arms
 Broken or weak valve springs
 Worn camshaft lobes.
Check the intake and exhaust manifolds for casting flash.

 Inspect the exhaust system for damaged or collapsed pipes.

Exhaust System Checks  Inspect the muffler for signs of heat distress or for possible internal fail-
ure.
Check for possible plugged catalytic converter. Refer to Restricted Exhaust
System Diagnosis.
45
CUTS OUT, MISSES
Checks Action
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load
increases, but normally felt below 1500 RPM. The exhaust has a steady spitting sound at idle, low speed,
or hard acceleration for the fuel starvation that can cause the engine to cut-out.
Preliminary Checks None
1. Start the engine.
2. Check for proper ignition output voltage with spark tester J 26792.
3. Check for a cylinder misfire.
4. Verify that the spark plugs are the correct type and properly gapped.
Remove the spark plugs and check for the following conditions:
 Insulation cracks.
 Wear.
Ignition System Checks  Improper gap.
 Heavy deposits.
Visually/Physically inspect the secondary ignition for the following:
 Ignition wires for arcing and proper routing.

 Cross-firing.
 Primary ignition coil wires for cracks or carbon tracking
Perform a cylinder compression check. Check the engine for the following:

Engine Mechanical  Improper valve clearance.
Checks  Worn rocker arms.
 Check the intake and exhaust manifold passages for casting flash.
Check the fuel system:
Fuel System Checks  Plugged fuel filter.

 Low fuel pressure, etc. Refer to LPG Fuel System Diagnosis.
 Check the condition of the wiring to the low pressure lock-off solenoid.
Check for Electromagnetic Interference (EMI), which may cause a misfire con-
dition. Using the DST, monitor the engine RPM and note sudden increases in
Additional Check rpms displayed on the scan tool but with little change in the actual engine rpm.
If this condition exists, EMI may be present. Check the routing of the second-
ary wires and the ground circuit.
46
HESITATION, SAG, STUMBLE
Checks Action
DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The
condition can occur at any vehicle speed. The condition may cause the engine to stall if it’s severe
enough.
Preliminary Checks None.
 Check the fuel pressure. Refer to LPG Fuel System Diagnosis.
 Check for low fuel pressure during a moderate or full throttle accelera-
tion. If the fuel pressure drops below specification, there is possibly a
faulty low pressure regulator or a restriction in the fuel system.
Fuel System Checks  Check the TMAP sensor response and accuracy.
 Check Shut-Off electrical connection.
 Check the mixer air valve for sticking or binding.
 Check the mixer assembly for proper installation and leakage. Check the
EPR.
voltages for the equivalent gasoline operating conditions. If a problem is re-
ported on LPG and not gasoline, do not discount the possibility of a LPG only
ignition system failure and test the system accordingly.
lent. Verify that the spark plugs are the correct type and properly gapped.
 Check for faulty spark plug wires.
 Check for fouled spark plugs.
 Check for manifold vacuum or air induction system leaks.

Additional Check
 Check the alternator output voltage.
47
BACKFIRE
Checks Action
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping
noise.
Preliminary Check None.
Important! LPG, being a gaseous fuel, requires higher secondary igni-

tion system voltages for the equivalent gasoline operating conditions.
The ignition system must be maintained in peak condition to prevent
backfire.
 Check for the proper primary ignition coil wire output voltage using the
spark tester J26792 or the equivalent.
 Check the spark plug wires by connecting an ohmmeter to the ends of
each wire in question. If the meter reads over 30,000 ohms, replace the
wires.
Ignition System Checks  Check the connection at primary ignition coil wire.
 Check for deteriorated spark plug wire insulation.
Remove the plugs and inspect them for the following conditions:
 Wet plugs.
 Cracks.
 Wear.
 Improper gap.
 Heavy deposits.
Important! The LPG Fuel system is more sensitive to intake manifold

leakage than a gasoline fuel supply system.
Check the engine for the following:

Engine Mechanical  Engine compression.
Check  Manifold vacuum leaks.
 Intake manifold gaskets.
 Sticking or leaking valves.
 Exhaust system leakage.
 Check the intake and exhaust system for casting flash or other restric-
tions.
Fuel System Checks Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.
48
LACK OF POWER, SLUGGISHNESS, OR SPONGINESS
Checks Action
DEFINITION: The engine delivers less than expected power. There is little or no increase in speed
when partially applying the accelerator pedal.
 Refer to the LPG Fuel system OBD System Check.
 Compare the customer’s vehicle with a similar unit to verify customer has
an actual problem. Do not compare the power output of the vehicle oper-
ating on LPG to a vehicle operating on gasoline as the fuels do have
Preliminary Checks
different drive feel characteristics.
 Remove the air filter and check for dirt or restriction.
 Check the vehicle transmission.
 Refer to the OEM transmission diagnostics.
 Check for a restricted fuel filter, contaminated fuel, or improper fuel pres-
sure. Refer to LPG Fuel System Diagnosis.
 Check for the proper ignition output voltage with the spark tester J 26792
or the equivalent.
Fuel System Checks  Check for proper installation of the mixer assembly. Check all air inlet
ducts for condition and proper installation.
 Check for fuel leaks between the EPR and the mixer.
 Verify that the LPG tank valve is fully open.
 Verify that liquid fuel (not vapor) is being delivered to the EPR.
 Check the Heated Exhaust Gas Oxygen Sensors (HEGO) for contamina-
tion and performance.
Sensor Checks
 Check for proper operation of the TMAP sensor.
 Check for proper operation of the TPS and FPP sensors.

Exhaust System Checks  Inspect the muffler for signs of heat distress or for possible internal fail-
ure.
 Check for possible plugged catalytic converter.

 Engine compression.
Engine Mechanical
 Valve timing.
Check
 Improper or worn camshaft.
 Refer to Engine Mechanical in the Service Manual.
 Check the ECM grounds for being clean, tight, and in their proper loca-
tions.
 Check the alternator output voltage.
Additional Check If all procedures have been completed and no malfunction has been found,
review and inspect the following items:
 Visually and physically, inspect all electrical connections within the sus-
pected circuit and/or systems.
 Check the DST data.
49
POOR FUEL ECONOMY
Checks Action
DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Al-
so, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by
refueling records.
 Check the air cleaner element (filter) for dirt or being plugged.
 Visually check the vacuum hoses for splits, kinks, and proper connec-
tions.
 Properly inflated tires.
Check the operators driving habits for the following:

Preliminary Checks
 Excessive idling or stop and go driving.
 Carrying of very heavy loads.
 Rapid acceleration.
 Suggest to the owner to fill the fuel tank and to recheck the fuel economy
and/or suggest that a different operator use the equipment and record
the results.
 Check the EPR fuel pressure. Refer to LPG Fuel System Diagnosis.
Fuel System Checks
 Check the fuel system for leakage.
Sensor Checks  Check the TMAP sensor.
Verify that the spark plugs are the correct type and properly gapped.
 Wet plugs.
 Cracks.
 Wear.
 Improper gap.
Ignition System Checks  Burned electrodes.
 Heavy deposits.
Check the ignition wires for the following items:

 Cracking.
 Hardness.
Proper connections.
Check the engine thermostat to see if it is stuck open or for the wrong heat
Cooling System Checks
range.
 Check the transmission shift pattern.
Additional Check  Refer to the OEM Transmission Controls section the Service Manual.
 Check for dragging brakes.
50
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING
Checks Action
DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The
engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine.
Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance:
 Check for silicone contamination from fuel or improperly used sealant. If
contaminated, the sensor may have a white powdery coating result in a
high but false signal voltage (rich exhaust indication). The ECM will re-
Sensor Checks duce the amount of fuel delivered to the engine causing a severe
drivability problem.
Check the Temperature Manifold Absolute Pressure (TMAP) sensor re-

sponse and accuracy.
 Check for rich or lean symptom that causes the condition.
 Drive the vehicle at the speed of the complaint.
 Monitoring the oxygen sensors will help identify the problem.
 Check for a sticking mixer air valve.
Fuel System Checks  Verify proper operation of the EPR.
 Perform a cylinder compression test. Refer to Engine Mechanical in the
Service Manual.
 Check the EPR fuel pressure. Refer to the LPG Fuel System Diagnosis.
 Check mixer assembly for proper installation and connection.
 Check for the proper ignition output voltage using the spark tester
J26792 or the equivalent.
 Wet plugs.
 Cracks.
Ignition System Checks  Wear.
 Improper gap.
 Blistered insulators.
 Heavy deposits.
Check the spark plug wires by connecting an ohmmeter to the ends of each
wire in question. If the meter reads over 30,000 ohms, replace the wires.
kage than the gasoline fuel supply system.
 Check for vacuum leaks. Vacuum leaks can cause a higher than normal
Additional Checks idle and low throttle angle control command.
tions. Check the battery cables and ground straps. They should be clean
and secure. Erratic voltage may cause all sensor readings to be skewed
resulting in poor idle quality.
51
Checks Action
Check the engine for:
 Broken motor mounts.
Engine Mechanical  Low compression.
Check  Improper valve clearance.
52
SURGES/CHUGGLES
Checks Action
DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if
it speeds up and slows down with no change in the accelerator pedal.
Sensor Checks Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance.
 Check for Rich or Lean symptom that causes the condition.
 Drive the vehicle at the speed of the complaint. Monitoring the oxygen
sensors will help identify the problem.
 Check the fuel pressure while the condition exists. Refer to LPG Fuel
Fuel System Checks
System Diagnosis.
 Verify proper fuel control solenoid operation.
 Verify that the LPG tank valve is fully open.
 Check the in-line fuel filter for restrictions.
 Wet plugs.
Ignition System Checks  Cracks.
 Wear.
 Improper gap.
 Heavy deposits.
Check the Crankshaft Position (CKP) Sensor.
tions.
Additional Check  Check the generator output voltage.
 Check the vacuum hoses for kinks or leaks.
 Check Transmission
53
54
Gasoline Fuel System
55
GAS FUEL SYSTEM OPERATION
56
GASOLINE MULTIPORT FUEL INJECTION as indicated in the Recommended Maintenance
SYSTEM (MFI) Schedule. A more frequent replacement of the filter
may be required if the equipment operates in a dus-
The primary components of the Gasoline Multiport ty or dirty environment.
Fuel Injection (MFI) fuel system are the gasoline
fuel tank, electric fuel pump, fuel filter, fuel rails, FUEL METERING BODY AND PRESSURE
fuel pressure regulator, fuel injectors, O2 sensors, REGULATOR
engine control module and a catalytic converter.
The gas flows from the fuel filter to the fuel pres-
GASOLINE FUEL STORAGE TANK sure regulator block. Regulated fuel is then sent to
the fuel inlet pipe and through the fuel metering
The gasoline fuel storage tank location may vary on body to the injectors. Excess fuel is returned to the
equipment applications. The fuel tank may be inte- fuel tank for recirculation. The fuel pressure regula-
grated into the chassis frame or may be a tor has no adjustments and is integrated into the
standalone vessel mounted on the equipment. For fuel block assembly. The fuel inlet pipe contains a
precise location for the equipment application refer Schrader valve which is utilized to test the regu-
to the OEMs vehicle manual. lated pressure of the fuel system.
GASOLINE FUEL PUMP FUEL INJECTOR
The gasoline is drawn into the fuel system from the

fuel tank by a 12 volt electric fuel pump. Depend-
ing on the vehicle application, the fuel pump may
be mounted in the fuel tank or as a standalone
component. In both cases, the fuel pump will re-
ceive a signal from the ECM at Key ON to prime
the fuel system for a several seconds prior to start.
Priming of the fuel system provides for a quicker
start, when the engine begins to crank.
Gasoline Fuel Injector

The fuel pump is an emission control com- The fuel pressure is maintained on the top of the
ponent. If the fuel pump fails to operate, injector by the fuel pressure regulator. The injector
replace only with an OEM replacement part. is fed a “pulse” signal through the wire harness
The fuel pump is calibrated to supply the which causes the injector to open. The ECM con-
correct amount of fuel to the injectors. Re- trols the opening and duration of the injector.
placing the pump with anything other than During lower RPM operation the injector signals or
the recommended OEM replacement pump “pulses” are shorter than when the engine is oper-
could cause damage to the fuel system ating at higher rpms. The certified engine has been
and/or fuel tank. calibrated to deliver the precise amount of fuel for
optimum performance and emission control.
FUEL FILTER
THROTTLE CONTROL DEVICE—DRIVE BY
The fuel is drawn into the fuel pump and then WIRE
through the fuel filter to trap and remove small par-
ticles and prevent injectors from becoming Drive By Wire Engine speed control is maintained
damaged. Maintenance of the fuel filter is required by the amount of pressure applied to the foot pedal
located in the engine compartment. In a Drive By
57
Wire (DBW) application, there is no direct mechani-
cal connection between the operator pedal and the
throttle shaft. Speed and load control are deter-
mined by the ECM. Defaults programmed into the
ECM software and throttle position sensors allow
the ECM to maintain safe operating control over the
engine. In a drive by wire application the Electronic
Throttle Control device or throttle body assembly is
connected to the intake manifold of the engine.
The electronic throttle control device utilizes an
electric motor connected to the throttle shaft. In
addition, a Foot Pedal Position sensor (FPP) is lo- Three-Way Catalytic Converter
cated in the operator’s compartment.
ENGINE CONTROL MODULE
When the engine is running electrical signals are
sent from the foot pedal position sensor to the en- To obtain maximum effect from the catalyst and
gine ECM when the operator depresses or release accurate control of the air fuel ratio, the emission
the foot pedal. The ECM then sends an electrical certified engine is equipped with an onboard
signal to the motor on the electronic throttle control computer or Engine Control Module (ECM). The
to increase or decrease the angle of the throttle ECM receives input data from sensors mounted
blade thus increasing or decreasing the air/fuel to the engine and fuel system and then outputs
charge to the engine. The electronic throttle control various signals to control engine operation.
device incorporates two internal Throttle Position
Sensors (TPS) which provide output signals to the
ECM as to the location of the throttle shaft and
blade. The TPS information is used by the ECM to
correct for speed and load control as well as emis-
sion.
THREE-WAY CATALYTIC CONVERTER Engine Control Module (ECM) Inputs & Outputs
The Catalytic Converter is a component of the One specific function of the controller is to main-
emissions system which is designed and calibrated tain a closed loop fuel control which is
to meet the emission standards in effect for 2007- accomplished by use of the Heated Exhaust Gas
2009. Oxygen sensor (HEGO) mounted in the exhaust
system. The HEGO sensor sends a voltage sig-
The exhaust gases pass through the honeycomb nal to the controller which then outputs signals to
catalyst which is coated with a mixture of metals change the amount of fuel being delivered from
(such as platinum, palladium, and rhodium) to oxid- the regulator or mixer to the engine.
ize and reduce CO, HC and NOX emission gases.
The controller also performs diagnostic functions
on the fuel system and notifies the operator of
engine malfunctions by turning on a Malfunction
Indicator Light (MIL) mounted in the dash. Mal-
functions in the system are identified by a
Diagnostic Trouble Code (DTC) number. In addi-
tion to notifying the operator of the malfunction in
the system, the controller also stores the informa-
tion about the malfunction in its memory. A
technician can than utilize a computerized diag-
nostic scan tool to retrieve the stored diagnostic
58
code and by using the diagnostic charts in this
manual to determine the cause of the malfunc-
tion. In the event a technician does not have the
computerized diagnostic tool, the MIL light can be
used to identify the diagnostic code to activate
the “blink” feature and count the number of blinks
to determine the diagnostic code number to lo-
cate the fault in the system.
HEATED EXHAUST GAS OXYGEN SENSORS
The Heated Exhaust Gas Oxygen (HEGO) Sen-

sors are mounted in the exhaust system, one
upstream and one downstream of the catalytic HEGO1 (upstream or before the catalytic con-
converter. The HEGO sensors are used to verter) and HEGO2 (downstream) voltage
measure the amount of oxygen present in the ex- output.
haust stream to determine whether the fuel air
ratio is to rich or to lean. It then communicates
this measurement to the ECM. If the HEGO sen-
sor signal indicates that the exhaust stream is too
rich, the ECM will decrease or lean the fuel mix-
ture during engine operation. If the mixture is too The Heated Exhaust Gas Oxygen Sensor
lean, the ECM will richen the mixture. If the ECM (HEGO) is an emissions control compo-
determines that a rich or lean condition is present nent. In the event of a failure, the HEGO
for an extended period of time which cannot be should only be replaced with the recom-
corrected, the ECM will set a diagnostic code and mended OEM replacement part. The
turn on the MIL light in the dash. HEGO is sensitive to silicone based prod-
ucts and can become contaminated.
By monitoring output from the sensor upstream Avoid using silicone sealers or air or fuel
and the sensor downstream of the catalytic con- hoses treated with a silicone based lubri-
verter, the ECM can determine the performance cant.
of the converter.
TMAP SENSOR
T–MAP Sensor
The Heat Exhaust Gas Oxygen (HEGO) Sensor The Air Temperature/Manifold Absolute Pressure
or TMAP sensor is a combination of two sensors:
1) A variable resistor used to monitor the differ-
ence in pressure between the intake manifold
and outside or atmospheric pressure. The
ECM monitors the resistance of the sensor to
59
determine engine load (the vacuum drops COOLANT TEMPERATURE SENSOR
when the engine is under load or at wide
open throttle). When the engine is under load, The Engine Coolant Temperature sensor or ECT
the computer may alter the fuel mixture to im- is a variable resistance thermistor that changes
prove performance and emissions. resistance as the engine's coolant temperature
changes. The sensor's output is monitored by the
2) The intake air temperature or IAT sensor is a ECM to determine a cold start condition and to
variable resistance thermistor located in the air regulate various fuel and emission control func-
intake passage which measures the tempera- tions via a closed loop emission system.
ture of the incoming air. The ECM uses the
resistance value to monitor incoming air tem- OIL PRESSURE SENSOR
perature and calculate the engine’s airflow
requirement. The ECM provides a voltage di- The Engine Oil Pressure Sensor is designed to
vider circuit so that when the air is cool, the ensure adequate lubrication throughout the en-
signal reads a higher voltage, and lower when gine. It provides a pressure value for the oil that
warm. On cold starts, the ECM richens the is monitored by the ECM. If the pressure drops,
fuel/air mixture. a DTC will occur and the engine will shut down.
60
Gasoline Closed Loop Control Schematic
61
62
Gasoline System
Diagnosis
63
GASOLINE SYSTEM DIAGNOSIS
Gasoline Injection Systems
FUEL SYSTEM DESCRIPTION used fuel is returned to the fuel tank by a sepa-
rate return fuel line. The fuel pump pressure
The Engine Control Module (ECM) receives in- test port is located on the fuel rail.
formation from various engine sensors in order
to control the operation of the fuel injectors. The DIAGNOSTIC AIDS
electric fuel pump prevents fuel flow unless the
engine is cranking or running. During Key ON, This procedure is intended to diagnose a ve-
the electric fuel pump receives a short prime hicle operating on Gasoline. If the vehicle will
cycle from the ECM which allows gasoline to not continue to run on Gasoline, refer to Hard
flow from the tank through fuel filter and fuel Start section for preliminary checks. Before
lines to the pressure regulator before it reaches starting this procedure, verify that the vehicle
the fuel injector. With the Ignition ON engine has a sufficient quantity of fuel.
OFF and fuel pump running, the pressure
should be TBD-TBD kPa (TBD-TBD psi). At TOOLS REQUIRED:
idle, manifold pressure is much lower than at-
mospheric pressure, which creates a high  J 34730-1 or equivalent
vacuum. This vacuum will offset the pressure  J 37287 or equivalent
regulator diaphragm, resulting in a lower fuel
pressure. Fuel pressure at idle will vary some- DIAGNOSTIC SCAN TOOL
what depending on barometric pressure but
should be approximately 69 kPa (10 psi) less  Diagnostic Scan Tool Software (DST).
than the ignition ON engine OFF pressure. Un-
64
TEST DESCRIPTION lated pressure and permanently damage the
pressure regulator. With battery voltage
The numbers below refer to step numbers in applied to the pump, pressure should rise
the diagnostic table. above TBD-TBD kPa (TBD-TBD psi) as the
valve in the return pipe is partially closed.
4. Connect fuel pressure gage (Refer to the
Fuel Injection Pressure Tester Owner’s Ma- NOTICE: Do not allow the pressure to ex-
nual supplied in the IMPCO Test Kit for ceed TBD kPa (TBD psi) as damage to the
instructions on relieving gasoline fuel pres- fuel pressure regulator may result.
sure for fuel systems without a Schrader
valve or test port. Wrap a shop towel 17. Fuel pressure above TBD kPa (TBD psi)
around the fuel connection to absorb any may cause a rich starting condition, followed
small amount of fuel leakage that may occur by black smoke and a strong fuel odor in the
when installing the gage. With ignition ON exhaust.
engine OFF and the fuel pump running,
pressure should be TBD-TBD kPa (TBD- 18. This test is to determine if the high fuel
TBD psi). pressure is due to a restricted fuel return
pipe or a faulty fuel pressure regulator.
6. When the engine is idling, manifold pres-
sure is low (High Vacuum) and is applied to 21. The pressure regulator may be fitted with a
the pressure regulator diaphragm. This va- screen which is designed to trap contami-
cuum will offset spring pressure and result nants introduced during engine assembly. If
in a lower pressure. Fuel pressure at idle dirty it can be removed and cleaned if re-
will vary somewhat depending on barome- quired.
tric pressure but should be less than the
pressure noted in step 4. 23. A system that does not hold pressure is
caused by one of the following:
11. Fuel pressure that drops off during accele-
ration or cruise may cause a lean condition  Leaking fuel pump check
and result in a loss of power, surging or  Leaking fuel feed hose
misfire. This condition can be diagnosed us-  Leaking valve/seat within the pressure
ing the Diagnostic Scan Tool. If the fuel in regulator
the system is very lean the Heated Exhaust  Leaking injector/fuel metering block as-
Gas Oxygen (HEGO) will stop toggling and sembly.
output voltage may drop below 100 mV and
stay low during the lean condition. 26. A leaking injector can best be determined
by checking for a fouled or saturated spark
14. Fuel pressure below TBD-TBD kPa (TBD- plug(s). If a leaking injector cannot be de-
TBD psi) under full load may cause a lean termined by a fouled or saturated plug the
condition and may set a DTC. Drivability following procedure should be used.
conditions can include hard starting when
cold, hesitation, and lack of power or  Remove the fuel metering body but
misfire. leave the lines connected.
 Inspect the injector tips for leakage un-
15. Restricting the fuel return pipe may cause der pressure.
the fuel pressure to build above the regu-
65
GASOLINE FUEL SYSTEM DIAGNOSTIC CHART

Did you perform the On Board (OBD) System Go to OBD
Go to Step
1 Check? - System Check
(2)
Section
Important: Inspect the fuel system for damage or Check all sys-
external leaks before proceeding with this diag- tem power
nostic. fuses and
Go to Step
2  Turn ON the ignition, with the engine OFF. power relay
(3)
 Command the fuel pump ON with the DST or circuit. Refer to
fuel pump test circuit. wiring harness
Does the fuel pump operate? schematic.
Important: Verify that adequate fuel is in the fuel
tank before proceeding with this diagnostic.
 Turn OFF the ignition.
 Turn OFF all accessories.
 Install the fuel pressure gage.
 Turn ON the ignition, with the engine OFF.
(The fuel pump relay may need to be com- TBD-TBD
Go to Step Go to Step
3 manded ON a few times in order to obtain the kPa (TBD-
(4) (10)
highest possible fuel pressure) TBD psi)
 DO NOT start the engine.
 Command the fuel pump ON with the DST or
fuel pump test circuit.
 Observe the fuel pressure gage with the fuel
pump commanded ON.
Is the fuel pressure within the specified range?
Important: The fuel pressure may vary slightly
when the fuel pump stops operating. After the
fuel pump stops operating, the fuel pressure TBD-TBD
should stabilize and remain constant. Go to Step
4 kPa (TBD- Go to Step (5)
(8)
 Monitor the fuel pressure gage for 1 minute. TBD psi)
Does the fuel pressure decrease by more than
the specified value?
 Relieve the fuel pressure to the first specified
value. TBD-TBD
Go to Step
5  Monitor the fuel pressure gage for 5 minutes. kPa (TBD- Go to Step (6)
(22)
Does the fuel pressure decrease by more than TBD psi)
the second specified value?
 Turn ON the ignition, with the engine OFF
 Monitor the fuel pressure gauge TBD-TBD
6  Start the engine kPa (TBD-
(7) (21)
Does the fuel pressure decrease by the specified TBD psi)
value when the engine is started?
66
 Operate the vehicle within the conditions of
the customer concern.
Refer to the
 Monitor the adaptive parameters with the Go to Step
7 symptom diag-
DST (15)
nostic charts
Do any of the DST readings indicate a lean con-
dition?
 Relieve the fuel pressure. Refer to the fuel
pressure relief procedure.
 Drain any remaining fuel into an approved
gasoline container.
 Install the J 37287 Fuel Line Shut-Off Adap-
ters between the rear fuel pipes and the
chassis fuel pipes.
 Open the valves on the fuel pipe shut-off
Go to Step
8 adapters. Go to Step (9)
(17)
 Command the fuel pump relay ON with the
DST or fuel pump test circuit.
 Bleed the air from the fuel pressure gage.
 Command the fuel pump relay ON and then
OFF with the DST or fuel pump test circuit.
 Close the fuel feed pipe shut-off valve.
 Monitor the fuel pressure gage for 1 minute.
Does the fuel pressure remain constant?
 Open the fuel feed pipe shut-off valve.
 Command the fuel pump relay ON and then Go to Step Go to Step
9
OFF with the DST or fuel pump test circuit. (21) (18)
 Close the fuel return pipe shut-off valve.
 Monitor the fuel pressure gage for 1 minute.
Does the fuel pressure remain constant?
Is the fuel pressure more than the specified val- TBD kPa Go to Step Go to Step
10
ue? (TBD psi) (12) (11)
Is the fuel pressure more than the specified val- TBD kPa Go to Step Go to Step
11
ue? (TBD psi) (14) (15)
 Relieve the fuel pressure. Refer to the fuel
pressure relief procedure
 Disconnect the rear fuel return pipe from the
chassis pipe.
 Attach a length of flexible hose to the chassis
fuel pipe. TBD kPa Go to Step Go to Step
12
(TBD psi) (20) (13)
 Place the open end of the flexible fuel hose
into an approved gasoline container.
 Monitor the fuel pressure gage while the fuel
pump is operating.
Is the fuel pressure within the specified range?
67
 Inspect the engine fuel return pipe and the
13 chassis fuel return pipe for a restriction.
(23) (21)
Did you find and correct the condition?
 Relieve the fuel pressure. Refer to Fuel
Pressure Relief Procedure.
 Disconnect the rear fuel return pipe from the
chassis pipe.
 Install the J 37287 between the rear fuel re-
turn pipe and the chassis fuel pipe.
 Open the valve in the fuel pipe shut-off adap-
ter. Turn ON the ignition, with the engine
OFF.
 Bleed the air from the fuel pressure gage. TBD kPa Go to Step Go to Step
14
Monitor the fuel pressure gage. (TBD psi) (21) (15)
Caution: DO NOT allow the fuel pressure to
exceed TBD kPa (TBD psi). Excessive pres-
sure may damage the fuel system.
 Command the fuel pump relay ON with the
DST or fuel pump test circuit.
 Slowly close the valve in the fuel return pipe
shut-off adapter, while the fuel pump is oper-
ating.
Does the fuel pressure increase to more than the
specified value?
Inspect the following components for a restric-
tion:
15  The fuel filter
(23) (16)
 The fuel feed pipe
 Inspect the wiring harness connectors and
ground circuits of the fuel pump for poor
16 connections. Refer to system wiring sche-
(23) (17)
matic
 Remove the fuel sender assembly if the
pump is located inside the fuel tank.
 Inspect the following items:
 The fuel pump flex hose for damage
 The in-tank fuel pump harness connectors Go to Step Go to Step
17
for poor connections (23) (22)
 The fuel strainer or external filter for a restric-
tion.
 The fuel tank for contaminants
68
 Open the fuel return pipe shut-off valve.
 Remove the upper intake manifold. Install the
engine compartment fuel feed and fuel return
pipes to the fuel meter body. Go to Step Go to Step
18
 Turn ON the ignition, with the engine OFF. (21) (19)
 Inspect for a fuel leak from the fuel pressure
regulator.
Is the fuel pressure regulator leaking fuel?
 Remove the fuel injectors from the intake
manifold in order to isolate the leaking fuel Go to Step
19 -
injector. (23)
Did you complete the replacement?
 Repair the restricted fuel return pipe between
Go to Step
20 the chassis fuel pipe and the fuel tank. -
(23)
Did you complete the repair?
 Inspect for a missing or damaged O-ring seal
before replacing the fuel pressure regulator. If
Go to Step
21 the O-ring seal is not missing or damaged, -
(23)
replace the fuel pressure regulator.
 Replace the fuel sender assembly or external
Go to Step
22 fuel pump if so equipped. -
(23)
 Connect any disconnected components, fus-
es, etc.
 Using the DST clear DTC information from
the ECM.
 Turn the ignition OFF and wait 30 seconds. Go to OBD
23 System OK
 Start the engine and operate the vehicle to System Check
full operating temperature
 Observe the MIL
 Observe engine performance and drivability
Does the engine operate normally with no stored
codes?
69
70
Gasoline Symptom
Diagnostics
71
GAS SYMPTOM DIAGNOSTICS
Checks Action
Before using this section, you should have performed On Board Diagnostic
Check and determined that:
1. The ECM and MIL are operating correctly.

Before Using This 2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists
Section but without a MIL.
Several of the following symptom procedures call for a careful visual and
physical check. These checks are very important as they can lead to prompt
diagnosis and correction of a problem.
1. Verify the customer complaint.
2. Locate the correct symptom table.
3. Check the items indicated under that symptom.
4. Operate the vehicle under the conditions the symptom occurs. Verify
HEGO switching between lean and rich. IMPORTANT! Normal HEGO
Fuel System Check
switching indicates the fuel system is in closed loop and operating cor-
rectly at that time.
5. Use the DST to take a “snapshot” under the condition that the symptom
occurs. Go to Engine Scan Tool Data List to verify normal sensor values
and parameters.
 Check all ECM system fuses and circuit breakers.

 Check the ECM ground for being clean, tight and in its proper location.
 Check the vacuum hoses for splits, kinks and proper connections.
 Check thoroughly for any type of leak or restriction.
 Check for air leaks at all the mounting areas of the intake manifold sealing
surfaces.

 Cracking.
 Hardening.
Visual Checks  Proper routing.
 Carbon tracking.
Check the wiring for the following items:

 Proper connections
 Pinches or cuts.
The following symptom tables contain groups of possible causes for each
symptom. The order of these procedures is not important. If the scan tool
readings do not indicate the problems, then proceed in a logical order, ea-
siest to check or most likely to cause the problem.
72
INTERMITTENT
Checks Action
DEFINITION: The problem may or may not turn ON the MIL or store a Diagnostic Trouble Code (DTC).
Do not use the DTC tables. If a fault is an intermittent, the use of the DTC
Preliminary Checks
tables may result in the replacement of good parts.
Faulty electrical connections or wiring can cause most intermittent problems.

Check the suspected circuit for the following conditions:
 Faulty fuse or circuit breaker, connectors poorly mated, terminals not fully
seated in the connector (backed out). Terminals not properly formed or
damaged.
 Wire terminals poorly connected.
Faulty Electrical Con-
 Terminal tension is not adequate.
nections or Wiring
 Carefully remove all the connector terminals in the problem circuit in or-
der to ensure the proper contact tension.
 If necessary, replace all the connector terminals in the problem circuit in
order to ensure the proper contact tension (except those noted as “Not
Serviceable”). See section Wiring Schematics.
 Checking for poor terminal to wire connections requires removing the
terminal from the connector body.
If a visual and physical check does not locate the cause of the problem, drive
Operational Test the vehicle with a scan tool. When the problem occurs, an abnormal voltage
or scan reading indicates a problem circuit.
The following components can cause intermittent MIL illumination and no

DTC(s):
 A defective relay.
 Switch that can cause electrical system interference. Normally, the prob-
Intermittent MIL Illumi- lem will occur when the faulty component is operating.
nation  The improper installation of add on electrical devices, such as lights, 2-
way radios, electric motors, etc.
 The ignition secondary voltage shorted to a ground.
 The MIL circuit or the Diagnostic Test Terminal intermittently shorted to
ground.
 The MIL wire grounds.
To check for the loss of the DTC Memory:
1. Disconnect the MAP sensor.

Loss of DTC Memory 2. Idle the engine until the MIL illuminates.
3. The ECM should store a MAP DTC which should remain in the memory
when the ignition is turned OFF. If the MAP DTC does not store and re-
main, the ECM is faulty.
73
NO START
Checks Action
DEFINITION: The engine cranks OK but does not start.
Using the DST:
 Check for proper communication with both the ECM

 Check all system fuses located in the engine fuse holder. Refer to En-
ECM Checks
gine Controls Schematics.
 Check battery power, ignition power and ground circuits to the ECM.
Refer to Engine Control Schematics. Verify voltage and/or continuity for
each.
 Check the MAP sensor.
Sensor Checks
 Check cam angle sensor (RPM).
 Check for fuel pump electrical circuit.
 Verify proper fuel pump pressure.
 Verify proper Fuel rail pressure.
Fuel System Checks
 Check electrical connections of fuel injectors.
 Refer to the Gasoline Fuel System Diagnosis.
lent.
 Check the spark plugs for the following conditions:
 Wet plugs.
 Cracks.
 Wear.
 Improper gap.
 Heavy deposits.

Engine Mechanical  Low compression.
Checks  Improper valve clearance.

 Inspect the catalytic converter and muffler for signs of heat distress or for
Exhaust System Checks
possible internal failure.
74
HARD START
Checks Action
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run,
or may start but immediately dies.
Preliminary Checks Make sure the vehicle’s operator is using the correct starting procedure.
 Check the Engine Coolant Temperature sensor with the scan tool. Com-
pare the engine coolant temperature with the ambient air temperature on
a cold engine. If the coolant temperature reading is more than 10 de-
grees greater or less than the ambient air temperature on a cold engine,
Sensor Checks
check for high resistance in the coolant sensor circuit. Check the Crank-
shaft Position (CKP) sensor.
 Check the Throttle Position Sensor (TPS) and Foot Pedal Position (FPP)
sensors.

Fuel System Checks  Verify proper fuel rail pressure.
Check for the proper ignition voltage output with J 26792 or the equivalent.
Verify that the spark plugs are the correct type and properly gapped.

 Wet plugs.
 Cracks.
 Wear.
 Heavy deposits.
 Check for moisture in the distributor cap.
Important:
1. If the engine starts but then immediately stalls, check the Crankshaft Po-
sition (CKP) sensor.
2. Check for improper gap, debris or faulty connections.
 Vacuum leaks.
Engine Mechanical
 Low compression.
Checks
 Check the intake and exhaust manifolds for casting flash.
75
HARD START
Checks Action

 Inspect the muffler for signs of heat distress or for possible internal failure.
76
CUTS OUT, MISSES
Checks Action
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load
increases, but normally felt below 1500 RPM. The exhaust has a steady spitting sound at idle, low speed,
or hard acceleration for the fuel starvation that can cause the engine to cut-out.
 Start the engine.
 Check for proper ignition output voltage with spark tester J 26792.
 Verify that the spark plugs are the correct type and properly gapped
 Check for a cylinder misfire.
Remove the spark plugs in these cylinders and check for the following condi-
tions:
 Improper gap.
 Heavy deposits.

 Cross-firing.
 Primary ignition coil wires for cracks or carbon tracking.
 Perform a cylinder compression check.

Engine Mechanical  Improper valve timing.
Checks  Worn rocker arms.
 Check the intake and exhaust manifold passages for casting flash.
Check the fuel system:

Fuel System Checks  Check the in-line fuel filter for restrictions.
 Low fuel pressure, etc. Refer to Gas Fuel System Diagnosis.
 Check for Electromagnetic Interference (EMI), which may cause a missing

condition.
 Using a scan tool, monitor the engine RPM and note sudden increases in
Additional Check
rpms is displayed on the scan tool but with little change in the actual en-
gine RPM. If this condition exists, EMI may be present.
 Check the routing of the secondary wires and the ground circuit.
77
HESITATION, SAG, STUMBLE
Checks Action
DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The
condition can occur at any vehicle speed. The condition may cause the engine to stall if it’s severe
enough.
 Verify proper fuel rail pressure.
Fuel System Checks
lent.
Remove Spark Plugs:

 Check for fouled spark plugs.
 Wear.
 Improper gap.
 Heavy deposits.

 Cross-firing.
 Primary ignition coil wires for cracks or carbon tracking.
 Check for manifold vacuum or air induction system leaks.
Additional Check
 Check the generator output voltage.
78
BACKFIRE
Checks Action
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping
noise.
 Check for the proper primary ignition coil wire output voltage using the
spark tester J26792 or the equivalent.
wires.
 Check the connection at primary ignition coil wire.
 Check for deteriorated spark plug wire insulation.
 Check the spark plugs.
 Wet plugs.
 Cracks.
 Wear.
 Improper gap.
 Heavy deposits.
 Manifold vacuum leaks.
Engine Mechanical
 Intake manifold gaskets.
Check
 Sticking or leaking valves.
 Exhaust system leakage.
 Check the intake and exhaust system for casting flash or other restric-
tions.
Fuel System Checks Perform a fuel system diagnosis. Refer to Gas Fuel System Diagnosis.
79
LACK OF POWER, SLUGGISHNESS, OR SPONGINESS
Checks Action
DEFINITION: The engine delivers less than expected power. There is little or no increase in speed
when partially applying the accelerator pedal.
 Refer to the Gas Fuel system OBD System Check.

 Compare the customer’s vehicle with a similar unit to verify customer has
an actual problem. Do not compare the power output of the vehicle oper-
ating on gas to a vehicle operating on LPG as the fuels do have different
Preliminary Checks
drive feel characteristics.
 Remove the air filter and check for dirt or restriction.
 Check the vehicle transmission.
 Refer to the OEM transmission diagnostics.
 Check the in-line fuel filter for restrictions, contaminated fuel, or improper
fuel pressure. Refer to Gas Fuel System Diagnosis.
Fuel System Checks  Check for fuel pump electrical circuit.
 Verify proper fuel rail pressure.
 Check the Heated Exhaust Gas Oxygen Sensor (HEGO) for contamina-
tion and performance.
Sensor Checks
 Check for proper operation of the MAP sensor.
 Check for proper operation of the TPS and FPP sensors.

 Inspect the muffler for signs of heat distress or for possible internal failure.
 Check for possible plugged catalytic converter.

 Valve timing.
Engine Mechanical  Improper or worn camshaft.
Check  Refer to Engine Mechanical in the Service Manual.
 Check for the proper ignition output voltage with the spark tester J 26792
or the equivalent.
tions.
 Check the generator output voltage.
Additional Check If all procedures have been completed and no malfunction has been found,
review and inspect the following items:
 Visually and physically, inspect all electrical connections within the sus-
pected circuit and/or systems.
 Check DST data.
80
POOR FUEL ECONOMY
Checks Action
DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Al-
so, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by
refueling records.
 Check the air cleaner element (filter) for dirt or being plugged.
 Visually check the vacuum hoses for splits, kinks, and proper connec-
tions.
 Check for properly inflated tires.
Check the operators driving habits for the following:

Preliminary Checks
 Excessive idling or stop and go driving.
 Carrying of very heavy loads.
 Rapid acceleration.
 Suggest to the owner to fill the fuel tank and to recheck the fuel econo-
my and/or suggest that a different operator use the equipment and
record the results.
 Refer to Gas Fuel System Diagnosis.
Fuel System Checks
 Check the fuel system for leakage.
Sensor Checks  Check the MAP sensor.
 Wet plugs.
 Cracks.
 Wear.
 Improper gap.
Ignition System Checks  Burned electrodes.
 Heavy deposits.
Check the ignition wires for the following items:

 Cracking.
 Hardness.
 Proper connections.
Check the engine thermostat to see if it is stuck open or for the wrong heat
Cooling System Checks
range.
 Check the transmission shift pattern.
Additional Check  Refer to the OEM Transmission Controls section the Service Manual.
 Check for dragging brakes.
81
Checks Action
DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The
engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine.
Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance:
 Check for silicone contamination from fuel or improperly used sealant. If
contaminated, the sensor may have a white powdery coating result in a
high but false signal voltage (rich exhaust indication). The ECM will re-
Sensor Checks
duce the amount of fuel delivered to the engine causing a severe
drivability problem.
 Check the Manifold Absolute Pressure (MAP) sensor response and ac-
curacy.
 Check for rich or lean symptom that causes the condition.

 Drive the vehicle at the speed of the complaint.
Fuel System Checks  Monitoring the oxygen sensors will help identify the problem.
 Refer to the Gas Fuel System Diagnosis.
 Verify that the spark plugs are the correct type and properly gapped
 Wet plugs.
 Cracks.
 Improper gap.
 Blistered insulators.
 Heavy deposits.
wires.
 Check for vacuum leaks. Vacuum leaks can cause a higher than normal
idle and low throttle angle control command.
Additional Checks
tions. Check the battery cables and ground straps. They should be clean
and secure. Erratic voltage may cause all sensor readings to be skewed
resulting in poor idle quality.
Check the engine for:
 Broken motor mounts.
Engine Mechanical  Improper valve clearance.
Check  Low compression.
82
SURGES/CHUGGLES
Checks Action
DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if
it speeds up and slows down with no change in the accelerator pedal.
Sensor Checks Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance.
 Check for Rich or Lean symptom that causes the condition.

 Drive the vehicle at the speed of the complaint. Monitoring the oxygen
sensors will help identify the problem.
Fuel System Checks
 Check the fuel pressure while the condition exists. Refer to Gas Fuel
System Diagnosis.
 Wet plugs.
 Cracks.
 Wear.
 Improper gap.
 Heavy deposits.
 Check the Crankshaft Position (CKP) sensor.
tions.
Additional Check  Check the generator output voltage.
 Check the vacuum hoses for kinks or leaks.
 Check Transmission .
83
84
Electrical Section
85
86
Diagnostic Scan Tool
87
CONTENTS
 Installation of the DST package to a personal computer (PC).

 Software login and password functionality.
 DST service pages.
 Updating the ECM calibration using a MOT file.
 DTC pages.
Examples and snapshots used in this manual are based off of the initial DST tool release as of July, 2007.
This tool is frequently updated and the illustrations may vary depending on the changes included in any
updated DST display Interface. Terms, names and descriptions of parts and servicing procedures will be
updated based on trade, brand, or common description to more accurately describe the part or service pro-
cedure.
DST INSTALLATION INSTRUCTIONS
Before installing the DST software, please be sure your computer meets the minimum system requirements.
Supported operating systems are:
 Windows Vista (32-Bit)

 Windows XP (32-Bit)
 Windows 2000
Minimum processor speed:
 Pentium II 450 MHz

 Pentium III 1.0 GHz for Windows Vista
Minimum RAM requirement:
 Windows Vista 512 MB

 Windows XP 256 MB
 Windows 2000 128 MB
* At least one available RS232 serial or USB port.

* ECOM cable supports USB port only.
88
 Open the DST_Series III folder
 Open the Latest_GCP_Display folder
89
 Double click on “setup.exe” (application file) to start the windows installer. If a previous version of
the GCP software is installed, the uninstaller may remove the previous version and exit. You will be
required to start the installer again to install the new version.
 Click “Next” to continue
90
91
 Click the “Finish” box to complete the installation.
 Click “Yes” to restart your computer
92
 Once installed, the software can be accessed from Start Menu →Programs → Impco
GCP Display → Impco GCP Display
93
INSTALLING THE USB ADAPTER DRIVER
If your computer does not have an RS232 serial port you will need to install the USB adapter driver.
You do not need to install this driver if you plan to use the ECOM DLC cable.
94
 Open the “USB Driver” folder
 Double click on “setup.exe” (application file) and follow the on screen prompts.
Installing the ECOM DLC cable driver
The ECOM USB cable is designed to replace both the serial DLC and the USB adapter cables. It also
provides communication to the ECM on the CAN line for systems that are CAN enabled. It requires the
installation of the ECOM driver and is compatible with the series II and series III DST software pro-
grams.
95
 Double click on “setup.exe” (application file).
96
 Select install ECOM drivers only. Click “Next” and follow the on screen prompts.
97
PASSWORD LOGIN
Figure 1 shows the password dialog box, which is displayed when a software session begins. Login
can be accomplished in two ways.
1. Enter an “All S/N Password” which is a password applicable to all ECMs of a given original equip-
ment manufacturer (OEM).
2. Enter a “Single S/N Password” and corresponding ECM serial number for a single ECM. A Single
Serial Number password is unique to a specific ECM serial number and permits authorized service
personnel to make changes or view information for a specific ECM.
3. In most instances the top “all” serial number boxes should be used for password entry. In this case,
do not check the single serial number box. Each password is a 16-character alpha-numeric string
specific to each Spectrum customer and determines which pages and variables are visible through
the software. Passwords are assigned by the OEM support group and may change periodically.
Check the “save password” box to automatically retain the password for future use.
Figure 1: Populated Password Dialog Box
98
PASSWORD DIALOG BOX FUNCTIONS
 Clear Password Button Erases the current password from the password field.
 Paste Password Button Allows the user to copy a 16-character string from any word processor
and paste the string in the password field.
 Single Serial Number Access Checkbox Tells the software that the password is applicable for sin-
gle serial number access.
 Serial Number Field Only applicable when Single Serial Number Access Checkbox is checked.
The entry field must be populated for the 6-digit serial number for which the Single Serial Number
Access password applies (NOTE: Leading zeros included in the serial number are not required).
 Save Password and S/N Checkbox Retains the password, and serial number (if applicable) for the
next software session.
Should an invalid password be entered, the error prompt shown in figure (2) will be displayed
and the software will not load. This prompt signifies the following:
 The All S/N password is invalid.

 The Single S/N password is incorrect for the Single Serial Number entered.
 An All S/N password is entered for Single Serial Number use.
 The Single Serial Number password is valid; however, the Single Serial Number Access Checkbox is
not checked.
Figure 2: Password Error Prompt
99
If the Single S/N password entered is correct for the software but does not match the entered S/N of the
targeted ECM, the prompt in Figure 3 will be displayed.
Figure 3: Incorrect Serial Number Message
Figure 4 shows the communication status if a valid software password is entered when attempting to
connect to an ECM with a different key. In this instance the software will load but will not connect to
the target (ECM).
Figure 4: Not Authorized to Connect Message
In the event you receive this error message call your OEM support group for more information.
CONNECTING THE PC TO THE SPECTRUM FUEL SYSTEM
Connecting the DST cable
A laptop computer, with the diagnostic cable and software is the required tool for performing proper di-
agnostic testing of the Spectrum fuel system. It is also used to monitor sensor and actuator values and
to read and clear Diagnostic Trouble codes. The DST software also performs several special tests.
100
 Connect the system diagnostic cable to the RS232 port on the back of the computer. If you do not
have a RS232 port, use the USB to RS232 adapter supplied in the IMPCO ITK test kit. Be sure to
install the USB driver to enable the USB adapter for use with your computer.
 Connect the diagnostic cable to the DLC (diagnostic link connector) labeled in the electrical sche-
matic. The DLC is located on the engine harness. The new 8 pin DLC requires the use of the 4 to
8 pin adapter included in the late model ITK test kits.
 Turn the computer ON.
 Start Windows.
 From the start menu select Programs → Impco GCP Display → Impco GCP Display
 Place the ignition key in the ON position.
Within several seconds the system Gauge screen should now appear and a green banner in the upper
left hand will read “Connected.”
 Connecting to the PC using the ECOM cable
 To connect using the ECOM cable you must select ECOM from the COM Port drop down menu.
101
 You will now need to configure the ECOM communication protocol.
 Select the CAN for systems with CAN enabled or serial for all others. Then select OK. You are
now ready to connect using the ECOM USB DLC cable.
102
DST SERVICE PAGES
Gauge Page
Provides system data in large easy to read displays. Displays ECM configuration information for the
ECM software, hardware, serial numbers and calibration dates.
103
Raw Volts Page
The raw volts page displays the sensor inputs and outputs in a raw voltage format. This page is most
commonly used to check values in the diagnostic trouble shooting charts.
Service 1
104
The Service 1 screen is used to clear the adaptive learn, shows the MIL status and provides a display
for rpm, coolant temperature and spark advance. It also provides a large display to monitor the closed
loop mixture control.
Tests Page
Provides diagnostic information voltages and sensor outputs and includes diagnostic engine tools such
as spark and injector kill controls. Please note that not all features are available for all applications.
The disabled item menus are grayed out or rendered inoperative.
SPARK KILL
The spark kill mode allows the technician to disable the ignition on individual cylinders. If the Spark Kill
diagnostic mode is selected with the engine running below 1000 rpm, the minimum throttle command
will lock into the position it was in when the test mode was entered. If the Spark System Test mode is
selected with the engine running above 1000 rpm, the throttle will continue to operate normally. Disabl-
ing Ignition Outputs to disable the ignition system for an individual cylinder, use the mouse to highlight
the “Spark Kill” button and select the desired primary ignition coil wire. The spark output can be re-
enabled by using the mouse to highlight the “Spark Kill” button and selecting “Normal.” If the engine is
running below 1000 rpm, the spark output will stay disabled for 15 seconds and then re-set. If the en-
gine is running above 1000 rpm, the spark output will stay disabled for 5 seconds and then re-set. This
test mode has a timeout of 10 minutes. Record the rpm drop related to each spark output disabled.
The spark outputs are arranged in the order which the engine fires, not by cylinder number.
105
INJECTOR KILL
The Injector Kill mode is used to disable individual fuel injectors. If the Injector Kill mode is selected
with the engine running below 1000 rpm, the minimum throttle command will lock into the position it
was in when the test mode was entered. If the Injector Kill mode is selected with the engine running
above 1000 rpm, the throttle will continue to operate normally. To disable an injector, use the mouse
to select the desired injector. The word “Normal” will change to the Injector you have selected. The
injector driver can be re-enabled by selecting again. If the engine is running below 1000 rpm, the in-
jector driver will stay disabled for 15 seconds and then re-set. If the engine is running above 1000
rpm, the injector driver will stay disabled for 5 seconds and then re-set. Record the change in rpm
while each driver is disabled.
DBW TEST MODE
The DBW (Drive by Wire) test mode allows the technician to control the throttle directly with the foot
pedal or throttle input and is used during the diagnostic routines specified for FPP and TPS for Spec-
trum systems that use DBW control. FPP position displays the current position of the foot pedal as a
percentage. FPP volts display the voltage which the ECM is reading from the FPP sensor. TPS
Command displays the commanded throttle position expressed as a percentage, which is being sent
to the throttle. TPS Position is the actual percent of throttle opening being sent to the ECM from the
throttle. TPS volts display the actual TPS signal voltage the ECM is receiving from the throttle. To
select this test mode the engine must be off and the key must be in the ON position.
EXTERNAL POWER TEST
The external power test manually activates relays (relay power, fuel pump, and drive-by wire power)
controlled by the ECM while the engine is in the “Stopped” or “Running” states. Reverts to normal
operation if “Automatic” state is selected or ignition voltage is cycled from high to low.
106
Faults Page
Stores DTC codes that may have occurred in the past (Historic Faults) or current set codes (Active
Faults). Includes useful system voltages and sensor readings used while working with the fuel and
emission trouble shooting charts. Shows power derate mode status. To erase a historic DTC code,
double click on the code with the left mouse button. Then choose to “Clear All Faults.”
PLOT/LOG MENU FUNCTIONS
The Plot/Log menu allows the user to graphically plot or numerically log variables that have been
tagged for plotting/logging. To plot or log variables, a tag must be assigned to each variable of interest.
A variable is tagged for plotting/logging through a single right-mouse click in the variable’s vicinity.
Once a variable has been tagged for plotting/logging, it is highlighted in green.
Figure 5 shows an example of variables that have been tagged. A maximum of twenty (20) variables
may be tagged for logging and a maximum of ten (10) variables may be tagged for plotting. The maxi-
mum achievable sample frequency/minimum period is dependent on the number of variables tagged.
107
Figure 5: Tagged Variables for Plot/Log
Once the variables have been tagged as highlighted by the green color fill, select the “Plot/Log” func-
tion in the top menu bar as shown below in figure 6.
Figure 6
108
 Select “Plot Tags” to open the snapshot window
Other functions available from the Plot/Log menu include:
 Clear Tags: Releases all plot/log variables.

 Plot Tags (Ctrl + P, or P): Graphically plot all tagged variables.
 Load Plot Setup: Loads and tags variables for plotting/logging that have been stored in a plot file
(.plt).
 Log Tags (Ctrl + L): Numerically log all variables that have been tagged for plotting/logging.
Once the Plot Tags menu item has been selected, tagged variables are graphically plotted in a strip
chart interface. An example of a plot is shown in Figure 7. Capabilities of the plotter are outlined in
Table 1.
Start/Stop Button Start or stop plotting of selected variables

Save plotted data displayed in the plot to a comma-separated val-
Save Button ue file (CSV) on the PC hard drive. Format must not be altered if
the Load function is to be used.
Convert the plot into a snapshot that may be panned, zoomed,

Snapshot Button
scrolled, and saved
Close Button Close the DST Plot interface

Load tags from a previously saved plot (.plt) file to allow for similar
Load Setup Button
plots and logs to be generated
Load a previously saved plot from the PC into the DST Plot inter-
Load Plot Button
face
Variable Selector Menu Selects the active variable for axis scaling
Single Shot Acquisition When checked, this does not allow the plot to scroll past the ‘Time
Checkbox* Interval’ thereby preserving plotted data for post-processing.
Exclusive Serial Use When checked, this allows exclusive serial communication for the
Checkbox* plot variables. Other variables on the active page are not updated.
Min Y Value Field* Specify the minimum Y-axis scaling for the active variable
Max Y Value Field* Specify the maximum Y-axis scaling for the active variable
Define the sample period for recording and display Frequency
Sample Interval (ms) Field*
(Hz.) = 1000/Sample Interval (ms)
Time Interval (s) Field* Defines the total sample acquisition time for the plot.
*Accessible only when plotter is not running.
109
Start plot
Variable selector
Figure 7: DST Plot
 Click on the “Start” button to start the DST plot function.

 Click on the variable selector button to view selected sensors
110
Figure 8: DST Plot Snapshot
 Click on the “Save” button to save the snapshot as a file. To replay the saved file, open the
edis_saplot program from the windows start menu.
111
 Start Menu → Programs → Impco GCP Display → edis_saplot
DST PLOT INTERFACE FUNCTIONS

A graphic tool incorporated in the plotter is the snapshot function. This function allows data collected in a
plot to be transferred into a second window for quick graphical post-processing. The snapshot allows the
user to zoom in/out, pan left/right, and move cursors along the signal traces to measure the variable val-
ues in virtual real-time. An example of a snapshot is shown in Figure 8. Any CSV file in plot format (.plt)
may be loaded into the snapshot. Table 2 outlines the available hot key functions of the snapshot screen.
SNAPSHOT HOT KEY FUNCTIONS
Command Function
<Single, left-click on trace> Snap closest cursor to data
<Ctrl + Up/Down Arrows> Move/pan plot along y axis
<Ctrl + Left/Right Arrows> Move/pan plot along t axis
<Ctrl+Shift + Up/Down Arrows> Zoom plot in and out in y axis
<Ctrl+Shift + Left/Right Arrows> Zoom plot in and out in t axis
<Ctrl + Home> Resize plot to default settings
<Ctrl + Page Up> Zoom out by 10%
<Ctrl + Page Down> Zoom in by 10%
<Page Up> Toggle to previous cursor
<Page Down> Toggle to next cursor
<Left/Right Arrow> Follow selected data along trace
<Up/Down Arrow> Follow selected data along trace
<Shift + Left/Right Arrow> Move 10 points along trace
<Shift + Up/Down Arrow> Move 10 points along trace
<Home> Go to first visible point on current plot
<End> Advance to last visible point on current plot
<Shift + Up/Down Arrow> Toggle between traces/variables
Table 1
112
DST LOGGER
Another data capture function incorporated in the software is the DST logger. This tool serves as a PC
data logger for any variable available in the ECM through the interface software. Figure 9 shows the in-
terface display for configuring the DST Log. The interface allows the user to create the filename, set
the sample rate for acquisition, set the time interval for sampling, and display the progress of acquisi-
tion. A maximum of twenty (20) variables may be tagged for the log. The amount of data stored is only
limited by available PC RAM. The resulting text file may then be viewed by any standard Windows text
editor/reader program. To create a log file select the “Log Tags” in the drop down menu as shown in
figure 6.
Figure 9: DST Log Interface
REPROGRAMMING THE ECM
New software upgrades may become available for in field applications. ECM software upgrades are
possible using the DST. Updates are released to service in MOT files (A MOT file has an extension
.mot and is a binary S-record file that contains the full calibration and embedded software algorithms).
The MOT file is the one file necessary to completely configure or update an existing ECM. The MOT
may be supplied on a floppy disk, CD ROM or downloaded from the OEM service network. To update
the ECM calibration follow the instructions listed on the next three pages.
113
 Turn the ignition key to the ON position.
 Verify the DST is “connected” to the ECM.
 From the “File” menu select “Reprogram target.”
 Navigate to the media where you have stored the MOT file. In the example above the MOT file
was stored on the on the floppy (A) drive.
 Highlight the correct .mot file using the left mouse button.
 Click on “Load.”
114
 Click “Yes” to continue.
 Click the “Yes” box to continue with the update. Refrain from using other functions on the computer
while the download takes place.
Do not disconnect the DLC, remove

power or use the PC for any other func-
tion during this process. Any
interruption during this reprogram
process may render the ECM non-
programmable in the field.
The status bar shows the update process.
115
Message is displayed confirming the update was successful.
116
MALFUNCTION INDICATOR LAMP (MIL)
The Spectrum Fuel system has built-in diagnostics for system trouble shooting. The system has a dash
mounted malfunction indicator lamp (MIL) that provides indications of an emissions related problem.
Most engine control system related problems that affect emissions or drivability of the vehicle will set a
(DTC) diagnostic trouble code and illuminate the MIL.
The MIL serves as notification to the operator of a problem related to the emission control system so
the driver can arrange for service as soon as possible. It will also display DTCs that have been stored
due to a system malfunction.
The MIL should illuminate when the key is in the ON position and the engine is not running. This fea-
ture verifies that the lamp is in proper working order. If the MIL does not illuminate with the vehicle key
ON/engine OFF, repair it as soon as possible. Once the engine is in start or run mode, the MIL should
turn off. If the lamp remains on while the engine is in the start or run mode a diagnostic trouble code
may be set.
The MIL will be turned OFF after three (3) consecutive run cycles or by clearing the active code with the
Diagnostic Scan Tool (DST).
SPECTRUM DIAGNOSTIC TROUBLE CODES (DTC)
Diagnostic Trouble Codes are set when the Spectrum ECM (Engine control module) runs a diagnostic
self test and the test fails. When a DTC is set, the ECM will illuminate the MIL on the instrument panel
and also save the DTC in memory. The ECM will continue to run the self test. If the system continues
to fail the test, the lamp will stay illuminated and the DTC is stored as an active DTC. If the self test
runs and passes, the DTC will be stored as historic DTC. All DTCs are stored as historic faults until
they are cleared. Most DTCs will automatically clear from memory if the DTC does not reset within 50
to 100 consecutive engine run cycles.
While a Diagnostic Trouble Code is current for a sensor, the ECM may assign a default “limp home”
value and use that value in its control algorithms. All of the system diagnostic self-tests run continuous-
ly during normal vehicle operation.
The Diagnostic Trouble Codes can be read by using either the MIL lamp or a laptop computer. Diag-
nostic Trouble Codes can be cleared from memory with a laptop computer, or by turning the ignition
key to the OFF position and removing the ECM power fuse or battery cable for at least 15 seconds.
If more than one DTC is detected, start the diagnostic repair with the lowest DTC number set. Diag-
nose each problem to correction unless directed to do otherwise by the diagnostic chart. The DTCs are
numbered in order of importance. Both DTC 112 and DTC122 pertain to the oxygen sensor, so it is
possible that a repair that corrects DTC 112 may also correct the problem causing the DTC 122.
Diagnostic test charts contained in this manual refer to the DST to be connected and in the “System
Data Mode.” This simply means that the DST is connected and communicating with the PC. In some
instances the chart will call out a special test mode. An example of this would be instructions for the
DST to be connected and in the DBW (drive by wire) mode. Always be sure to follow the special in-
structions to avoid a false diagnosis of fuel system components.
117
DLC COMMUNICATION ERROR
The ECM 5 volt reference circuit powers the Spectrum diagnostic link cable. In the event that the 5 volt
reference signal is open or shorted to ground, you will not be able to connect to the system. If you are
unable to connect, follow the quick checks listed below:
Be sure you are using the correct password and latest software for the system you are connecting to.
Check the ECM system power and ground circuits. Refer to DTC 562 for the power schematic. Also
check for +12 volts switched power at ECM pin 45 with the ignition key ON.
Check for power at the DLC connector for + 5 volts between pin 1 and pin 2 with the ignition key in the
ON position.
You may still be able to retrieve a code using the blink code function if none of the above recommenda-
tions prove useful. In the event of a 5 volt reference signal malfunction, DTC 642 or DTC 643 should
set. If you find one of these codes using the blink code function, follow the DTC diagnostic chart rec-
ommendations for that specific DTC.
BLINK CODE FUNCTION
Although the DST is considered a required tool to access the DTC codes, codes may be retrieved with-
out a laptop computer using the blink code function. To enable this function follow the steps below:
 Jump pins A and D at the DLC connector.
 Turn the ignition key to the on position
 The system will now enter the self diagnostic blink code mode. Be ready with pen and paper to
write down any codes that may be stored.
 The ECM will flash the MIL indicator with a pause between represented numbers that represent
DTC codes. The sequence starts with code 1654. Code 1654 confirms the system has entered the
blink code mode. The ECM will flash code 1654 (3) times before displaying the actual DTC code
that may be set.
Example:
One short blink (pause) six short blinks (pause) five short blinks (pause) four short blinks.
 If no DTC codes are found, the ECM will continue to flash 1654 only. This means no stored DTC
codes were found.
 If one of the numbers in the DTC code is zero (0), no flash will occur to represent the zero value—it
will be represented as a short pause.
118
Diagram 1
When using the DST program to clear a DTC, always select the “Clear All Faults” function to imme-
diately turn the MIL OFF after a successful repair (as shown in diagram 1 above).
INTERMITTENT PROBLEMS
Intermittent fuel system problems can prove to be the most challenging to repair. It is most important
to remember when looking to find the cause of these problems, to operate the system in the condition
when and where the problem occurs. An example of this would be, if the DST showed a lean fuel mix-
ture at full load, one of the first things to look at would be the fuel pressure. The fuel pressure would
need to be monitored while the machine is operating at full load, not at idle because the leaning effect
does not occur at idle. Electrical problems should be treated the same way. One excellent tool for
finding intermittent electrical problems is the DST plot/log function. Set up the plot for the code that
sets. An example of this would be if an intermittent IAT code set, tag the IAT voltage and watch the
plot. While watching the plot, agitate the electrical wire connection at the sensor and ECM connector.
The resolution of the plot screen is such that you will be able to see any unstable voltages that you
would otherwise not see with a standard DVOM.
Caution should be used when pressure washing the under hood of any electrical system. Avoid direct
pressure spray on the system electrical connectors. They are splash proof, but if water is sprayed di-
rectly at the connector moisture can become trapped behind the connector seal and cause serious
system problems.
Extra care must be taken when probing electrical pins and terminals. Do not bend or spread these
terminals as this can also be a source of intermittent problems cause by improper handling of these
connectors.
119
120
Engine Wire Schematic
121
HHI 2007-2009 Emission Certified LPG & Bi-Fuel System 2.0L Engine
122
HHI 2007-2009 Emission Certified LPG & Bi-Fuel System 2.0L Engine
Connector Manufacturer
Description Type Manufacturer Remarks
Number (CN) Number
1 ECM Female 90P FCI 900901-00 Gold Pin
2 CAM Female 3P AMP 85205-3
3 Electronic Throttle Control Female 6P AMP 1-967616-1
4 TMAP Female 4P AMP 368162-1
5 ECT Female 3P KUM KBP016-0327
6 Ignition Female 6P KUM PB625-06027
7 Diagnostic Female 4P Weather Pack 12015798 Male: 12015024
8 OIL Switch Female 1P AMP 172320-2 Rubber Cover
9 Crank Female 3P AMP 85205-3
10 Alternator Female 3P Sumitomo 6189-0443
11 HEGO 1 Female 4P AMP 174257-2
12 HEGO 2 Male 4P AMP 12160825
13 Shut-Off Female 2P AMP 282080-1
14 LP Temp Female 2P Packard 12162197 12162195
15 EPR Female 8P AMP 776286-1 Gold Pin
16 Manifold Assy Female 4P AMP 368162-1
17 Injector 1 Female 2P KET MG641152 KUM- PU465-02127
21 System Interf. Female 16P AMP 368047-1
22 Starter Solenoid 10/20A DECO 95225-38050
23 Power 30A DECO 95225-38050 ISO Micro Relay
24 Fuel Pump 10/20A DECO 95225-38050 ISO Mini Relay
25 Fuse 1 5A Pacific 95225-38050 ISO Micro Relay
26 Maxi-Fuse 60A Little Des-Fuse Box
Fuse 2 20A Pacific Mini Fuse Des-Fuse Box
27 Starter Solenoid Femail 1P AMP 172320-2
28 Ground 10mm Ring
29 Fuel Pump+ 4mm Ring
30 Fuel Pump- 5mm Ring
31 Alternator+ 8mm Ring
32 Battery+ 8mm Ring Battery 1 & 2
123
124
Engine Wire Harness Repair
125
ON-VEHICLE SERVICE REPAIRING TWISTED/SHIELDED CABLE
WIRE HARNESS REPAIR
The ECM harness electrically connects the

ECM to a various components in both the en-
gine and passenger compartments.
Wire harnesses should be replaced with prop- 1. Remove outer jacket

er part number harnesses. When wires are
spliced into a harness, use wire with high tem- 2. Unwrap aluminum/Mylar tape. Do not re-
perature insulation only. move Mylar.
Low current and voltage levels are used in the

system, so it is important that the best possible
bond at all wire splices be made by soldering
the splices.
3. Untwist conductors, strip insulation as ne-
CONNECTORS AND TERMINALS cessary.
Use care when probing a connector or replac-

ing terminals in them to prevent shorting
opposite terminals and damage certain compo-
nents. Always use jumper wires between
connectors, for circuit checking. Do not probe 4. Splice wire using splice clips and rosin
through the Weather-Pack seals with oversized core solder. Wrap each splice to insulate.
wire probes. Use tachometer adapter J 35812
(or equivalent) which provides an easy hook up 5. Wrap with Mylar and drain wire (uninsu-
of the tach lead. The connector test adapter kit lated) wire.
J 35616 (or equivalent), contains an assort-
ment of flexible connectors used to probe
terminals during diagnosis. Fuse remover and
test tool BT 8616, or equivalent, is used for re-
moving a fuse and to adapt fuse holder, with a
6. Tape over entire juncture and secure.
meter, for diagnosis. Do not solder oxygen
sensor wire terminals as these wire ends are
used for the sensors oxygen reference.
Open circuits are often difficult to locate by

sight due to dirt, oxidation, or terminal misa-
lignment. Merely wiggling a connector on a
sensor, or in the wiring harness, may correct
the open circuit condition. This should always
be considered, when an open circuit, or failed
sensor is indicated. Intermittent problems may
also be caused by oxidized or loose connec-
tions.
Before making a connector repair, be certain of

the type of connector. Weather-Pack and
Compact Three connectors look similar, but are
serviced differently.
126
REPAIRING TWISTED LEADS METRI-PACK
Some connectors use terminals called Metri-Pack

Series 150. They are also called “Pull-To-Seat”
terminals because of the method of installation. The
wire is inserted through the seal and connector, the
terminal is crimped on the wire and then pulled back
1. Locate Damaged Wire. into the connector to seat it in place.
2. Remove insulation as required.
3. Splice two wires together suing splice

clips and rosin core solder.
4. Cover splice with tape to insulated from

other wires.
5. Retwist as before and tape with electrical
tape and hold in place.
MICRO-PACK
Refer to Figure 2 and repair procedure for re- Metri-Pack Series 150 Terminal Removal
placement of a Micro-Pack terminal.
1. Slide the seal back on the wire.
2. Insert tool BT-8518, or J 35689, or equivalent, as
shown in insert “A” and “B” to release the ter-
minal locking tab (2).
3. Push the wire and terminal out through the con-
nector. If reusing the terminal, reshape the
locking tab (2).
WEATHER-PACK
A Weather-Pack connector can be identified by a

rubber seal, at the rear of the connector. The con-
nector is used in the engine compartment to protect
against moisture and dirt that may oxidize and/or
corrode the terminals. Given the low voltage and
current levels found in the electronic system, this
Micropack Connector protection is necessary to ensure a good connec-
tion.
1. Cable
2. Terminal
3. Locking Tang
4. Tool J33095/BT8234-A
127
WEATHER-PACK TERMINAL REPAIR backup, or secondary locking feature for the connec-
tor. They are used to improve the connector
reliability by retaining the terminals, if the small ter-
minal lock tabs are not positioned properly.
Weather-Pack connections cannot be replaced with

standard connections. Additional instructions are
provided with Weather-Pack connector and terminal
packages.
1. Open secondary lock hinge on connector.
2. Remove terminal using tool.
3. Cut wire immediately behind cable seal
4. Replace terminal.
a. Slip new seal onto wire
b. Strip 5 mm (.2”) of insulation from wire.
c. Crimp terminal over wire and seal.
5. Push terminal and connector and engage

locking tangs.
6. Close secondary lock hinge.
Use tool J M28742, or BT8234-A or equivalent

to remove the pin and sleeve terminals. If the
removal is attempted with an ordinary pick,
there is a good chance that the terminal will be
bent, or deformed. Unlike standard blade type
terminals, these terminals cannot be straigh-
tened once they are bent.
Verify that the connectors are properly seated

and all of the sealing rings in place, when con-
necting leads. The hinge type flap provides a
128
Diagnostic Trouble
Codes (DTCs)
129
DTC 16-Never Crank Synced at Start
Conditions for setting the DTC
 Crankshaft Position sensor

 Check Condition-Engine cranking
 Fault Condition-Cranking rpm above 90 and more than 4 cranking revolutions without syn-
chronization
 MIL Command-ON
Circuit Description
The Crankshaft position sensor is a 5 volt powered sensor mounted in the engine block. A
pulse wheel located on the crankshaft is used to measure engine rpm and its signal is used to
synchronize the ignition and fuel systems. This fault will set
Diagnostic Aid
Reversed sensor wires, poor wire connections or faulty system ground are most frequently the
cause of this code set.
130
DTC 16-Never Crank Synced at Start
Did you perform the On-Board (OBD) System Go to OBD
Check? Go to Step System
1
(2) Check Sec-
tion
 Check that the ECM ground terminal CN28 is Repair the
clean, tight and in the proper location. circuit as ne-
cessary.
Go to Step
2 Are the ground terminals clean and tight? Refer to Wir-
(3)
ing Repairs in
Engine Elec-
trical.
 Key On, Engine OFF
Repair the
 Disconnect the CKP (Crankshaft position)
circuit as ne-
Sensor connector CN9
cessary.
3  Using A DVOM check for voltage at the CKP 5.0 volts
Go to Step
Refer to Wir-
sensor connector circuit 119 and engine (4)
ing Repairs in
ground Engine Elec-
trical.
Do you have voltage?
 Key OFF Repair the
 Disconnect ECM connector CN1 circuit as ne-
 Using a DVOM check for continuity on the Go to Step
cessary.
4 crank signal circuit 125 between CKP con- Refer to Wir-
(5)
nector CN9 and ECM connector CN1 ing Repairs in
Engine Elec-
Do you have continuity between them? trical.
 Using a DVOM check for continuity on the Repair the
sensor ground circuit 120 between CKP con- circuit as ne-
nector and ECM connector. cessary.
Go to Step
5 Refer to Wir-
(6)
Do you have continuity between them? ing Repairs in
Engine Elec-
trical.
 Inspect the CKP connector CN9 terminals for Repair the
damage, corrosion or contamination. circuit as ne-
cessary.
Go to Step
6 Did you find a problem? Refer to Wir-
(7)
ing Repairs in
Engine Elec-
trical.
 Inspect the ECM connector CN1 terminals Repair the
for damage, corrosion or contamination. circuit as ne-
cessary.
Go to Step
(8)
ing Repairs in
Engine Elec-
trical.
131
 Replace CKP sensor
Go to Step
8 -
(10)
Is the replacement complete?
 Replace ECM
Go to Step
9 -
(11)
es, etc.
the ECM.
 Start the engine and operate the vehicle to
full operating temperature Go to Step
10 System OK
 Observe the MIL (9)
 After operating the engine within the test pa-
rameters of DTC-16 check for any stored
codes.

codes?
es, etc.
the ECM.
Go to OBD
11 System OK System
 Observe the MIL Check
codes.

codes?
132
133
DTC 92-FRP High Voltage (Bi-fuel/Gasoline Only)
Conditions for Setting the DTC


 Fuel pressure check
 Check condition-engine running
 Fault Condition-FP voltage greater than 4.80 volts
 MIL-On
 Adaptive-disabled
Circuit Description
The FRP (fuel rail pressure) sensor is a combined temperature and pressure sensor located in
the gasoline delivery system that provides accurate gasoline supply information to the ECM. It is
used to measure the temperature and pressure of the supplied fuel. This reading is used in con-
junction with other inputs to insure the proper amount of fuel is delivered to the engine for the
operating conditions. This fault will set if the gasoline pressure sensor voltage exceeds 4.80
volts. The adaptive Learn will be disabled and the MIL command is on.
134
DTC 92-FRP High Voltage (Bi-fuel/Gasoline Only)
Go to OBD
Did you perform the On-Board (OBD) System Go to Step System
1
Check? (2) Check Sec-
tion
 Key ON
Intermittent
 DST (Diagnostic Scan Tool) open in System
problem
Data Mode Greater than Go to Step
2 Go to Inter-
4.80 volts (3)
mittent
Does DST display FRP (Fuel Pressure) voltage section
greater than 4.80 volts?
 Key OFF
 Disconnect the FRP sensor connector CN16
and jump circuits 120 and 113
Less than Go to Step Go to Step
3  Key ON
0.10 volts (4) (6)
Does the DST display FRT voltage less than
0.10 volts?
Repair the
 Check wire harness and FRP sensor con-
circuit as ne-
nector for damage corrosion or
cessary. See Go to Step
4 contamination
wire harness (5)
repair sec-
Any problems found?
tion.
 Replace FRP sensor.
5 Go to Step
Is the replacement complete? (11)
 Key OFF
 Jump FRP sensor connector CN16 signal
circuit 113 to engine ground
Less than Go to Step Go to Step
6  Key ON
0.10 volts (8) (7)
Does the DST display FRP voltage less than
0.10 volts?
 Key OFF
 Disconnect the ECM wire harness connector
Repair the
CN1
circuit as ne-
7  Check for continuity on FRP signal circuit Go to Step
cessary. See
113 between FRP sensor connector CN16 (9)
wire harness
and ECM connector CN1 repair section
Do you have continuity between them?
135
 Key OFF
 Disconnect the ECM wire harness connector Repair the
CN1 circuit as ne-
 Check for continuity on the sensor ground Go to Step cessary. See
8
circuit 120 between FRP sensor connector (9) wire harness
CN16 and ECM connector CN1 repair sec-
tion.
Repair the
 Re-check wire harness and FRP sensor
circuit as ne-
connector for damage corrosion or contami-
cessary. See Go to Step
9 nation.
wire harness (10)
repair sec-
Any problems found?
tion.
 Replace the ECM.
Go to Step
10
(11)
es, etc.
the ECM.
Go to OBD
11  Start the engine and operate the vehicle to System OK System
full operating temperature. Check
 Observe the MIL.
 Observe engine performance and driveabili-
ty.

codes?
136
137
DTC 107-TMAP Low Voltage
 Manifold Absolute Pressure Sensor

 Check Condition-Engine cranking or running
 Fault Condition-MAP voltage less than 0.050 with throttle position greater than 5.0% and en-
gine RPM less than 4000
 MIL-ON
 Adaptive-Disabled
Circuit Description
The Manifold Absolute Pressure sensor is a pressure transducer connected to the intake mani-
fold. It is used to measure the pressure of air in the intake manifold. This reading is used in
conjunction with other inputs to estimate the airflow rate to the engine, which determines the fuel
flow rate. This fault will set if the MAP voltage is less than 0.050 with TPS greater than 5.0% and
engine RPM less than 4000. The adaptive Learn is disabled during this fault and the MIL com-
mand is on.
138
DTC 107-MAP Low Voltage
Go to OBD
1 -
tion
 Key On, Engine running.
 DSC (Diagnostic Scan Tool) connected in Intermittent
System Data Mode problem
Go to Step
2 Go to Inter-
(3)
Does DST display MAP voltage of 0.050 or mittent
less with the engine running with TPS above section
5.0%?
 Key OFF
 Disconnect the MAP sensor connector
CN4
 Jump the 5 volt reference circuit 119 and
3 MAP signal circuit 123 together
(4) (8)
 Key ON
Does the DST display MAP voltage of 4.50

volts or greater?
Repair the
 Inspect MAP connector and pins for cor- circuit as
rosion, contamination or mechanical necessary.
Go to Step
4 damage Refer to Wir-
(5)
ing Repairs
Any problems found? in Engine
Electrical.
 Disconnect ECM connector CN1 circuit as
 Check for continuity on MAP signal circuit necessary.
5 123 between MAP sensor connector CN4 Go to Step Refer to Wir-
and ECM connector CN1. (6) ing Repairs
in Engine
Do you have continuity between them? Electrical.
Repair the
 Check for continuity on 5 volts supply cir- circuit as
cuit 119 between MAP sensor connector necessary.
6 CN4 and ECM connector CN1. Go to Step Refer to Wir-
(7) ing Repairs
Do you have continuity between them? in Engine
Electrical.
139
Repair the
 Check for continuity on MAP sensor circuit as
ground circuit 120 between MAP sensor necessary.
Go to Step
7 connector CN4 and ECM connector CN1 Refer to Wir-
(17)
ing Repairs
Electrical.
 Probe MAP signal circuit 119 on MAP
connector CN4 with a test light connected
to battery voltage Go to Step Go to Step
8
(9) (13)
Does the DST display MAP voltage of 4.0 or
greater?
 Disconnect ECM connector circuit as
 Check for continuity on 5 volts supply cir- Go to Step
necessary.
9 cuit 119 between MAP sensor connector Refer to Wir-
(10)
CN4 and ECM connector CN1 ing Repairs
in Engine
Repair the
 Check for continuity between MAP sensor circuit as
connector CN4 5 volt reference circuit 119 necessary.
Go to Step
10 and engine ground Refer to Wir-
(11)
ing Repairs
Do you have continuity? in Engine
Electrical.
Repair the
 Inspect ECM and MAP wire harness con- circuit as
nector and terminals for corrosion, necessary.
Go to Step
11 contamination or mechanical damage Refer to Wir-
(16)
ing Repairs
Electrical.
 Replace ECM. Refer to ECM replacement
in the Engine Controls Section. Go to Step
12 -
(17)
 Disconnect ECM connector Repair the

circuit as
 Check for continuity on the MAP signal
necessary.
circuit 123 between MAP sensor connec- Go to Step
13 Refer to Wir-
tor CN4 and ECM connector CN1 (14)
ing Repairs
in Engine
140
Repair the
 Check for continuity between MAP sensor circuit as
connector CN4 signal circuit 123 and en- necessary.
Go to Step
14 gine ground Refer to Wir-
(15)
ing Repairs
Do you have continuity? in Engine
Electrical.
Repair the
 Inspect ECM connector and wire harness circuit as
connector terminals for corrosion, conta- necessary.
Go to Step
15 mination or mechanical damage Refer to Wir-
(16)
ing Repairs
Electrical.
 Replace ECM. Refer to ECM replacement
in the Engine Controls Section. Go to Step
16 -
(18)
 Replace MAP sensor

Go to Step
17 -
(18)
 Remove all test equipment except the

DST.
 Connect any disconnected components,
fuses, etc.
 Using the DST clear DTC information
from the ECM.
 Turn the ignition OFF and wait 30
seconds.
 Start the engine and operate the vehicle Go to OBD
18 to full operating temperature System OK System
 Observe engine performance and drivea-
bility
 After operating the engine within the test
parameters of DTC-107 check for any
stored codes.
Does the engine operate normally with no

stored codes?
141
DTC 108-MAP High Pressure


 MAP pressure check
 Check condition-engine running
 Fault Condition-MAP greater than 16.00 psia with TPS less than 3.0% and RPM greater than
1000
 MIL-On
 Adaptive-disabled
Circuit Description
The Manifold Absolute Pressure sensor is a pressure transducer connected to the intake mani-
fold. It is used to measure the pressure of air in the intake manifold. This reading is used in
conjunction with other inputs to estimate the airflow rate to the engine, which determines the fuel
flow rate. This fault will set if the MAP pressure is greater than 16.00 psia with TPS greater than
3.0% and engine rpm greater than 1000. The adaptive Learn will be disabled and the MIL com-
mand is on.
142
DTC 108-MAP High Pressure
Go to OBD
1 -
tion
 Key On, Engine running at full operating
temperature.
Intermittent
 DST (Diagnostic Scan Tool) connected in the
problem
System Data Mode Go to Step
2 Go to Inter-
(3)
mittent
Does DST display MAP pressure of 16.00 psia section
or greater with the engine running above 1000
RPM and a TPS value less than 3.0%?
 Key OFF
 Disconnect the MAP sensor connector CN4
 Key ON Go to Step Go to Step
3
(4) (6)
Does the DST display MAP pressure less than
0.05 psia?
 Probe MAP connector CN4 ground circuit
120 with a test light connected to battery vol-
4 tage.
(5) (8)
Does the test light come on?
 Check MAP mechanical vacuum connection
for correct mounting or possible damage
5 causing vacuum leakage.
(6) (10)
Is the MAP sensor mechanical connection OK?
circuit as ne-
 Disconnect ECM connector CN1 and inspect
cessary.
terminals for damage corrosion or contami- Go to Step
6 Refer to Wir-
nation. (7) ing Repairs in
Engine Elec-
Is the connection OK? trical.
 Replace MAP sensor
Go to Step
7
(11)
Is the repair complete?
143
 Disconnect ECM connector C001 Repair the
circuit as ne-
 Check for continuity on sensor ground circuit
cessary.
120 between MAP sensor connector CN4 Go to Step
8 Refer to Wir-
and ECM connector CN1 (9)
ing Repairs in
Engine Elec-
 Replace ECM. Refer to ECM replacement in
the Engine Controls Section. Go to Step
9 -
(11)
 Correct MAP mechanical connection
Go to Step
10 -
Has the MAP mechanical connection problem (11)
been corrected?
es, etc.
the ECM.
Go to OBD
11 System OK System
codes.

codes?
144
145
DTC 111-IAT Higher Than Expected 1
 Intake Air Temperature

 Check Condition-Engine Running
 Fault Condition-Intake Air Temperature greater than 200 degrees F. with engine rpm great-
er than 1000
 MIL-On
 Adaptive-Disabled during active fault
 Power derate level 1
Circuit Description
The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure)
sensor. A temperature sensitive resistor is used in the TMAP located in the intake manifold of
the engine. It is used to monitor incoming air temperature, and the output in conjunction with
other sensors is used to determine the airflow to the engine. The ECM provides a voltage di-
vider circuit so that when the air is cool, the signal reads higher voltage, and lower when warm.
This fault will set if the Intake Air Temperature is greater than 200 degrees F. with engine
speed greater than 1000 rpm. Power derate level one will be in force and effect limiting maxi-
mum power output.
Diagnostic Aid
This fault will set when inlet air is much hotter than normal. The most common cause of high in-
let air temperature is a problem with the inlet air system. Ensure that the air inlet is not
obstructed, modified or damaged. Inspect the air inlet system for cracks or breaks that may al-
low unwanted under hood air in to the air inlet system.
146
Diagnostic Aid
 This fault will set when inlet air is much hotter than normal. The most common cause of
high inlet air temperature is a problem with the inlet air system. Ensure that the air inlet is
not obstructed, modified or damaged.
 Inspect the air inlet system for cracks or breaks that may allow unwanted under hood air in
to the air inlet system
 If none of the above can be found, follow the diagnostic steps for DTC 112-IAT Low Vol-
tage
147
DTC 112-IAT Low Voltage

 Check Condition Engine Cranking or Running
 Fault Condition-IAT Sensor Voltage less than 0.050
 MIL-On during active fault
Circuit Description
vider circuit so that when the air is cool the signal reads higher voltage, and lower when warm.
This fault will set if the signal voltage is less than 0.050 volts for 1 second anytime the engine is
cranking or running. The ECM will use the default value for the IAT sensor in the event of this
fault.
148
DTC 112-IAT Voltage Low
Go to OBD
1
tion
 Key On Intermittent
 DST (Diagnostic Scan Tool) connected in problem
Go to Step
2 System Data Mode Go to Inter-
(3)
mittent
Does DST display IAT voltage of 0.050 or less? section
 Key Off
 Disconnect the TMAP sensor connector CN4
3  Key ON Go to Step Go to Step
(4) (5)
Does the DST display IAT voltage of 4.90 volts
or greater?
 Replace TMAP sensor.
4 Go to Step
 Key OFF
Repair the
 Disconnect ECM wire harness connector
circuit as ne-
CN1
cessary.
5  Check for continuity between TMAP sensor Refer to Wir-
Go to Step
connector CN4 circuit 120 and TMAP sensor (6)
ing Repairs in
connector CN4 IAT circuit 136 Engine Elec-
trical.
Repair the
 Check for continuity between TMAP sensor circuit as ne-
connector CN4 IAT circuit 136 and engine cessary.
Go to Step
6 ground. Refer to Wir-
(7)
ing Repairs in
Do you have continuity? Engine Elec-
trical.
149
7
(8)
es, etc.
the ECM.
Go to OBD
8 System OK System
codes.

codes?
150
151
DTC 113-IAT Voltage High

 Fault Condition-IAT Sensor Voltage greater than 4.95 volts
Circuit Description
vider circuit so that when the air is cool, the signal reads higher voltage, and lower when warm.
This fault will set if the signal voltage is greater than 4.950 volts anytime the engine is running.
The ECM will use a default value for the IAT sensor in the event of this fault.
152
DTC 113-IAT Voltage High
Go to OBD
1 -
tion
 Key On
Intermittent
 DST (Diagnostic Scan Tool) connected in
problem
2 Go to Inter-
(3)
mittent
Does DST display IAT voltage of 4.950 or great- section
er?
 Key Off
and jump pins 1 and 2 together
0.10 volts Go to Step Go to Step
3  Key On (9) (4)
or less
Does the DST display IAT voltage of 0.10 volts
or less?
 Key OFF
 Jump TMAP sensor connector CN4 signal
circuit 136 to engine ground
0.10 volts or Go to Step Go to Step
4  Key ON less (7) (6)
Does DST display IAT voltage of 0.10 volts or
less?
 Replace TMAP sensor.
5 Go to Step
 Key OFF
Repair the
circuit as ne-
C001.
cessary.
 Check for continuity between TMAP sensor Go to Step
6 Refer to Wir-
connector CN4 signal circuit 136 and ECM (10)
ing Repairs in
connector CN1 IAT circuit 136. Engine Elec-
trical.
Repair the
 Check for continuity between TMAP sensor circuit as ne-
connector CN4 ground circuit 120 and ECM cessary.
Go to Step
7 connector CN1 ground circuit 120 Refer to Wir-
(10)
ing Repairs in
Do you have continuity between them? Engine Elec-
trical.
153
Go to Step
8
(11)
 Re-check wire harness and TMAP sensor Repair the
connector for damage corrosion or contami- circuit as ne-
nation cessary.
Go to Step
9 Refer to Wir-
(5)
Any problems found? ing Repairs in
Engine Elec-
trical
 Re-check wire harness and TMAP sensor Repair the
connectors for damage corrosion or conta- circuit as ne-
mination cessary.
Go to Step
10 Refer to Wir-
(8)
Any problems found? ing Repairs in
Engine Elec-
trical
es, etc.
the ECM.
Go to OBD
11 System OK System
codes.

codes?
154
155
DTC 116-ECT/CHT Higher Than Expected 1

ECT Sensor
 Engine Coolant Temperature Resistance Scaling
Ohms
 Fault Condition-ECT greater than 230 F Temp(deg F)
±10%
248.0 116
 Power derate 1 in effect
230.0 147
Circuit Description 212.0 188
200.0 220
The ECT (Engine Coolant Temperature) sensor is a temperature sen- 185.0 275
sitive resistor located in the engine coolant passage. It is used for the
176.0 322
engine airflow calculation, gasoline cold enrichment and to enable
other temperature dependant features. The ECM provides a voltage 160.0 420
divider circuit so that when the coolant is cool, the signal reads higher 140.0 587
voltage, and lower when warm. This fault will set if the coolant tem- 120.0 825
perature reading exceeds 230 degrees F and engine RPM is greater 104.0 1,148
than 500 for 30 seconds. Power derate level 1 will go into effect in an
attempt to bring the temperature down. 85.0 1,700
68.0 2,450
45.0 4,100
32.0 5,790
-4.0 15,480
-40.0 48,140
156
Diagnostic Aid
 Thoroughly inspect the entire cooling system and for any signs of coolant leakage including:
coolant lines and hoses, water pump, engine block, radiator, etc.
 Insure the radiator cap is in good repair and maintaining suitable cooling system pressure.
 Compare the ECM measured temperature value with an analog temperature measurement (IR
temperature measurement, thermometer, etc.) if possible.
 If no problems are found continue with DTC 117 ECT low voltage diagnostic
157
DTC 117-ECT/CHT-Low Voltage
 Engine Coolant Temperature ECT Sensor

 Check Condition-Engine Running Resistance Scaling
 Fault Condition-ECT sensor voltage less than 0.10 Ohms
Temp(deg F)
 MIL-On during active fault ±10%
 Adaptive-Disabled during active fault 248.0 116
230.0 147
Circuit Description
212.0 188
The ECT (Engine Coolant Temperature) sensor is a temperature 200.0 220
sensitive resistor located in the engine coolant passage. It is used for 185.0 275
the engine airflow calculation, gasoline cold enrichment and to ena- 176.0 322
ble other temperature dependant features. The ECM provides a 160.0 420
voltage divider circuit so that when the coolant is cool, the signal
140.0 587
reads higher voltage, and lower when warm. This fault will set if the
signal voltage is less than 0.10 volts anytime the engine is running. 120.0 825
The ECM will use a default value for the ECT sensor in the event of 104.0 1,148
this fault. 85.0 1,700
68.0 2,450
45.0 4,100
32.0 5,790
-4.0 15,480
-40.0 48,140
158
DTC 117-ECT/CHT Low Voltage
Go to OBD
1
tion
Go to Step
(3)
mittent
Does DST display ECT voltage of 0.10 or less? section
 Key Off
 Disconnect the ECT wire harness connector
CN5
3  Key ON (4) (5)
Does the DST display ECT voltage of 4.90 volts

or greater?
Replace ECT sensor.
4 Go to Step
 Key OFF
Repair the
circuit as ne-
CN1
cessary.
5  Check for continuity between ECT sensor Refer to Wir-
Go to Step
connector CN5 signal circuit 137 and sensor (6)
ing Repairs in
ground circuit 120 Engine Elec-
trical.
Repair the
 Check for continuity between ECT sensor circuit as ne-
connector CN5 signal circuit 137 and engine cessary.
Go to Step
6 ground. Refer to Wir-
(7)
ing Repairs in
trical.
159
7
(8)
es, etc.
the ECM.
Go to OBD
8 System OK System
codes.

codes?
160
161
DTC 118-ECT/CHT High Voltage

ECT Sensor
 Engine Coolant Temperature Resistance Scaling
Ohms
 Fault Condition-ECT sensor voltage exceeds 4.90 volts Temp(deg F)
±10%
248.0 116
230.0 147
200.0 220
The ECT (Engine Coolant Temperature) sensor is a temperature sen- 185.0 275
sitive resistor located in the engine coolant passage. It is used for the
176.0 322
engine airflow calculation, gasoline cold enrichment and to enable
other temperature dependant features. The ECM provides a voltage 160.0 420
divider circuit so that when the coolant is cool, the signal reads higher 140.0 587
voltage, and lower when warm. This fault will set if the signal voltage is 120.0 825
greater than 4.90 volts anytime the engine is running. The ECM will 104.0 1,148
use a default value for the ECT sensor in the event of this fault.
85.0 1,700
68.0 2,450
45.0 4,100
32.0 5,790
-4.0 15,480
-40.0 48,140
162
DTC 118-ECT/CHT Voltage High
Go to OBD
1
tion
 Key On
Intermittent
problem
2 Go to Inter-
(3)
mittent
Does DST display ECT voltage of 4.90 or great- section
er?
 Key Off
 Disconnect the ECT sensor connector CN5
and Jump circuits 120 and 137 together
0.10 volts or Go to Step Go to Step
3  Key On less (4) (8)
Does the DST display ECT voltage of 0.10 volts
or less?
See resis-
 Read the ECT voltage on the DST and com- tance chart
pare the reading at a known temperature to vs. tempera-
4 the chart. ture in the
(6) (5)
DTC 118
Is the resistance value correct? circuit de-
scription
 Replace ECT sensor
5 Go to Step
Repair the
 Inspect the ECT wire harness connector ter- circuit as ne-
minals for damage, corrosion or cessary.
Go to Step
6 contamination Refer to Wir-
(7)
ing Repairs in
Did you find a problem? Engine Elec-
trical.
 Disconnect ECM wire harness connector circuit as ne- Intermittent
CN1 cessary. problem
7  Inspect ECM connector CN1 circuits 120 and Refer to Wir- Go to Inter-
137 for damage corrosion or contamination ing Repairs in mittent
Engine Elec- section
Did you find a problem? trical.
163
 Jump the ECT connector CN5 signal circuit
137 at the ECT connector to engine ground Go to Step Go to Step
8
(9) (12)
Does DST display ECT voltage of 0.10 or less?
 Disconnect ECM wire harness connector circuit as ne-
 Using a DVOM check for continuity on Go to Step
cessary.
9 ground circuit 120 between ECT connector Refer to Wir-
(10)
CN5 and ECM connector CN1 ing Repairs in
Engine Elec-
Repair the
circuit as ne-
 Inspect ECM connector CN1 circuits 120 and
cessary.
137 for damage, corrosion or contamination Go to Step
10 Refer to Wir-
(11)
ing Repairs in
Did you find a problem?
Engine Elec-
trical.
 Replace ECM
Go to Step
11
(14)
 Key OFF
Repair the
circuit as ne-
CN1
cessary.
12  Using a DVOM check for continuity on ECT Go to Step
Refer to Wir-
signal circuit 137 between ECT connector (13)
ing Repairs in
CN5 and ECM connector CN1 Engine Elec-
trical.
Repair the
circuit as ne-
 Inspect ECM connector CN1 circuit 120 and
cessary.
137 for damage, corrosion or contamination Go to Step
13 Refer to Wir-
(11)
ing Repairs in
Engine Elec-
trical.
164
es, etc.
the ECM.
Go to OBD
14 System OK System
codes.

codes?
165
DTC 121-TPS 1 Lower Than TPS 2
E le c tro n ic T h ro ttle C irc u it W ire ECM

# C o lo r
180 L DBW +
4 80
M o to r
182 Br DBW -
1 82
TPS1 147 Y T P S 1 S ig n a l
6 47
120 Gr S e n s o r G ro u n d
2 20
TPS2 148 W T P S 2 S ig n a l
5 48
119 R /W 5 V o lts
3 19
 Throttle Position Sensor 1 & 2

 Check Condition-Key On
 Fault Condition-TPS 1 20% lower than TPS 2
 MIL-On for remainder of key on cycle
 Engine shutdown
Circuit description
Dual throttle Position Sensors are used within the throttle that use variable resistors to deter-
mine signal voltage based on throttle plate position. TPS 1 will read low voltage when closed
and TPS 2 will read high voltage when closed. The TPS 1 and TPS 2 percentages are calcu-
lated from these voltages. Although the voltages are different, the calculated values for the
throttle position percentages should be very close to the same. The TPS values are used by
the ECM to determine if the throttle is opening as commanded. This fault will set if TPS 1 is
20% (or more) lower than TPS 2. At this point the throttle is considered to be out of specifica-
tion, or there is a problem with the TPS signal circuit. The MIL command is on and the engine
will shutdown.
166
DTC 121-TPS 1 Lower Than TPS 2
Go to OBD
Did you perform the On-Board (OBD) System Go to Step
1 System Check
Check? (2)
Section
 Key ON, Engine OFF
 DST (Diagnostic Scan Tool) connected in Intermittent
System Data Mode Go to Step problem
2
(3) Go to Intermit-
Does the DST display more than a 20% differ- tent section
ence between TPS 1 and TPS 2 voltage?
 Key OFF
 Disconnect electronic throttle connector CN3
 Key ON
Go to Step
3  Change DST mode to DBW (drive by wire) Go to Step (4)
(5)
test mode
Is the voltage for TPS 1 less than 0.1 volts?

 Disconnect ECM wiring harness connector TPS 1 circuit
CN1 shorted to
 Key ON voltage as
4  Using a DVOM check for voltage between necessary. Go to Step (9)
ECM connector CN1 TPS 1 signal circuit 147 Refer to Wir-
and engine ground ing Repairs in
Engine Elec-
Do you have voltage? trical.
 Jump TPS 1 signal circuit 147 to the 5 volt
reference circuit 119 at connector CN3
Go to Step
5 Go to Step (8)
(6)
Does DST display TPS 1 voltage over 4.90
volts?
Repair the
circuit as ne-
 Inspect wire terminals at throttle connector
cessary.
for damage corrosion or contamination
6 Refer to Wir- Go to Step (7)
ing Repairs in
Any problems found? Engine Elec-
trical.
 Replace the electronic throttle assembly
Go to Step
7
(12)
167
 Key OFF
Repair the
open circuit as
CN1
necessary.
8  Using a DVOM check for continuity on the Go to Step
Refer to Wir-
TPS 1 circuit 147 between throttle connector (9)
ing Repairs in
CN3 and ECM connector CN1 Engine Elec-
trical.
Repair the
 Using a DVOM check for continuity on sen- open circuit as
sor ground circuit 120 between throttle necessary.
Go to Step
(10)
ing Repairs in
trical.
Repair the
circuit as ne-
 Inspect ECM connector terminals for damage
cessary.
corrosion or contamination. Go to Step
10 Refer to Wir-
(11)
ing Repairs in
trical
 Replace ECM
Go to Step
11
(12)
es, etc.
the ECM.
full operating temperature Go to OBD
12 System OK
 Observe the MIL System Check
codes.

codes?
168
169
DTC 122-TPS 1 Signal Voltage Low

# C o lo r
180 L DBW +
4 180
M o to r
182 Br DBW -
1 182
6 147
2 120
5 148
119 R /W 5 V o lts
3 119
 Throttle Position Sensor 1

 Check Condition-Cranking or Running
 Fault Condition-TPS sensor less than 0.200 volts
 Engine shutdown
Circuit Description
mine signal voltage based on throttle plate position. TPS1 will read lower voltage when closed
and TPS2 will read higher voltage when closed. The TPS1 and TPS2 percentages are calcu-
the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable and
in the event of a failure the electronic throttle assembly must be replaced. This fault will set if
the TPS 1 voltage is less than 0.200 volts. The MIL command is ON and the engine will shut
down.
170
Go to OBD
1 - System Check
Check? (2)
Section
DBW (Drive by Wire) throttle test mode Go to Step
2 Go to Step (3)
(4)
Does the DST display TPS 1 voltage of 0.200
volts or less with the throttle closed?
 Slowly depress Foot Pedal while observing Intermittent
TPS 1 voltage Go to Step problem
3
(4) Go to Intermit-
Does TPS 1 voltage ever fall below 0.200 volts? tent section
 Key OFF
 Disconnect the electronic throttle connector
CN3
TPS 1 signal circuit 147 together at the throt- Go to Step
4 Go to Step (5)
tle connector CN3 (7)
 Key ON
Does DST display TPS 1 voltage of 4.0 volts or

greater?
 Key OFF
 Disconnect ECM wire harness connector Repair the
CN1 circuit as ne-
 Using a DVOM check continuity on the TPS Go to Step cessary. Refer
5 to Wiring Re-
1 circuit 147 between the electronic throttle (6)
connector CN3 and ECM connector CN1 pairs in
Engine Elec-
Do have continuity between them? trical.
 Replace ECM
Go to Step
6 -
(9)
Repair the
 Inspect the throttle wire harness connector circuit as ne-
terminals for damage, corrosion or contami- cessary.
7 nation Refer to Wir- Go to Step (8)
ing Repairs in
trical.
 Replace the electronic throttle
Go to Step
8 -
(9)
171
es, etc.
the ECM.
9 System OK
codes.

codes?
172
173
DTC 123-TPS 1 Signal Voltage High

# C o lo r
180 L DBW +
4 80
M o to r
182 Br DBW -
1 82
6 47
2 20
5 48
119 R /W 5 V o lts
3 19

 Fault Condition-TPS sensor voltage exceeds 4.800 volts
 Engine shutdown
Circuit Description
mine signal voltage based on throttle plate position. TPS1 will read lower voltage when closed
the ECM to determine if the throttle is opening as commanded. The TPS is not serviceable
and in the event of a failure the electronic throttle assembly must be replaced. This fault will
set if the TPS 1 voltage exceeds 4.800 volts. The MIL command is ON and the engine will shut
down.
174
Go to OBD
1 - System Check
Check? (2)
Section
 DST (Diagnostic Scan Tool) connected
Go to Step
2 Go to Step (3)
(4)
volts or greater with the throttle closed?
3
(4) Go to Intermit-
Does TPS 1 voltage ever exceed 4.800 volts? tent section
 Key OFF
 Disconnect electronic throttle connector
C017
Go to Step
4  Key ON Go to Step (5)
(7)
Does DST display TPS 1 voltage less than 0.2

volts?
 Key OFF
CN1 circuit as ne-
 Key ON cessary.
5  Using a DVOM check for voltage between Refer to Wir- Go to Step (6)
TPS 1 signal circuit 147 at the ECM connec- ing Repairs in
tor CN1 and engine ground Engine Elec-
trical.
 Replace ECM
Go to Step
6 -
(11)
 Back probe sensor ground circuit at the ECM
side of the wire harness circuit 120 with a
7 test light connected to battery voltage
(8) (10)
Repair the
 Inspect the electronic throttle connector ter- circuit as ne-
minals for damage, corrosion or cessary.
8 contamination Refer to Wir- Go to Step (9)
ing Repairs in
trical.
Go to Step
9 -
(11)
175
 Key OFF
Repair the
 Disconnect ECM connector C001
circuit as ne-
 Using a DVOM check for continuity on the cessary. Refer
sensor ground circuit 120 between the elec- Go to Step
10 to Wiring Re-
tronic throttle connector CN3 and ECM (6)
pairs in
connector CN1. Engine Elec-
trical.
Do have continuity between them?
es, etc.
the ECM.
11 System OK
codes.

codes?
176
177

 Fault Condition-Intake Air Temperature greater than 210 degrees F. with engine speed
greater than 1000 rpm
 MIL-On for active fault
 Engine Shut Down
Circuit Description
vider circuit so that when the air is cool, the signal reads a higher voltage, and lower when
warm. This fault will set if the Intake Air Temperature is greater than 210 degrees F. with en-
gine speed greater than 1000 rpm. The MIL light command is on during this active fault and the
engine will shut down.
178
Diagnostic Aid
 This fault will set when inlet air is much hotter than normal. The most common
cause of high inlet air temperature is a problem with the inlet air system. Ensure
that the air inlet is not obstructed, modified or damaged.
 Inspect the air inlet system for cracks or breaks that may allow unwanted under
hood air in to the air inlet system
* If none of the above can be found, follow the diagnostic steps for DTC 112-IAT Low
Voltage.
179
DTC 129-BP Low Pressure
 Barometric Pressure
 Fault Condition-BP less than 8.30 psia
Circuit Description
The BP (Barometric Pressure) is estimated from the TMAP sensor. The barometric pressure
value is used for fuel and airflow calculations. This fault sets in the event the BP value is out of
the normal range.
180
DTC 129-BP Low Pressure
Go to OBD
1 -
tion
 Key On.
Intermittent
problem
2 Go to Inter-
(3)
mittent
Does DST display BP pressure of 8.30 psia or section
less?
 Key OFF
MAP signal circuit 123 together Go to Step Go to Step
3
 Key ON (4) (8)
Does the DST display BP pressure of 16.00 psia

or greater?
Repair the
 Inspect TMAP connector and wire harness circuit as ne-
connector terminals for corrosion, contamina- cessary.
Go to Step
4 tion or mechanical damage Refer to Wir-
(5)
ing Repairs in
trical.
 Check for continuity between TMAP sensor cessary.
5 connector CN4 circuit 123 and ECM connec- Go to Step Refer to Wir-
tor CN1 circuit 123 (6) ing Repairs in
Engine Elec-
Repair the
 Check for continuity on the 5 volt supply cir- circuit as ne-
cuit 119 between TMAP sensor connector cessary.
6 CN4 and ECM connector CN1 Go to Step Refer to Wir-
(7) ing Repairs in
trical.
Repair the
 Check for continuity on the sensor ground circuit as ne-
circuit 120 between TMAP sensor connector cessary.
Go to Step
7 CN4 and ECM connector CN1 Refer to Wir-
(17)
ing Repairs in
trical.
181
 Probe TMAP connector signal circuit 123
with a test light connected to battery voltage
8
(9) (13)
Does the DST display BP pressure of 16.00 psia
or greater?
 Check for continuity on the 5 volt supply cir- Go to Step
cessary.
9 cuit 119 between TMAP sensor connector Refer to Wir-
(10)
CN4 and ECM connector CN1 ing Repairs in
Engine Elec-
Repair the
open ground
 Check for continuity between TMAP sensor
circuit as ne-
connector 5 volt reference circuit 119 and
cessary. Go to Step
10 engine ground
Refer to Wir- (11)
ing Repairs in
trical.
Repair the
 Inspect TMAP and ECM connector pins for circuit as ne-
corrosion, contamination or mechanical cessary.
Go to Step
11 damage Refer to Wir-
(16)
ing Repairs in
trical.
the Engine Controls Section. Go to
12 -
Step(17)
 Disconnect ECM connector CN1 Repair the
circuit as ne-
cessary.
connector CN4 circuit 123 and ECM connec- Go to Step
13 Refer to Wir-
tor CN1 circuit 123 (14)
ing Repairs in
Engine Elec-
Repair the
open ground
circuit as ne-
connector CN4 MAP circuit 123 and engine
cessary. Go to Step
14 ground
Refer to Wir- (15)
ing Repairs in
trical.
182
Repair the
 Inspect ECM connector and wire harness circuit as ne-
connector pins for corrosion, contamination cessary.
Go to Step
15 or mechanical damage Refer to Wir-
(16)
ing Repairs in
trical.
16 -
(18)
 Replace TMAP sensor
Go to Step
17 -
(18)
es, etc.
the ECM.
Go to OBD
18 System OK System
codes.

codes?
183
DTC 134-EGO 1 Open/Inactive
 Heated Oxygen Sensor

 Check condition-Engine running
 Fault condition-EGO 1 pre catalyst persistently cold for more than 55 seconds
 Closed Loop-Disabled during active fault
Circuit Description
The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring
the oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow
with the Closed Loop multiplier and the Adaptive multiplier. This fault will set if EGO 1 is cold,
non-responsive, or inactive for more than 55 seconds.
184
Go to OBD
1
tion
 Key ON, Engine Running
System Data Mode problem. See
 Run engine to full operating temperature and Go to Step
Electrical
2 then idle for a minimum of 1 minute Section In-
(3)
termittent
Does DST display EGO 1 voltage fixed between Electrical Di-
0.40 and 0.50 volts after at least 1 minute of idle agnosis
run time?
 Key OFF
 Disconnect EGO 1 connector CN11
 Key ON
 Using a DVOM check for voltage at the EGO
1 connector CN11 between circuits 812 and Go to Step Go To Step
3 162 (8) (4)
(Check must be made within 30 seconds or
before power relay shuts down)

 Key OFF
 Using a DVOM check for voltage between
EGO 1 connector CN11 circuit 812 and en-
gine ground Repair sys-
 Key ON System Vol- Go to Step tem power
4
tage (5) relay open
(Check must be made within 30 seconds or circuit

 Disconnect ECM connector CN1
 Using a DVOM check for continuity on EGO
Repair open
heater 1 circuit 162 between EGO 1 connec- Go to Step
5 heater ground
tor CN11 and ECM connector CN1 (6) circuit
Do you have continuity?
185
Correct the
 Inspect wire harness connector CN5 pins problem as
and CN1 pins for damage, corrosion or con- required see
Go to Step
6 tamination Electrical
(7)
Section wire
Did you find a problem? harness re-
pair
 Replace ECM
Go to Step
7 -
(11)
 Key OFF
CN1
 Using a DVOM check for continuity between Go to Step Repair open
8
EGO 1 connector circuit 121 and ECM con- (9) EGO 1 circuit
nector circuit 121

 Using a DVOM check for continuity on the
sensor ground circuit 120 between EGO 1 Repair open
Go to Step
9 connector CN5 and ECM connector CN1 EGO 1 signal
(10)
ground
 Replace EGO 1 sensor
Go to Step
10 -
(11)
es, etc.
the ECM.
Go to OBD
11 System OK System
codes.

codes?
186
187

 Fault condition-EGO 2 post catalyst sensor cold persistently more than 55 seconds
Circuit Description
The EGO 2 sensor is used to optimize transient fuel mixture control. This fault will set if EGO 2
post catalyst sensor is cold, non-responsive, or inactive for more than 55 seconds.
188
Go to OBD
1 -
tion
 Key ON, Engine Running
 Run engine to full operating temperature and Go to Step
Electrical
2 then idle for a minimum of 1 minute. Section In-
(3)
termittent
Does DST display EGO 2 voltage fixed between Electrical Di-
0.4 and 0.5 volts after at least 1 minute of idle agnosis
run time?
 Key OFF
 Disconnect EGO 2 connector CN12
 Key ON
EGO 2 connector CN12 circuits 812 and 161 Go to Step Go To Step
3
(8) (4)
(Check must be made within 30 seconds or

 Key OFF
EGO 2 connector CN12 circuit 812 and en-
gine ground Repair sys-
 Key ON System Vol- Go to Step tem power
4
tage (5) relay open
(Check must be made within 30 seconds or circuit

 Using a DVOM check for continuity EGO
Repair open
heater 2 circuit 161 between EGO 2 connec- Go to Step
5 heater ground
tor CN12 and ECM connector CN1 (6) circuit
Correct the
problem as
 Inspect EGO 2 connector and ECM pins for
required see
damage, corrosion or contamination Go to Step
6 Electrical
(7)
Section wire
Did You find a problem? harness re-
pair
189
 Replace ECM
Go to Step
7 -
(11)
 Key OFF
CN1
8  Using a DVOM check for continuity on circuit Go to Step Repair open
122 between EGO 2 connector CN12 and (9) EGO 2 circuit
ECM connector CN1

sensor ground circuit 120 between EGO 2 Repair open
Go to Step
9 and ECM connector EGO 2 signal
(10)
ground
Go to Step
10 -
(11)
es, etc.
the ECM.
Go to OBD
11 System OK System
codes.

codes?
190
191
DTC 171-Adaptive Learn High (Bi-Fuel/Gasoline Only)

 Fault Condition-Adaptive multiplier out of range greater than 30%
 MIL-On
Circuit Description
with the Closed Loop multiplier and Adaptive multiplier. This fault will set if the adaptive multip-
lier exceeds the limits of normal operation. Always run the fuel system diagnostic checks
before using the following diagnostic chart.
Diagnostic Aid
Oxygen Sensor Wire Heated Oxygen sensor wires may be mis-routed and contacting the ex-
haust manifold.
Vacuum Leaks Vacuum leaks and crankcase leaks can cause a lean condition at especially
at light load.
Fuel Injectors The system may be lean due to contaminated or faulty fuel injectors
Fuel Pressure Low fuel pressure, faulty fuel regulator or contaminated fuel filter can cause fuel
the system to run lean
Exhaust Leaks If there is an exhaust leak, outside air can be pulled into the exhaust and past
the 02 sensor causing a false lean condition.
Fuel Quality Contaminated or spoiled fuel can cause the fuel system to be lean.
Ground Problem ECM grounds must be clean, tight and in the proper location.
192
DTC 171-Adaptive Learn High (Bi-Fuel/Gasoline Only)
 Perform the On-Board (OBD) System Check?
1
(3) (2)
Are any other DTCs present?
Visually and physically check the following items:
 The air intake duct for being collapsed or re-
stricted
 The air filter for being plugged
 System power fuses are good and in the
proper location
 The EGO 1 sensor installed securely and the
wire leads not contacting the exhaust manifold Go to Step Go to Step
2
or ignition wires (9) (4)
 ECM grounds must be clean and tight. Refer
to Engine Electrical Power and Ground Distri-
bution
 Fuel System Diagnostics. Refer to Fuel Sys-
tem Diagnostics
Was a repair made?

 Diagnose any other DTC codes before pro-
ceeding with this chart. Always repair existing
codes starting with the lowest numerical code
3 set first.
(9) (4)
Have any other DTC codes been detected, diag-
nosed and repaired?
 Disconnect EGO1 connector CN11
 Using a DVOM check for voltage between Repair the
EGO 1 connector circuit 812 pin B and engine open EGO
ground power circuit
 Key ON System vol- Go to Step as necessary.
4
tage (5) Refer to Wir-
(CHECK MUST BE MADE WITHIN 30 SECONDS ing Repairs in
OR BEFORE POWER RELAY SHUTS DOWN) Engine Elec-
trical.
 Key OFF
 Disconnect EGO 1 sensor wire harness
connector CN11 Repair the
shorted circuit
 Disconnect ECM wire harness connector CN1
as necessary.
 Key ON Go to Step
5 Refer to Wir-
 Using a high impedance DVOM check for (6)
ing Repairs in
continuity between EGO 1 connector signal Engine Elec-
circuit 121 and engine ground trical.

193
Repair the
 Using a high impedance DVOM check for
shorted circuit
continuity between EGO 1 connector signal
as necessary.
ground circuit 120 and EGO 1 signal circuit Go to Step
6 Refer to Wir-
121 (7)
ing Repairs in
Engine Elec-
Do you have continuity? trical.
continuity between EGO 1 heater ground cir- Repair the
Go to Step
7 cuit 162 and ECM connector CN1 circuit 162 open EGO
(8)
heater ground
Go to Step
8 -
(9)
es, etc.
 Using the DST clear DTC information from the
ECM.
 Start the engine and operate the vehicle to full
Go to OBD
operating temperature
9 System OK System
codes.

codes?
194
195
DTC 172-Adaptive Learn Low Gasoline (Bi-Fuel/Gasoline Only)

 MIL-On
Circuit Description
Diagnostic Aid
Fuel System The system will be rich if an injector fails to close properly. High fuel pressure
due to a faulty fuel regulator or obstructed fuel return line will cause the system to run rich.
Ignition noise Open or poor ground circuit to or in the ignition system or ECM wiring may
cause EMI (Electromagnetic interference). This noise could be interpreted by the ECM as igni-
tion pulses or voltage across the oxygen sensor input causing the system to run rich.
MAP Sensor A higher manifold pressure than normal can cause the system to run rich. Tem-
porarily disconnecting the MAP Sensor will allow the ECM to set a default value for MAP and is
a good way to quickly eliminate this as a problem.
IAT Sensor Check for a shifted sensor that could cause the ECM to sense lower than actual
temperature of incoming air. This can cause a rich exhaust condition.
ECT Sensor Check for a “skewed” sensor that could cause the ECM to sense engine tempera-
ture colder than it actually is. This can also cause a rich exhaust condition.
196
DTC 172-Adaptive Learn Low Gasoline (Bi-Fuel/Gasoline Only)
1
(3) (2)
stricted
 The EGO sensor is installed securely and the
2 wire leads not damaged or contacting the
(6) (4)
secondary ignition wires
 ECM grounds for being clean and tight.
 Fuel system diagnostic checks
Was a repair made?

ceeding with this chart.
3
(6) (4)
nosed and repaired?
 Key OFF
 Disconnect EGO sensor wire harness connec-
tor CN11 Repair the
circuit as ne-
cessary.
4  Key ON Refer to Wir-
Go to Step
 Using a DVOM check for voltage at EGO 1 (5)
ing Repairs in
connector CN11 signal circuit 121 and engine Engine Elec-
ground trical.

 Replace EGO sensor
Go to Step
5 -
(6)
197
es, etc.
ECM.
Go to OBD
6 System OK System
codes.

codes?
198
199
DTC 182-FRT Voltage Low (Gasoline/Bi-Fuel Only)
 Fuel Rail Temperature

 Fault Condition-FT sensor voltage less than 0.050 volts Rail Sensor Temp Resistance
 MIL-On in Ohms
 Adaptive-Disabled Degrees Degrees
(± 6%)
°C °F
Circuit Description -40 -40 48153
-20 -4 15614
The FRT (Fuel Rail Temperature) sensor is a temperature 0 32 5887
sensitive resistor located near the fuel outlet of the elec- 20 68 2510
tronic pressure regulator. It is used to help determine fuel 40 104 2000
charge density for accurate fuel mixture control. The ECM 60 140 612
provides a voltage divider circuit so that when the sensor 70 158 446
is cool the signal reads a higher voltage, and lower when 80 176 330
warm. This fault will set if the signal voltage is less than 100 212 186
0.050 volts anytime the engine is running. 120 248 110
130 266 85.45
200
DTC 182-FRT Voltage Low (Gasoline/Bi-Fuel Only)
Go to OBD
1
tion
Go to Step
(3)
mittent
Does DST display FT voltage of 0.050 or less? section
 Key Off
 Disconnect the FT wire harness connector
CN16
3  Key ON (4) (5)
Does the DST display FT voltage of 4.90 volts or

greater?
 Replace FT sensor.
4 Go to Step
 Key OFF
CN1 shorted circuit
5  Check for continuity between fuel tempera- as required. Go to Step
ture sensor connector CN16 circuits 120 and See Repairs (6)
138 in Engine
Electrical.
Repair the
 Check for continuity between the fuel tem- circuit as ne-
perature sensor connector signal circuit 138 cessary.
Go to Step
6 and engine ground. Refer to Wir-
(7)
ing Repairs in
trical.
201
7 _ _
(8)
es, etc.
the ECM.
8  System OK System
codes.

codes?
202
203
DTC 183-FRT Voltage High (Gasoline/Bi-Fuel Only)
 Fuel Rail Temperature

 Fault Condition-FT sensor voltage exceeds 4.90 Rail Sensor Temp Resistance
 MIL-On in Ohms
 Adaptive-Disabled during active fault Degrees Degrees
(± 6%)
°C °F
Circuit Description -40 -40 48153
-20 -4 15614
The FRT (Fuel Rail Temperature) sensor is a temperature 0 32 5887
sensitive resistor located in the gasoline supply line. It is used 20 68 2510
to help determine fuel charge density for accurate fuel mixture 40 104 2000
control. The ECM provides a voltage divider circuit so that 60 140 612
when the sensor is cool the signal reads a higher voltage, and 70 158 446
lower when warm. This fault will set if the signal voltage is 80 176 330
greater than 4.90 volts anytime the engine is running. 100 212 186
120 248 110
130 266 85.45
204
DTC 183-FT Voltage High (Gasoline/Bi-Fuel Only)
Go to OBD
1 -
tion
Go to Step
(3)
mittent
Does DST display FT voltage of 4.90 or greater? section
 Key Off
 Disconnect the FT sensor connector CN16
and jump connector circuits 120 and 138
3  Key On (4) (8)

less?
See tem-
 Using a DVOM check the resistance be- perature vs.
tween the two terminals of the FT sensor and resistance
4 compare the resistance reading to the chart chart in the
(6) (5)
DTC 183
Is the resistance value correct? schematic
page.
 Replace FT sensor
5 Go to Step -
Repair the
circuit as ne-
 Inspect the FT sensor connector terminals
cessary.
for damage, corrosion or contamination Go to Step
6 Refer to Wir-
(7)
ing Repairs in
trical.
7  Inspect ECM connector pins for damage cor- Refer to Wir- Go to Inter-
rosion or contamination ing Repairs in mittent
205
 Jump the fuel temperature sensor connector
signal circuit 138 to engine ground Go to Step Go to Step
8
(9) (12)
Does DST display FT voltage of 0.05 or less?
 Key OFF
Repair the
circuit as ne-
CN1
cessary.
Refer to Wir-
sensor ground circuit 120 between fuel tem- (10)
ing Repairs in
perature sensor and ECM connector Engine Elec-
trical.
 Inspect ECM connector pins for damage, Repair the
corrosion or contamination circuit as ne-
cessary.
Go to Step
(11)
ing Repairs in
Engine Elec-
trical.
206
 Replace ECM
11 Go to Step (14) -
 Key OFF
Repair the cir-
cuit as
 Using a DVOM check for continuity between necessary.
12 the fuel temperature connector CN16 signal Go to Step (13)
Refer to Wiring
circuit 138 and ECM connector circuit 138 Repairs in En-
gine Electrical.
Repair the cir-
 Inspect ECM connector pins for damage, cor- cuit as
rosion or contamination necessary.
13 Go to Step (11)
Refer to Wiring
Did you find a problem? Repairs in En-
gine Electrical.
es, etc.
ECM.
operating temperature Go to OBD
14 System OK
codes.

codes?
207
DTC 187-LP Temp Voltage Low
 LP Temperature
 Fault Condition-FT sensor voltage less than 0.050 volts
 MIL-On
Circuit Description
The LP Temp (Fuel Temperature) sensor is a temperature sensi- LP Sensor Resistance

tive resistor located near the fuel outlet of the electronic pressure Temperature in Ohms
regulator. It is used to help determine fuel charge density for accu- Degrees F. ( ± 10%)
rate fuel mixture control. The ECM provides a voltage divider circuit -40 100,700
so that when the sensor is cool the signal reads a higher voltage, -20 28,680
and lower when warm. This fault will set if the signal voltage is less 0 9,420
than 0.050 volts anytime the engine is running. 20 3,520
40 1,459
60 667
70 467
80 332
100 177
120 100
130 77
208
DTC 187-LP Temp Voltage Low
Go to OBD
1
tion
Go to Step
(3)
mittent
Does DST display FT voltage of 0.050 or less? section
 Key Off
 Disconnect the FT wire harness connector
CN14
3  Key ON (4) (5)

greater?
 Replace FT sensor.
4 Go to Step
 Key OFF
CN1 shorted circuit
5  Check for continuity between fuel tempera- as required. Go to Step
ture sensor connector CN14 circuits 120 and See Repairs (6)
139 in Engine
Electrical.
Repair the
 Check for continuity between the fuel tem- circuit as ne-
perature sensor connector signal circuit 139 cessary.
Go to Step
6 and engine ground. Refer to Wir-
(7)
ing Repairs in
trical.
209
7 _ _
(8)
es, etc.
the ECM.
8  System OK System
codes.

codes?
210
211
DTC 188-LP Temp Voltage High
 LP Temperature
 Fault Condition-FT sensor voltage exceeds 4.90
 MIL-On
Sensor Resistance
Temperature in Ohms
Circuit Description
Degrees F. ( ± 10%)
-40 100,700
The LP Temp (Fuel Temperature) sensor is a temperature sensi-
tive resistor located near the fuel outlet of the electronic pressure -20 28,680
regulator. It is used to help determine fuel charge density for accu- 0 9,420
rate fuel mixture control. The ECM provides a voltage divider circuit 20 3,520
so that when the sensor is cool the signal reads a higher voltage, 40 1,459
and lower when warm. This fault will set if the signal voltage is 60 667
greater than 4.90 volts anytime the engine is running. 70 467
80 332
100 177
120 100
130 77
212
DTC 188-LP Temp Voltage High
Go to OBD
1 -
tion
Go to Step
(3)
mittent
Does DST display FT voltage of 4.90 or greater? section
 Key Off
 Disconnect the FT sensor connector CN14
and jump connector circuits 120 and 139
3  Key On (4) (8)
less?
See tem-
 Using a DVOM check the resistance be- perature vs.
tween the two terminals of the FT sensor and resistance
4 compare the resistance reading to the chart chart in the
(6) (5)
DTC 188
Is the resistance value correct? schematic
page.
 Replace FT sensor
Go to Step
5 -
(14)
Repair the
circuit as ne-
 Inspect the FT sensor connector terminals
cessary.
6 Refer to Wir-
(7)
ing Repairs in
Engine Elec-
trical.
7  Inspect ECM connector pins for damage cor- Refer to Wir- Go to Inter-
rosion or contamination ing Repairs in mittent
213
 Jump the fuel temperature sensor connector
signal circuit 139 to engine ground Go to Step Go to Step
8
(9) (12)
Does DST display FT voltage of 0.05 or less?
 Key OFF
Repair the
circuit as ne-
CN1
cessary.
Refer to Wir-
sensor ground circuit 120 between fuel tem- (10)
ing Repairs in
perature sensor and ECM connector Engine Elec-
trical.
Repair the
circuit as ne-
 Inspect ECM connector pins for damage,
cessary.
corrosion or contamination Go to Step
10 Refer to Wir-
(11)
ing Repairs in
Engine Elec-
trical.
214
 Replace ECM
Go to Step
11 -
(14)
 Key OFF
Repair the
circuit as ne-
CN1
cessary.
12  Using a DVOM check for continuity between Go to Step
Refer to Wir-
the fuel temperature connector CN14 signal (13)
ing Repairs in
circuit 139 and ECM connector circuit 139 Engine Elec-
trical.
Repair the
circuit as ne-
 Inspect ECM connector pins for damage,
cessary.
13 Refer to Wir-
(11)
ing Repairs in
Engine Elec-
trical.
es, etc.
the ECM.
Go to OBD
14 full operating temperature System OK System
codes.

codes?
215

ECT Sensor Resistance
 Engine Coolant Temperature Scaling
Temp(deg F) Ohms ±10%
 Fault Condition-ECT greater than 248 F
248.0 116
 Engine shutdown 230.0 147
 212.0 188
200.0 220
176.0 322
The ECT (Engine Coolant Temperature) sensor is a temperature
sensitive resistor located in the engine coolant passage. It is 160.0 420
used for the engine airflow calculation, gasoline cold enrichment 140.0 587
and to enable other temperature dependant features. The ECM 120.0 825
provides a voltage divider circuit so that when the coolant is
104.0 1,148
cool, the signal reads higher voltage, and lower when warm.
This fault will set if the coolant temperature reading exceeds 248 85.0 1,700
degrees F and engine RPM is greater than 500 for 10 seconds. 68.0 2,450
The engine will shut down upon fault activation. 45.0 4,100
32.0 5,790
-4.0 15,480
-40.0 48,140
216
Diagnostic Aid
 Thoroughly inspect the entire cooling system and for any signs of coolant leakage
including: coolant lines and hoses, water pump, engine block, radiator, etc.
 Insure the radiator cap is in good repair and maintaining suitable cooling system
pressure.
 Compare the ECM measured temperature value with an analog temperature mea-
surement (IR temperature measurement, thermometer, etc.) if possible.
 If no problems are found continue with DTC 117 ECT low voltage diagnostic
217
DTC 219-Max Govern Speed Override

# C o lo r
180 L DBW +
4 80
M o to r
182 Br DBW -
1 82
6 47
2 20
5 48
119 R /W 5 V o lts
3 19
 Max Govern Speed Override

 Fault Condition-Engine rpm greater than 3900
Circuit description
This fault will set anytime the engine rpm exceeds 3900. The MIL command is ON during this
active fault
Diagnostic Aid
Check for other stored DTC codes before using the following DTC chart for this code set. Al-
ways diagnose and repair any existing codes starting with the lowest numerical code
first.
218
DTC 219-Max Govern Speed Override
Go to OBD
1
tion
 DST connected Go to Step Go to Step
2
(3) (4)
Are any other DTC codes present with DTC 219?
 Diagnose and repair any other DTC codes
stored before proceeding with this chart.
Go to Step
3
(4)
Have any other DTC codes been diagnosed and
repaired?
 Check the service part number on the ECM to
ensure the correct calibration is in use Go to Step Go to Step
4
(6) (5)
Is the Service Part Number Correct?
 Replace ECM with correct service part num-
ber Go to Step
5
(9)
 Check the mechanical operation of the throttle
6
(8) (7)
Is the mechanical operation of the throttle OK?
 Correct mechanical operation of the throttle.
Refer to Engine & Component section
Go to Step
7
(9)
Has the mechanical operation of the throttle been
corrected?
 Check engine for large manifold vacuum Go to OBD
leaks. Refer to Symptom Diagnostic section Go to Step System
8
(9) Check Sec-
Did you find and correct the vacuum leak? tion
219
es, etc.
ECM.
Go to OBD
9 System OK System
codes.

codes?
220
221
DTC 221-TPS 1 Higher Than TPS 2

# C o lo r
180 L DBW +
4 80
M o to r
182 Br DBW -
1 82
6 47
2 20
5 48
119 R /W 5 V o lts
3 19
 Throttle Position Sensor 1 & 2

 Fault Condition-TPS 1 20% higher than TPS2
 MIL-On for remainder of key on cycle
 Engine shutdown
Circuit Description
mine signal voltage based on throttle plate position. TPS 1 will read lower voltage when closed
and TPS 2 will read higher voltage when closed. The TPS 1 and TPS 2 percentages are calcu-
TPS 1 is 20% (or more) higher than TPS 2. At this point the throttle is considered to be out of
specification, or there is a problem with the TPS signal circuit. The MIL command is ON and
the engine will shutdown.
222
DTC 221-TPS 1 Higher Than TPS 2
Go to OBD
1 System Check
Check? (2)
Section
System Data Mode Go to Step problem
2
(3) Go to Intermit-
Does the DST display more than a 20% differ- tent section
ence between TPS 1 and TPS 2?
 Key OFF
 Key ON
Go to Step
3  Change DST mode to DBW (drive by wire) Go to Step (4)
(5)
test mode
Is the voltage for TPS 1 less than 0.1 volts?

 Disconnect ECM wiring harness connector TPS 1 circuit
CN1 shorted to
 Key ON voltage as
4  Using a DVOM check for voltage between necessary. Go to Step (9)
ECM connector TPS 1 signal circuit 148 and Refer to Wir-
engine ground ing Repairs in
Engine Elec-
Do you have voltage? trical.
 Jump TPS 1 signal circuit 147 to the 5 volt
reference circuit 119 at connector CN3
Go to Step
5 Go to Step (8)
(6)
Does DST display TPS 1 voltage over 4.900
volts
Repair the
circuit as ne-
 Inspect wire terminals at throttle connector
cessary.
for damage corrosion or contamination
ing Repairs in
trical.
 Replace the electronic Throttle
Go to Step
7
(12)
223
 Key OFF
Repair the
open circuit as
CN1
necessary.
Refer to Wir-
throttle connector CN3 TPS 1 signal circuit (9)
ing Repairs in
147 and ECM connector CN1 circuit 147 Engine Elec-
trical.
Repair the
 Using a DVOM check for continuity on the open circuit as
ground circuit 120 between throttle connector necessary.
Go to Step
9 CN3 and ECM connector CN1 Refer to Wir-
(10)
ing Repairs in
trical.
Repair the
circuit as ne-
 Inspect ECM connector terminals for damage
cessary.
corrosion or contamination. Go to Step
10 Refer to Wir-
(11)
ing Repairs in
trical
 Replace ECM
Go to Step
11 -
(12)
es, etc.
the ECM.
12 System OK
codes.

codes?
224
225

# C o lo r
180 L DBW +
4 80
M o to r
182 Br DBW -
1 82
6 47
2 20
5 48
119 R /W 5 V o lts
3 19

 Fault Condition-TPS 2 sensor voltage less than 0.200 volts
 MIL-ON during active fault
 Engine shutdown
Circuit Description
mine signal voltage based on throttle plate position.TPS1 will read lower voltage when closed
the TPS 2 voltage is less than 0.200 volts. The MIL command is ON and the engine will shut-
down.
226
Go to OBD
1 - System Check
Check? (2)
Section
2 Go to Step (3)
(4)
volts or less with the throttle closed
3
(4) Go to Intermit-
Does TPS 2 voltage ever fall below 0.200 volts? tent section
 Key OFF
 Jumper the 5 volt reference circuit 119 and
TPS 2 signal circuit 148 together at the throt-
Go to Step
4 tle connector CN3 Go to Step (5)
(7)
 Key ON
Does DST display TPS 2 voltage of 4.0 volts or

greater?
 Key OFF
CN1 circuit as ne-
 Using a DVOM check continuity on the TPS Go to Step cessary. Refer
5 to Wiring Re-
2 signal circuit 148 between TPS 2 connector (6)
CN3 and ECM connector CN1 pairs in
Engine Elec-
 Replace ECM
Go to Step
6
(9)
Repair the
 Inspect the electronic throttle wire harness circuit as ne-
connector terminals for damage, corrosion or cessary.
ing Repairs in
trical.
Go to Step
8 -
(9)
227
es, etc.
the ECM.
9 System OK
codes.

codes?
228
229

# C o lo r
180 L DBW +
4 80
M o to r
182 Br DBW -
1 82
6 47
2 20
5 48
119 R /W 5 V o lts
3 19

 Fault Condition-TPS 2 sensor exceeds 4.800 volts
 Engine shutdown
Circuit Description
mine signal voltage based on throttle plate position.TPS1 will read lower voltage when closed
the TPS 2 voltage is greater than 4.800 volts. The MIL command is ON and the engine will
shutdown.
230
Did you perform the On-Board (OBD) System Go to OBD
Go to Step
1 Check? - System Check
(2)
Section
2 Go to Step (3)
(4)
volts or greater with the throttle closed?
3
(4) Go to Intermit-
Does TPS 2 voltage ever exceed 4.800 volts? tent section
 Key OFF
4 Go to Step (5)
(7)
volts?
 Key OFF
CN1 circuit as ne-
 Key ON cessary.
electronic throttle connector TPS 2 signal cir- ing Repairs in
cuit 148 and engine ground Engine Elec-
trical.
 Replace ECM
Go to Step
6
(11)
 Probe sensor ground circuit at the ECM side
of the wire harness circuit 120 with a test
7 light connected to battery voltage
(8) (10)
 Inspect the electronic throttle wire harness Repair the
connector and terminals for damage, corro- circuit as ne-
sion or contamination cessary.
Did you find a problem? ing Repairs in
Engine Elec-
trical.
 Replace electronic throttle
Go to Step
9 -
(11)
231
cessary. Refer
10 sensor ground circuit 120 between throttle to Wiring Re-
(6)
connector CN3 and ECM connector CN1 pairs in
Engine Elec-
es, etc.
the ECM.
11 System OK
codes.

codes?
232
233
DTC 261 Injector Driver 1 Open or Low Side Short to Ground
 Injector loop open or low side short to ground

 Check Condition-key on and engine running
 Fault Condition-System voltage greater than 9 volts and injector low side less than 4.0 volts
for 10 injector firings
 Closed Loop-Disabled
Circuit Description
System battery voltage is supplied to each fuel injector. The ECM controls each fuel injector by
providing a ground signal to pulse the injector ON. This fault will set if the ECM detects low
feedback voltage at the injector driver circuit while the injector drive circuit is in the off-state and
battery voltage is greater than 9 volts.
Diagnostic Aid
Injector coil resistance will increase as the temperature of the injector increases. Injector driv-
ers at the ECM are numbered in sequence order and injectors by cylinder number.
234
DTC 261 Injector Driver 1 Open or Low Side Short to Ground
Go to OBD
1
tion
 Key On, Engine Running Intermittent
 DST (Diagnostic Scan Tool) connected in problem.
System Data Mode Go to Step Go to Inter-
2
 Clear System DTC 261 (3) mittent
electrical sec-
Does DTC 261 reset with the engine idling? tion
 Key OFF
 Disconnect the injector interface connector
CN17
 Using a high impedance DVOM, measure
the resistance between the fuel injector pins 20 ohms or Go to Step Go to Step
3
at the fuel metering body at an ambient tem- less (5) (4)
perature of 50 to 90 degrees F.
Does the DVOM display a resistance value of 20

ohms or less?
 Replace the Fuel Injector
4 Go to Step
CN17 Repair the
shorted to
 Disconnect the ECM connector CN1
ground injec-
 Using a DVOM measure the resistance at 5 Ohms or tor control Go to Step
5 connector CN17 between the injector control less circuit. (6)
circuit 164 and engine ground
See wire har-
ness repair
Does the DVOM display a resistance of 5 Ohms section
or less?
injector control circuit 164 between the injec- open injector
tor connector CN17 and the ECM connector Go to Step control circuit.
6
CN1 (7) See wire har-
ness repair
Do you have continuity between them? section
235
Go to Step
7
(8)
es, etc.
the ECM.
Go to OBD
8 System OK System
codes.

codes?
236
237
DTC 262-Injector Driver 1 Coil Shorted
 Injector coil shorted

 Fault Condition-Battery voltage at ECM less than16 volts and injector on state low side
greater than 4 volts for 10 injector firings
 MIL-On
Circuit Description
providing ground to pulse the injector. This fault will set if the ECM detects high feedback vol-
tage at the injector while the injector drive circuit is in the off-state with system battery voltage
less than 16 volts.
Diagnostic Aid
238
Go to OBD
1
tion
 Key On, Engine Running
Intermittent
problem
2 Go to Inter-
 Clear System DTC 262 (3)
mittent
section
Does DTC 262 reset with the engine idling?
 Key OFF
CN17
the resistance between the fuel injector pins Greater than Go to Step Go to Step
3
at the fuel metering body at an ambient tem- 5.0 Ohms (5) (4)

ohms or more?
4 Go to Step
Repair the
 Disconnect the ECM wire harness connector shorted to
CN1 voltage injec-
 Key ON tor driver
5  Using a DVOM check for voltage between circuit as ne- Go to Step
the ECM connector CN1 injector control cir- cessary. (6)
cuit 164 and engine ground Refer to Wir-
ing Repairs in
Does the DVOM display voltage? Engine Elec-
trical.
 Replace the ECM
Go to Step
6
(7)
239
es, etc.
the ECM.
7 System OK
 Observe the MIL system check
rameters of DTC262 check for any stored
codes.

codes?
240
241
DTC 264-Injector Driver 2 Open or Low Side Short to Ground

Circuit Description
Diagnostic Aid
242
Go to OBD
1
tion
system data mode Go to Step Go to Inter-
2
electrical sec-
 Key OFF
CN18
3
perature of 50 to 90 degrees F

ohms or less?
4 Go to Step
CN18 Repair the
shorted to
ground injec-
 Using a DVOM measure the resistance be- 5 Ohms or tor control Go to Step
5 tween the injector control circuit 167 at the less circuit. (6)
injector connector CN18 and engine ground
See wire har-
ness repair
or less?
Repair the
open injector
injector control circuit between the CN18
Go to Step control circuit.
6 connector and the ECM connector CN1
(7) See wire har-
ness repair
243
Go to Step
7
(8)
es, etc.
the ECM.
Go to OBD
8 System OK System
codes.

codes?
244
245

 MIL-On
Circuit Description
less than 16 volts.
Diagnostic Aid
246
Go to OBD
1
tion
Intermittent
problem
2 Go to Inter-
mittent
section
 Key OFF
CN18
3

ohms or more?
4 Go to Step
Repair the
CN1 voltage injec-
the ECM connector circuit167 and engine cessary. (6)
ground Refer to Wir-
ing Repairs in
trical.
 Replace the ECM
Go to Step
6
(7)
247
es, etc.
the ECM.
7 System OK
codes.

codes?
248
249

Circuit Description
Diagnostic Aid
250
Go to OBD
1
tion
system data mode Go to Step Go to Inter-
2
electrical sec-
 Key OFF
CN19.
3

ohms or less?
4 Go to Step
 Disconnect the ECM connector CN1 Repair the

shorted to
 Using a DVOM measure the resistance be-
ground injec-
tween the injector connector control circuit
5 Ohms or tor control Go to Step
5 165 and engine ground
less circuit. (6)
See wire har-
Does the DVOM display a resistance of 5 Ohms ness repair
or less? section
Repair the
 Using a DVOM check for continuity between
open injector
the CN19 connector injector control pin and
6 the ECM injector driver pin
(7) See wire har-
ness repair
251
Go to Step
7
(8)
es, etc.
the ECM.
Go to OBD
8 System OK System
codes.

codes?
252
253

 MIL-On
Circuit Description
less than 16 volts.
Diagnostic Aid
254
Go to OBD
1
tion
Intermittent
problem
2 Go to Inter-
mittent
section
 Key OFF
CN19
3

ohms or more?
4 Go to Step
Repair the
CN1 voltage injec-
ing Repairs in
trical.
 Replace the ECM
Go to Step
6
(7)
255
es, etc.
the ECM.
7 System OK
codes.

codes?
256
257

Circuit Description
Diagnostic Aid
258
Go to OBD
1
tion
System Data Mode Go to Step Go to Inter-
2
electrical sec-
 Key OFF
C20.
3

ohms or less?
4 Go to Step
CN20 Repair the
shorted to
ground injec-
 Using a DVOM measure the resistance be- 5 Ohms or tor control Go to Step
5 tween the injector control circuit 166 and less circuit. (6)
engine ground
See wire har-
ness repair
or less?
Repair the
open injector
injector control circuit 166 between the CN20
6 connector and the ECM connector CN1
(7) See wire har-
ness repair
259
Go to Step
7
(8)
es, etc.
the ECM.
Go to OBD
8 System OK System
codes.

codes?
260
261

 Fault Condition-Battery voltage at ECM less than 16 volts and injector on state low side
 MIL-On
Circuit Description
less than 16 volts.
Diagnostic Aid
262
Go to OBD
1
tion
Intermittent
problem
2 Go to Inter-
mittent
section
 Key OFF
CN20
3

ohms or more?
4 Go to Step
Repair the
CN1 voltage injec-
ing Repairs in
trical.
 Replace the ECM
Go to Step
6
(7)
263
es, etc.
the ECM.
7 System OK
codes.

codes?
264
265
DTC 336-Crank Sync Noise
 Crankshaft Position sensor

 Check Condition Engine running
 Fault Condition 1 invalid crank re-sync in less than 800 ms
 MIL On during active fault
 Adaptive Disabled
Circuit Description
The Crankshaft position sensor is a 5 volt powered sensor mounted to the lower front engine
block. A pulse wheel located on the crankshaft is used to measure engine rpm and its signal is
used to synchronize the ignition and fuel systems. This fault will set If no signal is present for
800ms or longer.
266
DTC 336-Crank Sync Noise
Go to OBD
1
tion
Repair the
circuit as ne-
 Check that the ECM ground terminal CN28 is
cessary.
clean, tight and in the proper location Go to Step
2 Refer to Wir-
(3)
ing Repairs in
Are the ground terminals clean and tight? Engine Elec-
trical.
 Key On, Engine OFF
Repair the
 Disconnect the CKP (Crankshaft position)
circuit as ne-
cessary.
3  Using A DVOM check for voltage at the CKP 5.0 volts
Go to Step
Refer to Wir-
sensor connector CN9 circuit 119 pin A and (4)
ing Repairs in
engine ground Engine Elec-
trical.
 Using a DVOM check for continuity between Go to Step
cessary.
4 CKP connector circuit 125 and ECM connec- Refer to Wir-
(5)
tor circuit 125 ing Repairs in
Engine Elec-
Repair the
 Using a DVOM check for continuity on sen- circuit as ne-
sor ground circuit 120 between CKP cessary.
Go to Step
(6)
ing Repairs in
trical.
Repair the
circuit as ne-
 Inspect the CKP connector CN9 terminals for
cessary.
6 Refer to Wir-
(7)
ing Repairs in
trical.
Repair the
circuit as ne-
 Inspect the ECM connector CN1 terminals
cessary.
7 Refer to Wir-
(8)
ing Repairs in
trical.
267
 Replace CKP sensor
Go to Step
8
(10)
 Replace ECM
Go to Step
9
(11)
es, etc.
the ECM.
10 System OK
codes.

codes?
es, etc.
the ECM.
Go to OBD
11 System OK System
codes.

codes?
268
269
DTC 337-Crank Loss
 Crankshaft position sensor

 Check Condition Engine cranking
 Fault Condition 6 cam pulse signals without crankshaft activity
 Adaptive Disabled
Circuit Description
The Crankshaft position sensor is a 5 volt powered sensor mounted to the lower front engine
block. A pulse wheel located on the crankshaft is used to measure engine rpm and its signal is
used to synchronize the ignition and fuel systems. The ECM must see a valid Crankshaft posi-
tion signal while cranking. If no crankshaft signal is present for 6 cam pulses this fault will set.
270
DTC 337-Crank Loss
Go to OBD
1
tion
Repair the
circuit as
necessary.
2 Refer to Wir-
(3)
ing Repairs
Are the ground terminals clean and tight? in Engine
Electrical.
 Key OFF
 Disconnect the CKP (Crankshaft Position)
Sensor connector CN9 Repair the
 Using A DVOM check for voltage at the CKP circuit as
sensor connector CN9 circuit 119 and engine necessary.
Go to Step
3 ground 5.0 volts Refer to Wir-
(4)
ing Repairs
(CHECK THIS BEFORE THE POWER RELAY in Engine
SHUTS OFF) Electrical.

 Disconnect ECM connector CN1 circuit as
 Using a DVOM check for continuity on crank Go to Step
necessary.
4 signal circuit 125 between CKP connector Refer to Wir-
(5)
and ECM connector ing Repairs
in Engine
Repair the
 Using a DVOM check for continuity on the circuit as
sensor ground circuit 120 between CKP con- necessary.
Go to Step
5 nector CN9 and ECM connector CN1 Refer to Wir-
(6)
ing Repairs
Electrical.
Repair the
circuit as ne-
 Inspect the CKP connector CN9 terminals for
cessary.
6 Refer to Wir-
(7)
ing Repairs in
trical.
271
Repair the
circuit as ne-
 Inspect the ECM connector CN1 for damage,
cessary.
7 Refer to Wir-
(8)
ing Repairs in
Did you find a problem Engine Elec-
trical.
 Replace the CKP sensor
Go to Step
8
(10)
 Replace ECM
Go to Step
9
(11)
es, etc.
the ECM.
10 System OK
codes.

codes?
es, etc.
the ECM.
Go to OBD
11 System OK System
codes.

codes?
272
273
DTC 341-Camshaft Sensor Sync Noise
 Camshaft position sensor

 Fault Condition 1 invalid cam re-sync in 700ms or less
 Adaptive learn disabled
 MIL-On
Circuit Description
The CMP (Camshaft Position Sensor) is used to synchronize the fuel and ignition systems.
This fault will set if the ECM detects erroneous pulses from the camshaft position sensor caus-
ing invalid cam re-sync.
274
DTC 341-Camshaft Sensor Sync Noise
Go to OBD
1
tion
Repair the
circuit as ne-
cessary.
2 Refer to Wir-
(3)
ing Repairs in
Are the ground terminals clean and tight? Engine Elec-
trical.
 Key OFF
Repair the
 Disconnect the CMP (Camshaft position)
circuit as ne-
cessary.
3  Using A DVOM check for voltage at the CMP 5.0 volts
Go to Step
Refer to Wir-
sensor connector CN2 circuit 119 and engine (4)
ing Repairs in
ground Engine Elec-
trical.
cessary.
4 CMP signal circuit 127 between CMP con- Refer to Wir-
(5)
nector CN2 and ECM connector CN1 ing Repairs in
Engine Elec-
Repair the
 Using a DVOM check for continuity on the circuit as ne-
sensor ground circuit 120 between CMP cessary.
Go to Step
(6)
ing Repairs in
trical.
Repair the
circuit as ne-
 Inspect the CMP connector terminals for
cessary.
6 Refer to Wir-
(7)
ing Repairs in
trical.
Repair the
circuit as ne-
 Inspect the ECM connector CN1 for damage,
cessary.
7 Refer to Wir-
(8)
ing Repairs in
Did you find a problem Engine Elec-
trical.
275
 Replace CMP sensor
Go to Step
8 -
(10)
 Replace ECM
Go to Step
9 -
(11)
es, etc.
the ECM.
10 System OK
codes.

codes?
es, etc.
the ECM.
Go to OBD
11 System OK System
codes.

codes?
276
277
DTC 342-Camshaft Sensor Loss
 CMP (Camshaft Position Sensor)

 Check Condition-Engine Cranking or Running
 Fault Condition-No cam pulse in 2.5 cycles with engine speed greater than 1000 rpm
Circuit Description
The CMP (Camshaft Position Sensor) is used to synchronize the fuel and ignition systems.
This fault will set if the ECM does not detect a cam pulse in 2.5 engine cycles whenever the
engine is greater than 1000 rpm. The engine may not run with this fault present.
278
DTC 342-Camshaft Sensor Loss
Go to OBD
1
tion
Repair the
 Check that the ECM ground terminal CN28 is circuit as ne-
clean, tight and in the proper location cessary.
Go to Step
2 Refer to wir-
(3)
Is the ground terminal clean tight and in the ing harness
proper location? repair sec-
tion.
 Key OFF
 Disconnect the CMP (Camshaft Position)
Repair the
 Key ON
circuit as ne-
 Using A DVOM check for voltage between cessary.
CMP sensor connector circuit 119 and en- Go to Step
3 5.0 volts Refer to wir-
gine ground (4)
ing harness
repair sec-
(RUN THIS VOLTAGE CHECK BEFORE THE tion.
POWER RELAY SHUTS OFF)

cessary.
4 CMP signal circuit 127 between CMP con- Refer to wir-
(5)
nector CN2 and ECM connector CN1 ing harness
repair sec-
Do you have continuity between them? tion.
Repair the
 Using a DVOM check for continuity on the circuit as ne-
sensor ground circuit between CMP connec- cessary.
Go to Step
5 tor CN2 and ECM connector CN1 Refer to wir-
(6)
ing harness
Do you have continuity between them? repair sec-
tion.
Repair the
circuit as ne-
 Inspect the CMP connector CN2 terminals
cessary.
6 Refer to wir-
(7)
ing harness
Did you find a problem? repair sec-
tion.
279
Repair the
circuit as ne-
 Inspect the ECM connector terminals for
cessary.
7 Refer to wir-
(8)
ing harness
Did you find a problem? repair sec-
tion.
 Replace the CMP.
Go to Step
8
(10)
 Replace ECM
Go to Step
9
(11)
es, etc.
the ECM.
10 System OK
codes.

codes?
es, etc.
the ECM.
Go to OBD
11 System OK System
codes.

codes?
280
281
DTC 359-Fuel Run-out Longer Than Expected
 LPG shut off valve

 Check Condition Key OFF
 Fault Condition Engine run down time greater than 20 seconds
 MIL-On
Circuit Description
The LPG shut off valve is supplied system battery power from the VSW fused source. The
ECM then provides a path to ground to turn the valve on. This fault will set in the event the en-
gine continues to run for more than 20 seconds after the key is turned off.
This fault indicates a possible problem with the electric LPG shut off solenoid.
282
DTC 359-Fuel Run-out Longer Than Expected

1 -
Check? (2)
 Disconnect the LPG shut off solenoid con-
nector CN13
 Using a DVOM check for power across ter-
minals (circuits 177 and 821) while cranking
System Vol- Go to Step Go to Step
2 the engine, then turn the key to the OFF posi-
tage (3) (5)
tion.
Did the voltage immediately turn OFF with the

Key cycle?
 Unplug the LPG Shut-off valve electrical con-
Intermittent
nector.
problem. See
 Start the engine and let it idle until the engine intermittent
stops. Go to Step
3 problems in
(4)
the electrical
(THIS MAY TAKE SEVERAL MINUTES) section of this
manual.
Did the engine ever stop?
 Replace the LPG shut off valve.
Go to Step
4 _
(8)
 Key OFF
CN1 Repair the
LPG solenoid Go to Step
5  Using a DVOM check for continuity between (6)
circuit 177 and engine ground control short
to ground
Correct the
 Inspect the ECM wire harness and connector
problem as
for damage corrosion or contamination Go to Step
6 required. See
(7)
wire harness
Did you find a problem? repair.
 Replace the ECM
Go to Step
7 _
(8)
283
es, etc.
the ECM.
Go to OBD
8 System OK System
 Observe engine performance and drivability
codes.

codes?
284
285
DTC 420-Catalyst Monitor Test (Bi-Fuel/Gasoline Only)

 Check condition Engine running
 Fault condition Catalyst monitor test failed
 Adaptive Disabled during active fault
 Closed Loop Disabled during active fault
Circuit Description
The catalyst monitor test is run under certain operating conditions to determine if the catalyst is
functioning correctly. If the test is failed the fault will set letting the operator know the catalyst
is not functioning as intended. Closed loop operation and adaptive learn capabilities are dis-
abled upon activation of this fault.
286
DTC 420-Catalyst Monitor Test (Bi-Fuel/Gasoline Only)
Diagnostic Aid
 Inspect the exhaust system for visual signs of damage, leaks, or modification and
repair if necessary.
 Insure the pre catalyst and post catalyst oxygen sensors are mounted correctly and
wiring is not damaged, melted, or corroded and repair if necessary.
 If none of the above problems are found replace the catalyst.
287
DTC 524-Oil Pressure Low
 Engine Oil Pressure low

 Check Condition-Engine running for 20 seconds or more with engine speed greater than
600 rpm
 Fault Condition Open pressure switch circuit voltage equal to or greater than 2.50 volts
 MIL-On
Circuit Description
The Oil Pressure Switch is used to communicate a low oil pressure condition to the ECM. En-
gine damage can occur if the engine is operated with low oil pressure. The ECM uses an
analog voltage input with an internal voltage reference. If the oil pressure circuit is grounded,
the input voltage will be near zero. If it is open, the input will be near 2.00 volts. The pressure
switch is normally open. This fault will set if the switch remains open with the engine running.
The MIL command is ON and the engine will shut down in the event of this fault to help prevent
possible engine damage.
288
DTC 524-Oil Pressure Low
Go to OBD
1
tion
 Verify that the engine has oil pressure using
a mechanical oil pressure gauge before pro-
Go to Step Repair faulty
2 ceeding.
(3) Oiling System
Does the engine have oil pressure above 5 psi?
 Key On, Engine Running DST connected in
System Data Mode
 Clear DTC 524
 Warm the engine by idling until the ECT Intermittent
temperature is above 160 degrees F. and problem
Go to Step
3 has been running for at least 20 seconds or Go to Inter-
(4)
more mittent
 Increase engine speed above 600 RPM section
Does DTC 524 reset and cause the engine to

shut down?
 Key OFF
 Disconnect the oil pressure switch harness
connector CN8 and ground it to a good en-
gine ground
 Clear DTC 524 Go to Step Go to Step
4
 Start engine, let idle for at least one minute (6) (5)
with ECT over 160 degrees F.
 Increase engine speed above 600 RPM
Does DTC 524 reset?

 Replace oil pressure switch
5 Go to Step
 Disconnect ECM harness connector CN1 open oil pres-
 Leave the oil pressure switch connector sure switch
grounded to a good engine ground circuit as ne-
Go to Step
6  Using a DVOM check for continuity between cessary.
(7)
oil pressure switch connector CN1 and en- Refer to Wir-
gine ground. ing Repairs in
Engine Elec-
289
Repair the
 Inspect the oil pressure switch connector circuit as ne-
terminal and ECM connector for damage cor- cessary.
Go to Step
7 rosion or contamination Refer to Wir-
(8)
ing Repairs in
trical.
 Replace ECM
Go to Step
8 -
(9)
es, etc.
the ECM.
Go to OBD
9 System OK System
codes.

codes?
290
291
DTC 562-System Voltage Low
 System Voltage to ECM

 Check Condition-Key on with engine speed greater than 1000 RPM
 Fault Condition-Battery voltage at ECM less than 9.0
Circuit Description
The battery voltage powers the ECM and must be measured to correctly to properly operate in-
jector drivers, solenoid valves and ignition coils. This fault will set if the ECM detects system
voltage less than 9.0 volts while the alternator should be charging. The adaptive learn is dis-
abled during this fault.
292
DTC 562 System Voltage Low
Go to OBD
1
tion
System Data Mode Go to Engine Go to Step
2
Electrical In- (3)
Does DST display system voltage greater than termittent
9.0 volts? section
 Check battery condition
Go to Step Replace Bat-
3
(4) tery
Is it OK?
 Check charging system
Go to Step Repair charg-
4
(5) ing System
Is it OK?
 Key OFF Repair ECM
 Disconnect the ECM connector CN1 Ground cir-
 Using a DVOM check the voltage between cuit. Go to
Go to Step
5 ECM connector CN1 circuits 160 and 179 Power and
(6)
and engine ground Ground sec-
tion in engine
Is the voltage greater than for each pin 9.0 volts? Electrical
Repair ECM
 Using a DVOM check voltage between bat-
power circuit.
tery positive and ECM connector CN1
Go to Power Go to Step
6 circuits 169 and 181
and Ground (7)
section in en-
Is the voltage greater than 9.0 volts? gine Electrical
 Replace ECM
Go to Step
7
(8)
293
es, etc.
the ECM.
Go to OBD
8 System OK System
codes.

codes?
294
295
DTC 563-System Voltage High

 System Voltage to ECM

 Fault Condition-System battery voltage at ECM greater than 16 volts
Circuit Description
The battery voltage powers the ECM and must be measured to correctly operate injector driv-
ers, trim valves and ignition coils. This fault will set if the ECM detects voltage greater than 16
volts anytime the engine is cranking or running. The adaptive learn function is disabled during
this fault. The ECM will shut down with internal protection if the system voltage ever exceeds
26 volts.
296
DTC 563-System Voltage High
Go to OBD
1
tion
Intermittent
problem
System Data Mode
Go To Step Go to Engine
2  Run engine greater than 1000 rpm (3) Electrical In-
termittent
Does DST display system voltage greater than section
16 volts?
 Check voltage at battery terminals with
DVOM with engine speed greater than 1000
3 rpm
(4) (5)
Is it greater than 16 volts?
 Repair the charging system
Go to Step
4
(6)
Has the charging system been repaired?
 Replace ECM
Go to Step
5
(6)
es, etc.
the ECM.
Go to OBD
6 System OK System
codes.

codes?
297
DTC 601-Flash Checksum Invalid
 Engine Control Module

 Check Condition Key on
 Fault Condition Internal microprocessor error
 MIL On
 Adaptive Disabled for the remainder of the key-ON cycle
 Power Derate level 2
Circuit Description
The ECM has several internal checks that must be satisfied each time an instruction is ex-
ecuted. Several different things can happen within the microprocessor that will cause this fault.
The ECM will attempt to reset itself in the event this fault is set. The MIL command is on and
will remain on until the code is cleared using the DST. Power Derate level 2 will be enforced li-
miting maximum power.
298
DTC 601-Flash Checksum Invalid
Go to OBD
1
tion
Intermittent
problem
2 Go to Inter-
 Clear system fault code (3)
mittent
section
Repair the
circuit as ne-
 Check ECM power and ground circuits cessary.
Go to Step
3 Refer to Wir-
(4)
Did the power and ground circuits check OK? ing Repairs in
Engine Elec-
trical.
 Replace ECM
Go to Step
4
(5)
es, etc.
the ECM.
Go to OBD
full operating temperature System
5 System OK
codes.

codes?
299
DTC 604-RAM Failure

 MIL On
 Adaptive Disabled for the remainder of the key-ON cycle
Circuit Description
miting maximum power output.
300
DTC 604-RAM Failure
Go to OBD
1
tion
problem
2 Go to Inter-
mittent
section
Repair the
circuit as ne-
Go to Step
3 Refer to Wir-
(4)
Engine Elec-
trical.
 Replace ECM
Go to Step
4
(5)
es, etc.
the ECM.
Go to OBD
5 System OK System
codes.

codes?
301
DTC 606-COP Failure

 MIL On
 Adaptive Disabled Power Derate level 2
Circuit Description
miting maximum power output.
302
DTC 606-COP Failure
Go to OBD
1
tion
Intermittent
problem
2 Go to Inter-
mittent
section
Repair the
circuit as ne-
Go to Step
3 Refer to Wir-
(4)
Are the power and ground circuits OK? ing Repairs in
Engine Elec-
trical.
 Replace ECM
Go to Step
4
(5)
es, etc.
the ECM.
Go to OBD
5 System OK
codes.

codes?
303
DTC 627-Fuel Pump Relay Coil Open (Bi-Fuel/Gasoline Only)
 Fuel pump relay check

 Check Condition-Key ON
 Fault Condition Relay coil open
Circuit Description
The fuel pump relay switches power out to the fuel pump for operation on gasoline fuel. This
fault will set if the ECM detects an open circuit on the relay control output.
Diagnostic Aid
Relay coil resistance changes with temperature. The following diagnostic charts have steps to
measure relay coil resistance values. When checking the resistance values be sure the relay is
at a reasonable temperature, between +20 and +100 degrees F.
304
DTC 627-Fuel Pump Relay Coil Open (Bi-Fuel/Gasoline Only)
Go to OBD
1
tion
 DST connected and in the System Data
Mode
 Key OFF
 Remove the fuel pump relay from the fuse
block Go to Step Go to Step
2
 Using a DVOM check the resistance of the (4) (3)
relay coil between the relay terminals for cir-
cuits 144B and 178
Is the resistance value less than 100 ohms?

 Replace the relay
Go to Step
3
(9)
 Check VSW fuse
Replace ECM Go to Step
4
fuse (5)
Is the fuse open?
 Using a DVOM check for continuity between open circuit
ECM connector CN1 circuit 178 and fuel Go to Step as required.
5
pump relay circuit 178 (6) See wiring
harness re-
Do you have continuity? pairs
 Remove ECM fuse Repair the
 Using a DVOM check for continuity on circuit open circuit
144B between fuse block cavity for the fuel Go to Step as required.
6
pump relay and the VSW fuse (7) See wiring
harness re-
 Check all system fuses.
 Check all relay placement positions in fuse
block.
 Run complete pin to pin checks on chassis
7 wiring to fuel system harness.
(9) (8)
 See complete fuel system schematic for fur-
ther details
Did you find the problem?
305
 Replace the ECM
Go to Step
8 _
(9)
es, etc.
the ECM.
Go to OBD
codes.

codes?
306
307
DTC 628-Relay Control Ground Short (Bi-Fuel/Gasoline Only)
 Fuel pump relay ground control

 Fault Condition Relay control shorted to ground
Circuit Description
fault will set if the ECM detects a short to ground on the relay control output.
Diagnostic Aid
308
DTC 628-Relay Control Ground Short (Bi-Fuel/Gasoline Only)
Go to OBD
1
tion
 Key On, DST connected in the System Data
Intermittent
Mode
problem
 Clear DTC 628 Go to Step
2 Go to Inter-
 Start the engine (3)
mittent
section
Does DTC 628 re-set?
 Using a DVOM check the resistance value
between ECM connector CN1 circuit 178 and Go to Step Go to Step
3
engine ground (4) (6)
Is the resistance less than 60 ohms?

Repair the
 Remove the power relay from the fuse block shorted to
 Using a DVOM check the resistance value ground relay
again between ECM connector circuit 178 control circuit Go to Step
4
and engine ground as necessary. (5)
See wiring
Is the resistance less than 60 ohms? harness re-
pairs
 Replace the power relay
Go to Step
5
(7)
 Replace ECM
Go to Step
6
(7)
es, etc.
the ECM.
 Start the engine and operate the vehicle to Go to OBD
7 System OK System
codes.

codes?
309
DTC 629-Relay Coil Short to Power (Bi-Fuel/Gasoline Only)
 Fuel pump relay check

 Fault Condition Relay coil shorted to power
Circuit Description
fault will set if the ECM detects a short circuit to power on the relay control output.
Diagnostic Aid
310
DTC 629-Relay Coil Short to Power (Bi-Fuel/Gasoline Only)
Go to OBD
1
tion
Mode
 Key OFF
 Remove the power relay from the fuse block
2  Using a DVOM check the resistance of the (3) (4)
relay coil between fuel pump relay terminals
for circuits 178 and 144B

Go to Step
3
(9)
relay terminals for circuits 178 and 144B Go to Step Go to Step
4
(3) (5)
 Key OFF
Repair the
CN1
short to pow-
5  Using a DVOM check for power between System bat-
er. See
Go to Step
ECM connector circuit 178 and engine tery voltage (6)
wiring har-
ground with the key ON ness repair.
Do you have power?
Go to Step
6
(7)
es, etc.
the ECM.
7 full operating temperature
(8) (9)
 Observe the MIL
codes.
Does DTC 687 still re-set?
311
 Replace the ECM
Go to Step
8 _
(9)
es, etc.
the ECM.
Go to OBD
codes.

codes?
312
313
DTC 642-External 5 Volt Reference Low
 External 5 volt reference

 Fault Condition-5 volt reference voltage lower than 4.60 volts
Circuit Description
The external 5 volt supply powers many of the sensors and other components of the fuel sys-
tem. The accuracy of the 5 volt supply is very important to the accuracy of the powered
sensors and fuel control by the ECM. The ECM is able to determine if they are overloaded,
shorted, or otherwise out of specification by monitoring the 5 volt supply. This fault will set if
the 5 volt reference is below 4.60 volts. Adaptive Learn will be disabled during this fault.
314
DTC 642-External 5 Volt Reference Low
Go to OBD
1
tion
 Key ON, Engine Running Intermittent
Go to Step
2 System Fault Mode Go to Inter-
(3)
mittent
Does DST display DTC 642? section
 Key OFF
 Using DVOM check for continuity between Go to Step Go to Step
3 ECM 5 volt reference circuit 119 and engine (5) (4)
ground

 Replace ECM
Go to Step
4
(7)
 While monitoring DVOM for continuity be-
tween ECM 5 volt reference circuit 119 and
engine ground
 Disconnect each sensor (below) one at a
time to find the shorted 5 volt reference.
When continuity to ground is lost the last
sensor disconnected is the area of suspicion.
Inspect the 5 volt reference supply wire leads
for shorts before replacing the sensor.
 ECT
 TMAP Repair short-
Go to Step
5  Electronic Throttle ed wire
(6)
 Gasoline Sensor harness
 LPG temperature sensor
 FPP
 TPS 1
 TPS 2
 Crankshaft Sensor
 Camshaft Sensor
While disconnecting each sensor one at a time

did you lose continuity?
 Replace the last disconnected sensor
Go to Step
6
(7)
315
es, etc.
the ECM.
Go to OBD
7 System OK System
codes.

codes?
316
317
DTC 643-External 5 Volt Reference High
 External 5 volt reference

 Fault Condition-5 volt reference higher than 5.40 volts
Circuit Description
The External 5 volt supply powers many of the sensors and other components in the fuel sys-
tem. The accuracy of the 5 volt supply is very important to the accuracy of the powered
sensors and fuel control by the ECM. The ECM is able to determine if they are overloaded,
shorted, or otherwise out of specification by monitoring the 5volt supply. This fault will set if the
5 volt reference is greater than 5.40 volts anytime the engine is cranking or running. Adaptive
Learn will be disabled during this fault
318
DTC 643-External 5 Volt Reference High
Go to OBD
1 -
tion
 Key ON, Engine running Intermittent
Go to Step
(3)
mittent
Does DST display DTC 643? section
Repair the
 Check all ECM ground connections circuit as ne-
 Refer to Engine electrical power and ground cessary.
Go to Step
3 distribution. Refer to Wir-
(4)
ing Repairs in
Are the ground connections OK? Engine Elec-
trical.
 Key OFF
circuit as ne-
 Key ON
cessary.
 Using DVOM check for Voltage between Go to Step
4 Refer to Wir-
ECM connector CN1 circuit 119 and engine (5)
ing Repairs in
ground Engine Elec-
trical.
 Replace ECM
Go to Step
5 -
(6)
es, etc.
the ECM.
Go to OBD
6 System OK System
codes.
Does the vehicle engine normally with no stored

codes?
319
DTC 685-Relay Coil Open
 Power relay check

 Fault Condition Relay coil open
Circuit Description
The power relay switches power out to various sensors, actuators and solenoids in the fuel
system. This fault will set if the ECM detects an open circuit on the relay control output.
Diagnostic Aid
320
DTC 685-Relay Coil Open
Go to OBD
1
tion
 DST connected and in the system data
mode
 Key OFF
relay coil between the relay terminals for cir-
cuits 173 and 160B

Go to Step
3
(9)
 Check ECM fuse
Replace ECM Go to Step
4
fuse (5)
Is the fuse open?
ECM connector CN1 circuit 173 and power Go to Step as required.
5
relay circuit 173 (6) See wiring
harness re-
 Remove ECM fuse Repair the
 Using a DVOM check for continuity on circuit open circuit
160B between fuse block cavity for the pow- Go to Step as required.
6
er relay and the ECM fuse (7) See wiring
harness re-
 Check all system fuses.
 Check all relay placement positions in fuse
block.
 Run complete pin to pin checks on chassis
7 wiring to fuel system harness.
(9) (8)
 See complete fuel system schematic for fur-
ther details
Did you find the problem?
321
 Replace the ECM
Go to Step
8 _
(9)
es, etc.
the ECM.
Go to OBD
codes.

codes?
322
323
DTC 686-Relay Control Ground Short
 Power relay ground control

 Fault Condition Relay control shorted to ground
Circuit Description
system. This fault will set if the ECM detects a short to ground on the relay control output.
Diagnostic Aid
measure relay coil resistance values. When checking the resistance values be sure the relay
is at a reasonable temperature, between +20 and +100 degrees F.
324
DTC 686-Relay Control Ground Short
Go to OBD
1
tion
 Key On, DST connected in the System Data
Intermittent
Mode
problem
 Clear DTC 686 Go to Step
2 Go to Inter-
 Start the engine (3)
mittent
section
Does DTC 686 re-set?
 Using a DVOM check the resistance value
between ECM connector CN1 circuit 173 and Go to Step Go to Step
3
engine ground (4) (6)
Is the resistance less than 60 ohms?

Repair the
 Remove the power relay from the fuse block shorted to
 Using a DVOM check the resistance value ground relay
again between ECM connector circuit 173 control circuit Go to Step
4
and engine ground as necessary. (5)
See wiring
Is the resistance less than 60 ohms? harness re-
pairs
Go to Step
5
(7)
 Replace ECM
Go to Step
6
(7)
es, etc.
the ECM.
7 System OK System
codes.

codes?
325
DTC 687-Relay Coil Short to Power
 Power relay check

 Fault Condition Relay coil shorted to power
Circuit Description
system. This fault will set if the ECM detects a short circuit to power on the relay control output.
Diagnostic Aid
326
DTC 687-Relay Coil Short to Power
Go to OBD
1
tion
Mode
 Key OFF
relay coil between power relay terminals for
circuits 173 and 160B

Go to Step
3
(9)
relay terminals for circuits 173 and 160B Go to Step Go to Step
4
(3) (5)
 Key OFF
Repair the
CN1
short to pow-
5  Using a DVOM check for power between System bat-
er. See wiring
Go to Step
ECM connector circuit 173 and engine tery voltage (6)
harness re-
ground with the key ON pair.
Do you have power?
Go to Step
6
(7)
es, etc.
the ECM.
7 full operating temperature
(8) (9)
 Observe the MIL
codes.
327
 Replace the ECM
Go to Step
8 _
(9)
es, etc.
the ECM.
Go to OBD
9 System OK System
codes.

codes?
328
329
DTC 1111-Fuel Rev Limit

# C o lo r
180 L DBW +
4 80
M o to r
182 Br DBW -
1 82
6 47
2 20
5 48
119 R /W 5 V o lts
3 19
 Fuel Rev Limit

 Check Condition Engine Running
 Fault Condition Engine rpm greater than 4,000
Circuit Description
This fault will set anytime Engine rpm is greater than 4,000. When these conditions are met the
ECM cuts off fueling to limit speed. This is to help prevent engine or equipment damage. The
MIL will be on during this active fault.
Diagnostic Aid
Always check for other stored DTC codes before using the following DTC chart for this code
set. Repair any existing codes starting with the lowest numerical code first.
330
DTC 1111-Fuel Rev Limit
Go to OBD
1
tion
 DST in Active Fault Mode
2
(3) (4)
Are any other DTC codes present with DTC
1111?
 Diagnose and repair any other DTC codes
before proceeding with this chart.
Go to Step
3
(4)
repaired?
ensure correct calibration is in use Go to Step
4 Go to Step 5
(6)
Is the service part number correct?
 Replace ECM with the correct service part
number Go to Step
5
(9)
6
(8) (7)
 Correct mechanical operation of the Throttle
Body.
Go to Step
7
(9)
corrected?
 Check engine for large manifold vacuum
Go to OBD
leaks. Refer to Fuel Systems symptom diag-
Go to Step System
8 nostics
(9) Check Sec-
tion
Did you find and correct the vacuum leak?
331
es, etc.
ECM.
Go to OBD
9 System OK System
codes

codes?
332
333
DTC 1112-Spark Rev Limit

# C o lo r
180 L DBW +
4 80
M o to r
182 Br DBW -
1 82
6 47
2 20
5 48
119 R /W 5 V o lts
3 19
 Spark Rev Limit

 Check Condition Engine running
 Fault Condition Engine RPM greater than 4200
Circuit description
This fault will set anytime the engine RPM exceeds 3900. During this condition the ECM will
shut off spark to the engine. This is to help prevent engine or equipment damage. The MIL
command is ON during this active fault and the engine will shut down.
Diagnostic Aid
Always check for other stored DTC codes before using the following DTC chart for this code
set. Repair any existing codes starting with the lowest numerical code first.
334
DTC 1112-Spark Rev Limit
Go to OBD
1 -
tion
 DST connected
2
(3) (4)
Are any other DTC codes present with DTC
1112?
Go to Step
3
(4)
repaired?
ensure correct calibration is in use Go to Step
4 Go to Step 5
(6)
Is the service part number Correct?
 Replace ECM with correct service part Num-
ber Go to Step
5
(9)
6
(8) (7)
 Correct mechanical operation of the throttle.
Refer to Engine & Component section
Go to Step
7
(9)
corrected?
 Check engine for large manifold vacuum
Go to OBD
leaks. Refer to Fuel Systems section Symp-
Go to Step System
8 tom Diagnostics
(9) Check Sec-
tion
Did you find and correct the vacuum leak?
335
es, etc.
ECM.
Go to OBD
9 System OK System
codes.

codes?
336
337
DTC 1151-Closed Loop Multiplier High LPG

 Check Condition-Engine running
 Fault Condition-Closed Loop multiplier out of range (greater than 35%)
 MIL-ON
Circuit description
The EGO sensor is used to determine if the fuel flow to the engine is correct by measuring the
oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with
the Closed Loop multiplier and the adaptive multiplier. This fault sets if the Closed Loop multip-
lier exceeds the limits of normal operation and cannot correctly modify the fuel flow within its
limits.
Diagnostic Aid
haust manifold.
Vacuum Leaks Large vacuum leaks and crankcase leaks can cause a lean exhaust condition
at especially at light load.
Fuel Mixer System can be lean due to faulty EPR (Electronic Pressure Regulator) or faulty
fuel mixer.
338
DTC 1151-Closed Loop Multiplier High LPG
1
(3) (2)

stricted
proper location
 The EGO 1 sensor installed securely and the Go to Step Go to Step
2 wire leads not contacting the exhaust manifold (9) (4)
or ignition wires
bution
tem Diagnostics
Was a repair made?

3 set first.
(9) (4)
nosed and repaired?
 Disconnect EGO1 connector C005
EGO 1 connector pin B and engine ground open EGO
power circuit
 Key ON
System vol- Go to Step as necessary.
4
(CHECK MUST BE MADE WITHIN 30 SECONDS ing Repairs in
OR BEFORE POWER RELAY SHUTS DOWN) Engine Elec-
trical.
 Key OFF
 Disconnect EGO 1 sensor wire harness con-
nector CN11 Repair the
shorted circuit
as necessary.
Go to Step
ing Repairs in

339
Repair the
shorted circuit
continuity at the EGO 1 connector CN11 be-
as necessary.
tween signal circuit 121 and sensor ground Go to Step
6 Refer to Wir-
circuit 120 (7)
ing Repairs in
Engine Elec-
continuity on the EGO 1 heater circuit 162 be-
Repair the
tween EGO 1 connector CN11 and ECM Go to Step
7 open EGO
connector CN1 (8)
heater ground
Go to Step
8 -
(9)
es, etc.
ECM.
Go to OBD
9 System OK System
codes.

codes?
340
341
DTC 1152-Closed Loop Multiplier Low LPG

 Functional Fault-Closed Loop multiplier out of range (at limit of-35%)
 MIL Disabled
Circuit Description
with the Closed Loop multiplier and the adaptive multiplier. This fault sets if the Closed Loop
multiplier exceeds the limits of normal operation. When the multiplier cannot correctly modify
the fuel flow within its limits, it is limited at-35%.
Diagnostic Aid
Fuel System High secondary fuel pressure will cause the system to run rich. A worn fuel mix-
er, faulty EPR (Electronic Pressure Regulator) may also cause the system to run rich.
Fuel Quality A drastic variation in fuel quality (very high butane content) may cause the fuel
system to run rich. Be sure that the specified HD-5 or HD-10 motor fuel grade propane is
used.
Air Filter A plugged, damaged or modified air filter may cause the system to run rich.
342
DTC 1152-Closed Loop Multiplier Low LPG
1
(3) (2)
stricted
 The EGO sensor installed securely and the
2 wire leads not damaged contacting the sec-
(6) (4)
ondary ignition wires
 Run the fuel system diagnostic checks
Was a repair made?

3
(6) (4)
nosed and repaired?
 Key OFF
tor Repair the
circuit short to
voltage as
4  Key ON necessary.
Go to Step
 Using a DVOM check for voltage between (5)
Refer to wir-
EGO 1 connector CN11 signal circuit 121 and ing harness
engine ground repair.

Go to Step
5 -
(6)
343
es, etc.
ECM.
Go to OBD
6 System OK System
codes.

codes?
344
345
DTC 1155-Closed Loop High (Bi-Fuel/Gasoline Only)

 Fault Condition-Closed Loop multiplier out of range greater than 35.0%
 MIL-On
Circuit Description
lier exceeds the limits of normal operation. Always run fuel system diagnostic checks before
using the following diagnostic chart.
Diagnostic Aid
haust manifold.
Vacuum Leaks Vacuum leaks and crankcase leaks can cause a lean condition at especially
at light load.
Fuel Injectors The system may be lean due to contaminated or faulty fuel injectors
346
DTC 1155-Closed Loop High (Bi-Fuel/Gasoline Only)
 Perform the On-Board (OBD) System Check
1
(3) (2)

stricted
proper location
or ignition wires
bution
tem Diagnostics
Was a repair made?

3 set first.
(9) (4)
nosed and repaired?
EGO 1 connector CN11 circuit 812 and en- Repair the
gine ground open EGO
power circuit
 Key ON
4
(CHECK MUST BE MADE WITHIN 30 ing Repairs in
SECONDS OR BEFORE POWER RELAY Engine Elec-
SHUTS DOWN) trical.
347
 Key OFF
shorted circuit
as necessary.
5 Refer to Wir-
ing Repairs in

Repair the
 Using a high impedance DVOM check for shorted circuit
continuity on the EGO1 connector between as necessary.
Go to Step
6 the signal circuit 121 and ground circuit 120 Refer to Wir-
(7)
ing Repairs in
trical.
continuity between EGO 1 heater ground pin Repair the
Go to Step
7 D and ECM pin 72 open EGO
(8)
heater ground
Go to Step
8
(9)
es, etc.
ECM.
Go to OBD
9 System OK System
codes.

codes?
348
349
DTC 1156-Closed Loop Low (Bi-Fuel/Gasoline Only)

 Fault Condition-Closed loop multiplier out of range greater than-35%
 MIL-On
Circuit Description
Diagnostic Aid
Fuel System The system will be rich if an injector fails to close properly. High fuel pressure
due to a faulty fuel regulator or obstructed fuel return line will cause the system to run rich.
Ignition noise Open or poor ground circuit to or in the ignition system or ECM wiring may
cause EMI (Electromagnetic interference). This noise could be interpreted by the ECM as igni-
tion pulses or voltage across the oxygen sensor input causing the system to run rich.
MAP Sensor A higher manifold pressure than normal can cause the system to run rich. Tem-
porarily disconnecting the MAP Sensor will allow the ECM to set a default value for MAP and is
a good way to quickly eliminate this as a problem.
IAT Sensor Check for a shifted sensor that could cause the ECM to sense lower than actual
temperature of incoming air. This can cause a rich exhaust condition.
ECT Sensor Check for a “skewed” sensor that could cause the ECM to sense engine tempera-
ture colder than it actually is. This can also cause a rich exhaust condition.
350
DTC 1156-Closed Loop Low (Bi-Fuel/Gasoline Only)
1
(3) (2)
 The air intake duct collapsed or restricted

 The EGO sensor installed securely and the
2 wire leads not damaged or contacting the
(6) (4)
 Run the fuel system diagnostic checks
Was a repair made?

3
(6) (4)
nosed and repaired?
 Key OFF
tor CN11 Repair the
shorted circuit
as necessary.
4 Refer to Wir-
 Using a DVOM check for voltage at the EGO (5)
ing Repairs in
connector C11 signal circuit 121 and engine Engine Elec-
ground trical.

Go to Step
5 -
(6)
351
es, etc.
ECM.
Go to OBD
6 System OK System
codes.

codes?
352
353
DTC 1161-Adaptive Learn High LPG

 MIL-On
Circuit Description
before using the following diagnostic chat.
Diagnostic Aid
haust manifold.
Vacuum Leaks Large vacuum leaks and crankcase leaks can cause a lean exhaust condition
at especially at light load.
Fuel Mixer System can be lean due to faulty EPR (Electronic Pressure Regulator) or faulty
fuel mixer.
354
DTC 1161-Adaptive Learn High LPG
1
(3) (2)

stricted
proper location
or ignition wires
bution
tem Diagnostics
Was a repair made?

3 set first.
(9) (4)
nosed and repaired?
EGO 1 connector pin B and engine ground open EGO
 Key ON power circuit
4
(CHECK MUST BE MADE WITHIN 30 tage (5) Refer to Wir-
SECONDS OR BEFORE POWER RELAY ing Repairs in
SHUTS DOWN) Engine Elec-
trical.
355
 Key OFF
shorted circuit
as necessary.
5 Refer to Wir-
ing Repairs in

Repair the
shorted circuit
continuity on the EGO connector CN11 be-
as necessary.
tween signal circuit 121 and ground circuit Go to Step
6 Refer to Wir-
120 (7)
ing Repairs in
Engine Elec-
continuity on the EGO 1 heater control circuit
Repair the
162 between EGO 1 connector CN11 and Go to Step
7 open EGO
ECM connector CN1 (8)
heater ground
Go to Step
8 -
(9)
es, etc.
ECM.
Go to OBD
operating temperature System
9 System OK
codes.

codes?
356
357
DTC 1162-Adaptive Learn Low LPG

 Fault Condition-Adaptive multiplier out of range greater than-30%
 MIL-On
Circuit Description
The EGO1 sensor is used to determine if the fuel flow to the engine is correct by measuring the
oxygen content in the exhaust gas. The ECM uses this information to correct the fuel flow with
the Closed Loop multiplier and Adaptive multiplier. This fault will set if the adaptive multiplier
exceeds the limits of normal operation. Always run the fuel system diagnostics before using
the following diagnostic chart.
Diagnostic Aid
Fuel System High Secondary fuel pressure will cause the system to run rich. A worn fuel mix-
er, faulty EPR (Electronic Pressure Regulator) may also cause the system to run rich.
Fuel Quality A drastic variation in fuel quality (very high butane content) may cause the fuel
system to run rich. Be sure that the specified HD-5 or HD-10 motor fuel grade propane is
used.
Air Filter A plugged, damaged or modified air filter may cause the system to run rich.
358
DTC 1162-Adaptive Learn Low LPG
1
(3) (2)

stricted
 The EGO sensor is installed securely and the Go to Step Go to Step
2
wire leads not damaged or contacting the (6) (4)
 Fuel system diagnostic checks
Was a repair made?

3
(6) (4)
nosed and repaired?
 Key OFF
tor CN11 Repair the
circuit as ne-
cessary.
Go to Step
 Using a DVOM check for voltage at EGO 1 (5)
ing Repairs in
connector signal circuit 121 and engine Engine Elec-
ground trical.

Go to Step
5 -
(6)
359
es, etc.
ECM.
Go to OBD
6 System OK System
codes.

codes?
360
361
DTC 1165-Catalyst Monitor Test

 Fault condition-Catalyst monitor test failed
Circuit Description
The catalyst monitor test is run under certain operating conditions to determine if the catalyst is
functioning correctly. If the test is failed the fault will set letting the operator know the catalyst
is not functioning as intended. Closed loop operation and adaptive learn capabilities are dis-
abled upon activation of this fault.
362
DTC 1165-Catalyst Monitor Test
Diagnostic Aid
 Inspect the exhaust system for visual signs of damage, leaks, or modification and
repair if necessary.
 Insure the pre catalyst and post catalyst oxygen sensors are mounted correctly and
wiring is not damaged, melted, or corroded and repair if necessary.
 If none of the above problems are found replace the catalyst.
363
DTC 1171-EPR Pressure Higher Than Expected
 EPR delivery pressure

 Check condition-Engine running or cranking
 Fault condition-EPR actual pressure greater than 1.0 inches above commanded pressure
 Adaptive disabled
Circuit Description
The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is
able to pass to the fuel mixer. Pressure readings are sent over the CAN to the ECM and in re-
turn the ECM sends back a control signal to the EPR to increase or decrease pressure for
precise mixture control. This code will set in the event the actual pressure is 1.0 inches water
pressure higher than the actual commanded pressure. Adaptive learn is disabled and the MIL
command is ON during this fault.
Diagnostic Aid
Always run the fuel system diagnostic pressure check before proceeding with the following di-
agnostic chart. High secondary fuel pressure due to a worn or damaged primary or secondary
seat may cause this fault to set
364
DTC 1171-EPR Pressure Higher Than Expected
Go to OBD
1
tion
Did you run the fuel pressure diagnostic test in
2 the fuel system diagnostic section with no prob-
(4) (3)
lems found?
 Run the EPR pressure test in the fuel system Follow the
diagnostic section EPR service
Go to Step recommenda-
3
(4) tions from the
Did the EPR pass the fuel pressure test specifi- fuel pressure
cations?
test chart.
 Inspect the EPR electrical connector pins Repair the
C018 for damage, corrosion or contamina- circuit as ne-
tion. cessary. Go to Step
4
Refer to wire (5)
harness re-
Did you find a problem? pair section.
 Replace or repair the EPR
Go to Step
5
(6)
es, etc.
the ECM.
Go to OBD
6 System OK System
codes.

codes?
365
DTC 1172-EPR Pressure Lower Than Expected
 EPR delivery pressure

 Fault condition-EPR actual pressure less than 1.0 inches below commanded pressure
Circuit Description
precise mixture control. This code will set in the event the actual pressure is 1.0 inches water
pressure lower than the actual commanded pressure. Adaptive is disabled and the MIL com-
mand is ON during this fault.
Diagnostic Aid
Always run the fuel system diagnostic pressure check before proceeding with the following di-
agnostic chart. Low secondary fuel pressure due to a fuel restriction or faulty regulator may
cause this fault.
366
DTC 1172-EPR Pressure Lower Than Expected
Go to OBD
1
tion
Did you run the fuel pressure diagnostic test in
Go to Step
2 the fuel system diagnostic section with no prob- Go to Step 3
(4)
lems found?
Follow the
 Run the EPR pressure test in the fuel system
EPR service
diagnostic section
Go to Step recommenda-
3
(4) tions from the
Did the EPR pass the fuel pressure test specifi-
fuel pressure
cations?
test chart.
Repair the
 Inspect the EPR electrical connector CN15 circuit as ne-
for damage, corrosion or contamination. cessary. Go to Step
4
Refer to wire (5)
Did you find a problem? harness re-
pair section.
 Replace or repair the EPR
Go to Step
5
(6)
es, etc.
the ECM.
Go to OBD
6 System OK System
codes.

codes?
367
DTC1173-EPR Communication Lost
 EPR CAN communication

 Fault condition-No packets received within 500 ms
Circuit Description
precise mixture control. This code will set in the event communication with the ECM is lost.
The MIL command is on.
368
DTC 1173-EPR Communication Lost
Go to OBD
1 -
tion
 Key ON Intermittent
 DST (Diagnostic Scan Tool) connected in problem. Go
the system data mode to Intermittent
 Clear DTC1173 Go to Step Problem sec-
2
 Key OFF (3) tion in the
 Key ON, and attempt to start the engine electrical sec-
tion of this
Does DTC1173 re-set? manual.
 Key OFF
 Disconnect EPR electrical connector CN15
 Key ON
 Using a DVOM check for system power be-
tween EPR connector circuit 217 and engine
ground System bat- Go to Step Go to Step
3
tery voltage (7) (4)
(Be sure to activate relay control ON using the
DST function or check before ECM relay control
times out)
Do you have power?

 Check the fuses
4
(5) (6)
Is the fuse open?
 Replace damaged fuse
Go to Step
5 _
(17)
 Using a DVOM check for system power at Repair the
power relay terminal 3 open circuit Repair the
between power relay
(Be sure to activate relay control ON using the System bat- power relay circuit as re-
6
DST function or check before ECM relay control tery voltage pin 3 and quired
times out) EPR pin 7 Go to Step
Go to Step (17)
Do you have power? (17)
Repair the
open ground
circuit as ne-
EPR connector circuit 181 and engine
Go to Step cessary.
7 ground
(8) Refer to wir-
ing repairs in
Do you have continuity? engine elec-
trical
369
 Key OFF
 Disconnect the EPR connector CN15 Repair the
open circuit
as necessary.
8 Refer to wir-
CAN-circuit 115 between EPR connector (9)
ing repairs in
CN15 and ECM connector CN1 engine elec-
trical
Repair the
 Using a DVOM check for continuity on the open circuit
CAN+ circuit 114 between EPR connector as necessary.
Go to Step
9 CN15 and ECM connector CN1 Refer to wir-
(10)
ing repairs in
trical
Repair the
EPR CAN termination circuit 312 and circuit as necessary.
Go to Step
10 114 on the EPR connector Refer to wir-
(11)
ing repairs in
trical
Repair the
EPR ground circuit 181 between EPR con- as necessary.
Go to Step
11 nector CN15 and ECM connector CN1 Refer to wir-
(12)
ing repairs in
trical
Repair the
EPR ground circuit between EPR connector as necessary.
Go to Step
12 circuit 181 and ECM circuit 169 Refer to wir-
(13)
ing repairs in
trical
Repair the
 Disconnect DST from the DLC connector shorted to
CN7 ground CAN
 Using a DVOM check for continuity between circuit as ne-
Go to Step
13 engine ground and EPR connector circuits cessary.
(14)
114 and 115 Refer to wir-
ing repairs in
trical
 Replace the EPR
Go to Step
14
(15)
370
 Remove all test equipment and reconnect
the DST.
es, etc.
the ECM.
15  Start the engine and operate the vehicle to Go to Step
System OK
full operating temperature (16)
 Observe the MIL
codes.
Does DTC1173 still re-set?

 Replace the ECM
Go to Step
16 _
(17)
es, etc.
the ECM.
codes.

codes?
371
DTC 1174-EPR Supply Voltage High
 EPR supply voltage

 Fault condition-internal EPR supply voltage too high
 Closed loop disabled
Circuit Description
precise mixture control. This code will set if the EPR internal supply voltage is too high.
Diagnostic Aid
This DTC indicates abnormal EPR internal voltages that are not measurable externally. Check
the system charging voltage to be sure this DTC and other over voltage DTC’s are not present.
Repair the charging system if it is found to be out of specification for high charge voltage. In the
event of multiple code sets, always start the diagnostic repair with the lowest numerical value
DTC first.
372
DTC 1174-EPR Voltage Supply High
Go to OBD
1
tion
Mode
Repair the
 Engine running Go to Step
2 charging sys-
 Check the system battery voltage. (3)
tem
Is the charging voltage within specifications?
 Using a DVOM compare the system battery
voltage to the DST display.
3 1 volt
(4) (5)
Is the voltage reading within 1 volt between the
two of them?
 Replace the EPR
Go to Step
4
(6)
 Replace the ECM
Go to Step
5
(6)
es, etc.
the ECM.
Go to OBD
6 System OK System
codes.

codes?
373
DTC 1175-EPR Supply Voltage Low
 EPR supply voltage

 Fault condition-EPR internal supply voltage low
Circuit Description
precise mixture control. This code will set if the internal EPR supply voltage is low. Adaptive is
disabled and the MIL command is ON.
Diagnostic Aid
This DTC indicates abnormal EPR internal voltages that are not measurable externally. Check
the system charging voltage to be sure this DTC and other low voltage DTC’s are not present.
Repair the charging system if it is found to be out of specification for low charge voltage. In the
event of multiple code sets, always start the diagnostic repair with the lowest numerical value
DTC first.
374
DTC 1175-EPR Voltage Supply Low
Go to OBD
1 -
tion
 DST connected and in the system data
mode
Repair the
 Engine running Go to Step
2 charging sys-
 Check the system battery voltage. (3)
tem
Is the charging voltage within specifications?
 Key OFF
 Disconnect the EPR electrical connector
CN15
 Using a DVOM check for power between the
EPR connector circuit 217 and engine
ground.
 Key ON
 Record the voltage reading.
3 (Be sure to activate relay control ON using the (6) (4)
DST function or check before ECM relay control
times out)
 Using a DVOM check the system battery

power at the battery terminals and record the
voltage reading.
Are the recorded voltage readings within 1 volt of

each other?
Correct the
problem as
necessary.
 Inspect the EPR connector and fuses for
See wiring
damage corrosion or contamination Go to Step
4 harness re-
(5)
pair in the
Did you find a problem? electrical sec-
tion of this
manual
Correct the
problem as
 Check the power relay circuit. Check the necessary.
power relay connections for damage corro- See wiring
5 sion or contamination harness
schematic in
Did you find a problem? the electrical
section of this
manual
375
 Key OFF
 Disconnect the ECM connector CN1 Repair the
 Using a DVOM check continuity between the poor EPR
EPR ground circuit 181 at EPR connector power ground
CN15 and ECM connector CN1 circuits 181 circuit. See
Less than Go to Step
6 and 169 wiring har-
0.5 Ohms (7)
ness repair in
(Do not forget to subtract any resistance val- the electrical
ue that may be present in you test cables) section of this
manual
Is the resistance reading less than 0.5 ohms?
 Replace the EPR
Go to Step
7
(8)
es, etc.
the ECM.
Go to Step
8 full operating temperature System OK
(9)
 Observe the MIL
codes.

 Replace the ECM
Go to Step
9
(10)
es, etc.
the ECM.
Go to OBD
10 System OK System
codes.

codes?
376
377
DTC 1176-EPR Internal Actuator Fault
 EPR internal actuator test

 Fault condition-Failed actuator
Circuit Description
precise mixture control. This code will set if the ECM detects an internal actuator fault with the
EPR. In the event of multiple code sets, always start the diagnostic repair with the lowest nu-
merical value DTC first. In most instances the EPR will need to be replaced in the event of this
code set.
378
DTC 1176-EPR Internal Actuator Fault
Go to OBD
1 -
tion
 DST connected and in the system data mode
 Check for any other current or active DTCs Go to Step Go to Step
2
(3) (6)
Does the DST show any other codes set?
 Repair any other DTC’s set starting with the
lowest DTC number first Go to Step
3
(4)
Have the other DTC’s set been corrected?
es, etc.
the ECM.
Go to Step
(5)
 Observe the MIL
codes.

 Replace the EPR
Go to Step
5
(6)
es, etc.
the ECM.
Go to OBD
6 System OK System
codes.

codes?
379
DTC 1177-EPR internal Circuitry Fault
 EPR internal circuitry test

 Fault condition-
Circuit Description
precise mixture control. This code will set if the ECM detects an internal circuitry fault in the
EPR. In the event of multiple code sets, always start the diagnostic repair with the lowest nu-
merical value DTC first. In most instances the EPR will need to be replaced in the event of this
code set.
380
DTC 1177-EPR Internal Circuitry Fault
Go to OBD
1
tion
2
(3) (6)
3
(4)
es, etc.
the ECM.
Go to Step
(5)
 Observe the MIL
codes.

 Replace the EPR
Go to Step
5
(6)
es, etc.
the ECM.
Go to OBD
6 System OK System
codes.

codes?
381
DTC 1178-EPR Internal Communication Error
 EPR internal communication test

 Fault condition-
Circuit Description
precise mixture control. This code will set if the ECM detects an internal communication error in
the EPR. In the event of multiple code sets, always start the diagnostic repair with the lowest
numerical value DTC first. In most instances the EPR will need to be replaced in the event of
this code set.
382
DTC 1178-EPR Internal Communication Error
Go to OBD
1 -
tion
2
(3) (6)
3
(4)
es, etc.
the ECM.
Go to Step
(5)
 Observe the MIL
codes.

 Replace the EPR
Go to Step
5
(6)
es, etc.
the ECM.
Go to OBD
6 System OK System
codes.

codes?
383
DTC 1612-RTI 1 Loss

 Check Condition-Key on
 Fault Condition-Internal microprocessor error
 MIL-On
 Adaptive-Disabled for the remainder of the key-ON cycle
Circuit Description
miting maximum power.
384
DTC 1612-RT 1 Loss
Go to OBD
1
tion
Intermittent
problem
2 Go to Inter-
mittent
section
Repair the
circuit as ne-
Go to Step
3 Refer to Wir-
(4)
Engine Elec-
trical.
 Replace ECM
Go to Step
4
(5)
es, etc.
the ECM.
Go to OBD
5 System OK
codes.

codes?
385
DTC 1613-RTI 2 Loss

 Check Condition- Key on
 Fault Condition- Internal microprocessor error
 MIL- On
 Adaptive- Disabled for the remainder of the key-ON cycle
Circuit Description
will remain on until the code is cleared using the DST. Power Derate level 2 will be enforced
limiting maximum power.
386
DTC 1613-RTI 2 Loss
Go to OBD
1 -
tion
Intermittent
problem
2 Go to Inter-
mittent
section
Repair the
circuit as ne-
Go to Step
3 Refer to Wir-
(4)
Engine Elec-
trical.
 Replace ECM
Go to Step
4
(5)
es, etc.
the ECM.
Go to OBD
5 System OK
codes.

codes?
387
DTC 1614-RTI 3 Loss

 MIL-On
Circuit Description
388
DTC 1614-RTI 3 Loss
Go to OBD
1 -
tion
Intermittent
problem
2 Go to Inter-
mittent
section
Repair the
circuit as ne-
Go to Step
3 Refer to Wir-
(4)
Engine Elec-
trical.
 Replace ECM
Go to Step
4 -
(5)
es, etc.
the ECM.
Go to OBD
5 System OK
codes.

codes?
389
DTC 1615-A/D Loss

 MIL-On
Circuit Description
390
DTC 1615-A/D Loss
Go to OBD
1 -
tion
Intermittent
problem
2 Go to Inter-
mittent
section
Repair the
circuit as ne-
Go to Step
3 Refer to Wir-
(4)
Engine Elec-
trical.
 Replace ECM
Go to Step
4 -
(5)
es, etc.
the ECM.
Go to OBD
5 System OK
codes.

codes?
391
DTC 1616-Invalid Interrupt

 MIL-On
Circuit Description
392
DTC 1616-Invalid Interrupt
Go to OBD
1 -
tion
Intermittent
problem
2 Go to Inter-
mittent
section
Repair the
circuit as ne-
Go to Step
3 Refer to Wir-
(4)
Engine Elec-
trical.
 Replace ECM
Go to Step
4 -
(5)
es, etc.
the ECM.
Go to OBD
5 System OK
codes.

codes?
393
DTC 1628-CAN Address Conflict
 CAN Rx
 Fault Condition- 5 or more address conflict errors
 MIL-ON
Circuit description
The CAN bus (controller area network) is used by the ECM to communicate with other digital
devices used throughout the fuel system. Information is sent over the CAN bus in digital infor-
mation “packets” that contain information for various control functions. Individual devices are
assigned network addresses. This fault will set if the ECM detects an address conflict, such as
two devices with the same address. This is usually not due to an infield failure and may be the
results of “add on” CAN devices
394
DTC 1628-CAN Address Conflict
Go to OBD
1 -
tion
System Data Mode problem
Go to Step
2 Go to Inter-
mittent
section
Does DTC1628 reset with the engine idling?
 Key OFF Contact the
 Disconnect one CAN device Repeat Step CAN device
 Clear DTC 1628 3 until all manufacturer
 Key ON (start engine if possible if not contin- CAN devices for additional
3
ue cranking for at least 3 seconds) have been CAN address
 Wait 5 seconds disconnected information
one at a time Go to Step
Does DTC 1628 re-set (4)
Has the CAN device been replaced or address Go to Step
4
conflict resolved? (5)
es, etc.
the ECM.
5 System OK System
codes.

codes?
395
DTC 2111-Unable To Reach Lower TPS

# C o lo r
180 L DBW +
4 80
M o to r
182 Br DBW -
1 82
6 47
2 20
5 48
119 R /W 5 V o lts
3 19
 Throttle Position Sensor

 Fault Condition-Actual throttle position is 20% greater than the throttle command
 Engine shutdown
Circuit Description
the ECM to determine if the throttle is opening as commanded. This fault will set if the actual
throttle position is 20% greater than the throttle command. During this active fault the MIL
command is ON and the engine will shutdown.
396
DTC 2111-Unable To Reach Lower TPS
Go to OBD
1 - System Check
Check? (2)
Section
Intermittent
data stream mode
Go to Step problem
2  Depress Foot Pedal until the Throttle Com- (3) Go to Intermit-
mand is between 63%-68% tent section
Is the TPS 1 voltage greater than 2.0 volts?
 Key OFF
 Probe TPS 1 signal circuit 147 with a test
light connected to battery voltage Go to Step
3 Go to Step (4)
 Key ON (6)

volts
 Key OFF
CN1 circuit as ne-
 Key ON cessary.
throttle connector TPS 1 signal circuit 147 ing Repairs in
and engine ground Engine Elec-
trical.
 Replace ECM
Go to Step
5
(13)
 Back probe sensor ground circuit 120 at
ECM connector CN1 with a test light con-
Go to Step
6 nected to battery voltage Go to Step (7)
(9)
 Key OFF
Repair the
circuit as ne-
CN1
cessary. Refer
to Wiring Re-
throttle connector signal ground circuit 120 (8)
pairs in
and ECM connector signal ground circuit 120 Engine Elec-
trical.
 Replace ECM
Go to Step
8
(13)
397
 Check throttle for foreign object in bore
9
(10) (11)
Did you find a foreign object in the bore?
 Remove foreign object
Go to Step
10 -
(13)
Is the removal complete?
Repair the
 Inspect the throttle wire harness connector circuit as ne-
terminals for damage, corrosion or contami- cessary.
Go to Step
11 nation Refer to Wir-
(12)
ing Repairs in
Did you find the problem? Engine Elec-
trical.
 Replace throttle
Go to Step
12 -
(13)
es, etc.
the ECM.
13 System OK
codes.

codes?
398
399
DTC 2112-Unable To Reach Higher TPS

# C o lo r
180 L DBW +
4 80
M o to r
182 Br DBW -
1 82
6 47
2 20
5 48
119 R /W 5 V o lts
3 19

 Fault Condition- Actual throttle position is 20% less than the throttle command
 Engine shutdown
Circuit Description
the ECM to determine if the throttle is opening as commanded. This fault will set if the actual
throttle position is 20% less than the throttle command. The MIL command is ON and the en-
gine will shutdown.
400
DTC 2112-Unable To Reach Higher TPS
Go to OBD
1 - System Check
Check? (2)
Section
Intermittent
DBW data stream mode
Go to Step problem
2  Depress foot pedal until the throttle com- (3) Go to Intermit-
mand is 63%-68%
tent section
Is the TPS voltage less than 2.0 volts?
 Key OFF
 Probe TPS 1 signal circuit 147 with test light
Go to Step
3 connected to battery voltage Go to Step (8)
(4)
 Key ON
Is TPS voltage 4.0 volts or greater?

 Check throttle bore for foreign object
Go to Step
4 Go to Step (6)
(5)
 Remove the foreign object
Go to Step
5
(11)
Has the object been removed?
Repair the
 Check the electronic throttle connector ter- circuit as ne-
minals for damage corrosion or cessary.
ing Repairs in
trical.
Go to Step
7
(11)
 Key OFF
Repair the
circuit as ne-
CN1
cessary. Refer
8 to Wiring Re-
TPS 1 signal circuit between throttle connec- (9)
pairs in
tor CN3 and ECM connector CN1 Engine Elec-
trical.
401
Repair the
shorted to
ground circuit
throttle connector TPS 1 signal circuit 147
as necessary. Go to Step
9 and engine ground
Refer to Wir- (10)
ing Repairs in
trical.
 Replace ECM
Go to Step
10
(11)
es, etc.
the ECM.
11 System OK
codes.

codes?
402
403
DTC 2115-FPP1 Higher Than IVS Limit
 Foot Pedal Position

 Fault Condition-FPP 1 sensor voltage greater than 1.0 volt and IVS at-idle
 MIL-On during active
 Power derate level 2
Circuit Description
The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on
pedal position. This fault will set if the FPP 1 voltage is greater than 1.0 volt and the IVS indi-
cates an at-idle condition. The two conditions conflict indicating a fault in the FPP or IVS
circuits. The MIL command is ON and power derate 2 is in effect during this code set limiting
full power output.
Diagnostic Aid
FPP sensors are OEM specific and vary in configuration. The exact wire color and pin num-
bers for the FPP connection must be verified in the OEM chassis wiring schematic. The FPP
sensor used in this system provides an FPP signal and an IVS (Idle validation) sensor in one
packaged assembly. FPP and IVS are not serviceable individually, and in the event of a failure
the complete foot pedal sensor assembly must be replaced.
404
DTC 2115-FPP 1 Higher Than IVS Limit
Go to OBD
1 -
tion
System Data Mode
Greater than Go to Step Go to Step
2
1.00 volt (4) (3)
Does the DST display FPP 1 voltage greater
than 1.00 volts with the foot pedal in the idle po-
sition?
Intermittent
 Depress the foot pedal about half way
problem
Less than Go to Step
3 Go to Inter-
Does IVS voltage drop below 1.0 volt with the 1.00 volt (5)
mittent
foot pedal depressed? section
 Disconnect the System Interface connector
CN21 Repair circuit
 Check for continuity between circuits 153 as necessary.
Go to Step
4 and 119 at the system interface connector See wiring
(6)
CN21 harness re-
pair section.
CN21 Repair circuit
Go to Step
(6)
CN21 harness re-
pair section.
 Check for continuity on the sensor ground Repair circuit
circuit 120 between the system interface as necessary.
Go to Step
6 connector CN21 and the ECM connector See wiring
(7)
CN1 harness re-
pair section.
Do you have continuity on the circuit?
 Inspect the FPP/IVS connector, the ECM
Repair circuit
connector CN1, and the system interface
as necessary.
connector CN21 for damage, corrosion, or Go to Step
7 See wiring
contamination. (8)
harness re-
pair section.
Any damage found?
 Replace FPP/IVS sensor
Go to Step
8 -
(10)
405
 Replace ECM
Go to Step
9 -
(11)
es, etc.
the ECM.
10 System OK
codes.

codes?
es, etc.
the ECM.
Go to OBD
11 System OK System
codes.

codes?
406
407
DTC 2122-FPP 1 High Voltage

 Fault Condition-FPP1 sensor voltage exceeds 4.00 volts
 Low rev limit
 Force idle
Circuit Description
pedal position. This fault will set if the FPP 1 voltage exceeds 4.00 volts at any operating con-
dition while the key is on. If the voltage exceeds 4.00 volts the FPP is considered to be out of
specification. The MIL command is ON. Forced idle and low rev limit will be in effect during this
code set limiting full power output.
Diagnostic Aid
408
DTC 2122-FPP 1 Voltage High
Go to OBD
1 -
tion
System Data Mode Greater than Go to Step Go to Step
2
4.00 volts (3) (3)
Does the DST display FPP voltage of 4.00 volts
or greater with the foot pedal in the idle position?
Intermittent
 Slowly increase FPP while observing FPP 1
problem
voltage Go to Step
3 Go to Inter-
(4)
mittent
Does DST FPP voltage ever exceed 4.00 volts? section
 Disconnect the FPP sensor connector
4
Does the DST now show FPP 1 voltage below or less (5) (6)
0.200 volts?
 Replace FPP sensor
Go to Step
5 -
(10)
 Key OFF
 Disconnect system interface connector CN21 Repair the
 Using a DVOM check continuity between Go to Step open ground
6
connector CN circuit 120 and ECM connector (7) circuit as re-
CN1 circuit 120 quired

 Key ON
the System Interface connector CN21 circuit signal shorted Go to Step
7 No voltage
153 and engine ground to voltage cir- (8)
cuit
Repair the
 Inspect ECM and FPP connectors for dam-
circuit as re-
age corrosion or contamination Go to Step
8 quired. See
(9)
wire harness
Did you find a problem? repair section
 Replace ECM
Go to Step
9 -
(10)
409
es, etc.
the ECM.
Go to OBD
10 System OK System
codes.

codes?
410
411
DTC 2123-FPP 1 Low Voltage

 Fault Condition-FPP sensor voltage less than 0.300
 Low rev limit
 Force idle
Circuit Description
pedal position. This fault will set if the FPP 1 voltage is less than 0.300 volts at any operating
condition while the key is on. If the voltage drops below 0.300 volts the FPP is considered to
be out of specification. The MIL command is ON. Forced idle and low rev limit will be in effect
during this code set limiting full power output.
Diagnostic Aid
412
DTC 2123-FPP 1 Low Voltage
Go to OBD
1 -
tion
System Data Mode
2
or less (3) (3)
Does the DST display FPP 1 voltage of 0.300
volts or less with the foot pedal in the idle posi-
tion?
 Slowly increase FPP while observing the Intermittent
FPP 1 voltage problem
Go to Step
3 Go to Inter-
(4)
Does the DST ever display FPP voltage below mittent
0.300 volts? section
CN21
 Jump the FPP 1 circuit 153 and 5 volt refer-
Greater than Go to Step Go to Step
4 ence circuit 119
0.300 volts (5) (7)
Does the DST now show FPP 1 voltage above
0.300 volts?
Repair the
 Inspect FPP 1 and CN21 connectors for circuit as re-
damage corrosion or contamination quired. See Go to Step
5
wiring har- (6)
Did you find a problem? ness repair
section
 Replace FPP 1 sensor
Go to Step
6 -
(12)
 Key OFF
 Using a DVOM check for continuity on the 5 open circuit
volt reference circuit 119 between system in- Go to Step as required.
7
terface connector CN21 and ECM connector (8) See wiring
CN1 harness re-
pair section
Repair the
 Using a DVOM check for continuity of the
open circuit
FPP1 circuit 153 between ECM connector
Go to Step as required.
8 CN1 and system interface connector CN21
(9) See wiring
harness re-
Do you have continuity? pair section
413
Repair the
 Key ON signal shorted
to ground cir-
cuit as Go to Step
9 ECM connector circuit153 and engine ground
required. See (10)
wiring har-
Do you have continuity? ness repair
section
Repair the
 Inspect system interface and ECM connec- circuit as re-
tors for damage corrosion or contamination quired. See Go to Step
10
wiring har- (11)
Did you find a problem? ness repair
section
 Replace ECM
11 Go to Step 12 -
es, etc.
the ECM.
Go to OBD
12 System OK System
codes.

codes?
414
415
DTC 2135-TPS 1/2 Voltages Out Of Range

# C o lo r
180 L DBW +
4 80
M o to r
182 Br DBW -
1 82
6 47
2 20
5 48
119 R /W 5 V o lts
3 19

 Fault Condition- TPS 1 and TPS 2 signals simultaneously out of range
 Engine shutdown
Circuit Description
the ECM to determine if the throttle is opening as commanded. This fault will set if the TPS 1
and TPS 2 signal voltages are simultaneously out of operational voltage ranges. The MIL
command is ON and the engine will shutdown.
416
DTC 2135-TPS 1/2 Out Of Range
Go to OBD
1 - System Check
Check? (2)
Section
Intermittent
DBW (Drive By Wire) test mode
Go to Step problem
2  Depress foot pedal until the throttle com- (3) Go to Intermit-
mand is 63%-68%
tent section
Is the TPS voltage less than 2.0 volts?
 Key OFF Repair circuit
 Disconnect electronic throttle connector CN3 119 as neces-
 Key ON sary. Refer to
Greater than Go to Step
3  Using a DVOM check the voltage between Wiring Re-
4.5 volts (4)
circuit 119 and engine ground pairs in
Engine Elec-
Is the voltage greater than 4.5 volts? trical.
Repair circuit
 Using a DVOM check the voltage between 120 as neces-
circuit 119 and circuit 120 at the throttle con- sary. Refer to
Greater than Go to Step
4 nector CN3 Wiring Re-
4.5 volts (5)
pairs in
Is the voltage greater than 4.5 volts? Engine Elec-
trical.
Repair circuit
147 as neces-
 Using a DVOM check continuity on circuit sary. Refer to
Go to Step
5 147 between connector CN1 and CN3 Wiring Re-
(6)
pairs in
trical.
Repair circuit
 Using a DVOM check continuity on circuit 148 as neces-
148 between connector CN1 and CN3 Go to Step sary. Refer to
6 Wiring Re-
(7)
Do you have continuity? pairs in
Engine Elec-
trical.
417
Repair circuit
 Using a DVOM check continuity on circuit 120 as neces-
120 between connector CN1 and CN3 Go to Step sary. Refer to
7 Wiring Re-
(8)
Do you have continuity? pairs in
Engine Elec-
trical.
Go to Step
8
(9)
es, etc.
the ECM.
9 System OK
codes.

codes?
 Replace ECM
Go to Step
10
(11)
es, etc.
the ECM.
11 System OK
codes.

codes?
418
419
DTC 2139-FPP 1 Lower Than IVS Limit

 Fault Condition-FPP 1 voltage less than 0.850 volts and IVS off-idle
 Power derate
Circuit Description
pedal position. This fault will set if the FPP 1 voltage is less than 0.850 volts and the IVS indi-
cates an off-idle state. The two conditions conflict indicating a fault in the FPP or IVS circuit.
The MIL command is ON and power derate level two are in effect during this code set limiting
full power output.
Diagnostic Aid
420
DTC 2139-FPP 1 Lower Than IVS Limit
Go to OBD
1 -
tion
System Data Mode Greater than Go to Step Go to Step
2
1.00 volt (5) (3)
Does the DST display IVS voltage less than 1.00
volts with the foot pedal in the idle position?
 Observe the FPP and IVS voltages
FPP less Intermittent
 Stroke the pedal while observing the voltage
than 0.85 problem
readings Go to Step
3 volts AND Go to Inter-
(4)
IVS less mittent
Does FPP voltage drop below 0.85 volts at any than 1.0 volt section
time while the IVS reads less than 1.0 volt?
CN21 Repair circuit
Go to Step
(6)
CN21 harness re-
pair section.
CN21 Repair circuit
Go to Step
(6)
CN21 harness re-
pair section.
 Check for continuity on the sensor ground Repair circuit
circuit 120 between the system interface as necessary.
Go to Step
6 connector CN21 and the ECM connector See wiring
(7)
CN1 harness re-
pair section.
Do you have continuity on the circuit?
 Inspect the FPP/IVS connector, the ECM
Repair circuit
connector CN1, and the system interface
as necessary.
connector CN21 for damage, corrosion, or Go to Step
7 See wiring
contamination. (8)
harness re-
pair section.
Any damage found?
421
 Replace FPP/IVS sensor

Go to Step
8 -
(10)
 Replace ECM
Go to Step
9 -
(11)
es, etc.
the ECM.
10 System OK
codes.

codes?
es, etc.
the ECM.
Go to OBD
11 System OK System
codes.

codes?
422
423
DTC 2229-BP High Pressure
 Barometric Pressure
 Fault Condition-BP greater than 16 psia
Circuit Description
The BP (Barometric Pressure) is estimated from the TMAP sensor. The barometric pressure
value is used for fuel and airflow calculations. This fault sets in the event the BP value is out of
the normal range.
424
DTC 2229-BP High Pressure
Go to OBD
1 -
tion
 Key On
Intermittent
problem
2  System Data Mode Go to Step
(3) Go to Inter-
mittent
Does DST display MAP pressure of 16 psia or section
greater?
3 Replace TMAP sensor. Is the repair complete? Go to Step 4 -
es, etc.
the ECM.
4 System OK System
codes.

codes?
425
DTC 2300-Primary Loop Open/Low Side Short to Ground
 Ignition Control Check

 Fault condition-Adaptive dwell greater than 2.0ms or total dwell greater than 14.0ms
Circuit Description
The ECM triggers ignition by providing ground to the ignition circuit 101. This code will set if
the ECM low side driver circuit 101 is open or shorted to ground.
426
Go to OBD
1
tion
 Key ON, Engine OFF Intermittent
 DST (Diagnostic Scan Tool) connected in problem. See
System Data Mode Electrical
Go to Step
2  Clear DTC-2300 Section In-
(3)
 Crank the engine termittent
Electrical Di-
Does DTC-2300 re-set? agnosis
 Remove and check the ignition fuse
3
(5) (4)
Is the fuse OK?
 Replace the ignition fuse
Go to Step
4
(12)
 Key ON
 Using a DVOM check for voltage at the igni-
tion fuse terminal circuit 927 Repair the
open power
Go to Step
5 circuit. See
(CHECK THIS BEFORE THE POWER RELAY (6)
wiring har-
CIRCUIT SHUTS DOWN)
ness repairs
 Key OFF
 Disconnect the ignition module connector
CN6 Repair the
open power
 Using a DVOM check for voltage between Go to Step
6 circuit. See
ignition module connector circuit 812 and (7)
wiring har-
engine ground
ness repairs
CN1
Repair the
shorted to Go To Step
7 coil control circuit 101 between ECM connec-
ground coil 1 (8)
tor CN1 and engine ground
circuit
coil control circuit 101 between ECM connec- open ignition
tor CN1 and ignition module connector CN6 Go to Step module cir-
8
(9) cuit. See
wiring har-
Do you have continuity? ness repairs.
427
 Replace the ignition module
Go to Step
9
(10)
es, etc.
the ECM.
10 System OK
(11)
 Observe the MIL
codes.
codes?
 Replace the ECM
Go to Step
11
(12)
es, etc.
the ECM.
12 System OK
system check
 Observe the MIL
codes.
codes?
428
429
DTC 2301-Primary Coil Shorted to Voltage

 Fault condition-Adaptive dwell less than-2.0ms or total dwell less than 4.0ms
Circuit Description
The ECM triggers the ignition coil 1 ignition by providing ground to the ignition connector circuit
101. This code will set if the ECM low side driver circuit 101 remains high or is shorted to vol-
tage.
430
Go to OBD
1
tion
Go to Step Intermittent
2  Clear DTC-2301
(3) problems in
 Crank the engine
the electrical
section.
Does DTC-2301 re-set?
 Key OFF
 Disconnect ignition module connector CN6 Repair the
 Using a DVOM check for voltage between shorted to Go to Step
3
ignition module connector CN6 circuit 101 voltage coil 1 (4)
and engine ground circuit

Go to Step
4
(6)
431
es, etc.
the ECM.
5 System OK
codes.

codes?
 Replace the ECM
Go to Step
6
(7)
es, etc.
the ECM.
7 System OK
codes.

codes?
432
433

Circuit Description
434
Go to OBD
1
tion
Go to Step
(3)
Electrical Di-
3
(5) (4)
Is the fuse OK?
Go to Step
4
(12)
 Key ON
Repair the
tion fuse terminal circuit 927
open power
Go to Step
5 circuit. See
wiring har-
CIRCUIT SHUTS DOWN)
ness repairs
 Key OFF
Repair the
CN6
open power
6  Using a DVOM check for voltage between Go to Step
circuit. See
wiring har-
engine ground ness repairs
CN1
Repair the
ground coil 1 (8)
circuit
Repair the
open ignition
coil control circuit 102 between ECM connec-
Go to Step module circuit
8 tor CN1 and ignition module connector CN6
(9) . See wiring
harness re-
pairs.
Go to Step
9
(10)
435
es, etc.
the ECM.
Go to Step
10 System OK
(11)
 Observe the MIL
codes.

codes?
 Replace the ECM
Go to Step
11
(12)
es, etc.
the ECM.
Go to OBD
12 System OK
system check
 Observe the MIL
codes.

codes?
436
437

Circuit Description
tage.
438
Go to OBD
1
tion
(3) problems in
the electrical
section.
 Key OFF
3

Go to Step
4
(6)
439
es, etc.
the ECM.
5 System OK
codes.

codes?
 Replace the ECM
Go to Step
6
(7)
es, etc.
the ECM.
7 System OK
codes.

codes?
440
441

Circuit Description
442
Go to OBD
1
tion
Go to Step
(3)
Electrical Di-
3
(5) (4)
Is the fuse OK?
Go to Step
4
(12)
 Key ON
open power
Go to Step
5 circuit. See
wiring har-
CIRCUIT SHUTS DOWN)
ness repairs
 Key OFF
CN6 Repair the
open power
6 circuit. See
wiring har-
engine ground
ness repairs
CN1
Repair the
ground coil 1 (8)
circuit
8
(9) cuit. See
wiring har-
443
Go to Step
9
(10)
es, etc.
the ECM.
10 System OK
codes.

codes?
 Replace the ECM
Go to Step
11
(12)
es, etc.
the ECM.
12 System OK
codes.

codes?
444
445

Circuit Description
tage.
446
DTC 2307-Primay Coil Shorted to Voltage
Go to OBD
1
tion
(3) problems in
the electrical
section.
 Key OFF
3

Go to Step
4
(6)
447
es, etc.
the ECM.
5 System OK
codes.

codes?
 Replace the ECM
Go to Step
6
(7)
es, etc.
the ECM.
7 System OK
codes.

codes?
448
449

Circuit Description
450
Go to OBD
1
tion
Go to Step
(3)
Electrical Di-
3
(5) (4)
Is the fuse OK?
Go to Step
4
(12)
 Key ON
open power
Go to Step
5 circuit. See
wiring har-
CIRCUIT SHUTS DOWN)
ness repairs
 Key OFF
CN6 Repair the
open power
6 circuit. See
wiring har-
engine ground
ness repairs
CN1
Repair the
ground coil 1 (8)
circuit
8
(9) cuit. See
wiring har-
451
Go to Step
9
(10)
es, etc.
the ECM.
10 System OK
codes.

codes?
 Replace the ECM
Go to Step
11
(12)
es, etc.
the ECM.
12 System OK
codes.

codes?
452
453

Circuit Description
tage.
454
Go to OBD
1
tion
Intermittent
problem. See
System Data Mode
(3) problems in
 Crank the engine the electrical
section.
 Key OFF
3

Go to Step
4
(6)
455
es, etc.
the ECM.
5 System OK
codes.

codes?
 Replace the ECM
Go to Step
6
(7)
es, etc.
the ECM.
7 System OK
codes.

codes?
456
Servicing the Fuel System
457
PROTECTION OF ELECTRICAL COMPONENTS INSTALLATION PROCEDURE
IMPORTANT
The ECM is calibrated for each engine. Verify you
have the correct controller by noting the P/N on the
To prevent permanent damage to the ECM ECM label. The calibration number can also be
and/or other electrical components, follow- found by connecting the DST and finding the calibra-
ing the steps listed below tion number on the Gauge Page.
1. ALWAYS turn ignition to OFF prior to removing 1. Mount controller into mounting bracket with four
the harness and/or the negative or positive screws. Torque to 7.5 Nm (5.5 ft. lbs.)
battery cable. 2. Plug connector into controller.
2. ALWAYS disconnect the negative and positive 3. Push lock into place.
battery cable (Remove the negative cable first) 4. Reconnect the negative battery cable.
when welding on a vehicle. 5. Install Diagnostic Service Tool.
3. NEVER use a charger or voltage supply in 6. Start the vehicle and let run until it reaches nor-
excess of 16 volts. mal operating temperature.
7. If a DTC code is found, refer to the Electrical
I. ENGINE CONTROL MODULE Section for further diagnosis.
This procedure relates to removal and installation II. ENGINE WIRE HARNESS REPLACEMENT
of the ECM--see Diagnostic Scan Tool for access-
ing ECM software. 1. Disconnect negative battery cable.
2. Lay out the new wire harness, noting the loca-
REMOVAL PROCEDURE tion, type of connectors, and identifying
markings. Take special note of identical or simi-
1. Disconnect Negative battery cable. lar connectors (such as the coils or HEGO
2. Push connector lock back to unlock connector, Sensors) to avoid crossing connections during
unplug the Wire Harness from ECM and re- installation. Note the routing of the existing wire
move. harness in and around the engine and the ve-
3. Remove four bolts mounting the controller to hicle. Refer to the Electrical Schematic.
the mounting bracket.
Ensure that all connections are made to the

correct locations on the engine and its com-
ponents. Crossing connections may cause
poor engine performance, a MIL warning
and/or permanent damage to the ECM.
3. Remove all wire harness connectors on the ve-

hicle.
4. Remove all clips and brackets holding the wire
harness and remove harness from vehicle.
5. Lay the new wire harness over the engine and
route each end to its connection. Verify that all
connectors match prior to installation.
6. Connect all connectors and ring terminals.
7. Install all clips and brackets to hold down the
harness.
ECM and its Four Mounting Bolts 8. Reconnect negative battery cable.
458
9. Start the vehicle and let run until it reaches IV. FUEL TEMPERATURE (FT) SENSOR
normal operating temperature. REPLACEMENT (LPG ONLY)
Section for further diagnosis.
III. LPG FUEL SYSTEM PRESSURE RELIEF
Fuel Temperature Sensor

The LPG fuel system operates at pressure
up to 21.5 bar (312 psi). To minimize per-
1. Relieve the LPG fuel system pressure. Refer to
sonal injury, relieve the LPG fuel system
III. LPG Fuel System Pressure Relief on page
pressure before servicing the LPG fuel sys-
459).
tem components.
2. Disconnect the negative battery cable.
3. Locate the Fuel Temperature Sensor on the
1. Close the valve on the LPG tank. EPR port.
2. Start and run the vehicle until the engine stalls 4. Remove retaining clip holding the Fuel Temp
running out of fuel. Sensor and remove the Sensor from the EPR
3. Turn the ignition switch to OFF. port.
5. Remove electrical connector.
6. Inspect the EPR for debris or “heavy ends” and
remove with a Safety Solvent if necessary.
Residual vapor pressure will be present in

the fuel system. Ensure the work area is
well ventilated before disconnecting any
fuel line. Only use a Safety Solvent to clean any part
of the fuel system. Harsh cleaners such as
carb or brake cleaners may damage
gaskets, O-rings, seals and other non-
metallic components in the fuel system.
Never use an open flame of any type to
check for LPG leaks. INSTALLATION
1. Lubricate O-rings on the sensor with petroleum

IMPORTANT
jelly or Vaseline.
Always inspect the LPG fuel system for leaks after
performing service. Check for leaks at the fittings
of the serviced or replaced component. Use a
commercially available liquid leak detector or an
electronic leak detector. When using both me-
thods, use the electronic leak detector first to
avoid contamination by the liquid leak detector
459
Contamination of the HEGO sensor can re-
sult from the use of an inappropriate RTV
sealer or silicone spray products. Do not
use silicone sprays or hoses which are as-
sembled using silicone lubricants. Always
use “oxygen sensor safe” RTV sealant for
repair procedures. Silicon contamination
will cause a high but false HEGO signal vol-
tage (rich exhaust indication). The ECM will
then reduce the amount of fuel delivery to
the engine, causing a severe driveability
problem. If silicone contamination is sus-
pected, remove and visually inspect the Location of the Oil Pressure Switch
sensor element. If contaminated, the portion
of the sensor exposed to the exhaust 3. Remove electrical connection from Oil Pressure
stream will have a white powdery coating. Switch.
Always be sure to eliminate the cause of 4. Unscrew and remove.
contamination before replacing the sensor.
INSTALLATION PROCEDURE
2. Install the sensor into the EPR port. Lock in 1. Apply Loctite 567 (or equivalent high-temp
place with retaining clip. thread locker/sealer) to the threads on the Oil
3. Reconnect electrical connector. Pressure Switch.
4. Reconnect the negative battery cable. 2. Install Oil Pressure Sender. Torque to 9.4-10.8
5. Using the DST, clear DTC information from the ft.lbs (12.7-14.7 Nm)
ECM. 3. Plug in electrical connector.
6. Turn the ignition OFF and wait 30 seconds. 4. Reconnect negative battery cable.
7. Start the vehicle and let run until it reaches 5. Start the vehicle and check for leaks. Let run
normal operating temperature. until it reaches normal operating temperature
8. If a DTC code is found, refer to the Electrical 6. If a DTC code is found, refer to the Electrical
Section for further diagnosis. Section for further diagnosis.
V. OIL PRESSURE SWITCH VI. TEMPERATURE MANIFOLD ABSOLUTE

PRESSURE SENSOR (TMAP)
REMOVAL PROCEDURE
REMOVAL PROCEDURE
2. Locate the Oil Pressure Switch on the side of 1. Disconnect the negative battery cable.
the engine. 2. Locate the TMAP Sensor on the intake manifold.
3. Remove the retaining screw.
4. Remove TMAP Sensor by pulling straight up
with a slight rocking motion.
460
5. Remove the sensor.
1. Apply a minimal amount of Loctite 962T or

equivalent sealer to threads on the Engine Coo-
lant Temperature Sensor. Remove any excess
sealer on the sensor threads.
2. Install Engine Coolant Temperature Sensor.
Torque to 10.8-14.5 ft.lbs. (14.7-19.6 Nm).
3. Refill the cooling system.
4. Reconnect electrical connector.
5. Reconnect the negative battery cable.
TMAP Sensor 6. Start the vehicle and let run until it reaches nor-
mal operating temperature.
INSTALLATION PROCEDURE 7. If a DTC code is found, refer to the Electrical
1. Install the TMAP and torque the retaining
screw to 19 in.lbs. (2.1 Nm). VIII. HEATED EXHAUST GAS OXYGEN SENSOR
2. Reconnect the negative battery cable. (HEGO)
3. Start the vehicle and let run until it reaches
normal operating temperature. REPLACEMENT
Section for further diagnosis. 1. Disconnect Negative battery cable.
2. Locate the affected Oxygen Sensor on the three
VII. ENGINE COOLANT TEMPERATURE way catalytic converter/muffler assembly. There
SENSOR (ECT) are two sensors: one between the engine and
catalytic brick (upstream) and one between the
REMOVAL PROCEDURE catalytic brick and tail pipe (downstream).
3. Disconnect the Oxygen sensor electrical connec-
1. Disconnect the negative battery cable. tor.
2. Locate the Engine Coolant Temperature Sen-
sor on the back of the engine (opposite end of
the fan).
HEGO and Connector
4. Using an Oxygen Sensor socket, remove the

Oxygen Sensor.
IMPORTANT
Before install the Oxygen sensor lubricate threads
with anti-seize compound P/N 5613695 or equiva-
Location of the Water Temperature Sensor lent. Avoid contaminating sensor tip with
compound.
3. Remove electrical connector.
4. Drain the cooling system.
461
1. Install Oxygen Sensor. Torque to 36.2-43.4
ft. lbs. (49.0-58.8 Nm)
2. Reconnect electrical connector to the Oxygen
Sensor.
3. Reconnect the negative battery cable. Contamination of the HEGO sensor can re-
4. Start the vehicle and let run until it reaches sult from the use of an inappropriate RTV
normal operating temperature. sealer or silicone spray products. Do not
5. If a DTC code is found, refer to the Electrical use silicone sprays or hoses which are as-
Section for further diagnosis. sembled using silicone lubricants. Always
IX. MIXER/ADAPTER/THROTTLE BODY & repair procedures. Silicon contamination
RELATED SEALS will cause a high but false HEGO signal vol-
REMOVAL PROCEDURE then reduce the amount of fuel delivery to
1. Disconnect the negative battery cable. problem. If silicone contamination is sus-
2. Relieve the LPG fuel system pressure. Refer to pected, remove and visually inspect the
III. LPG Fuel System Pressure Relief. sensor element. If contaminated, the por-
3. Remove the air intake duct. tion of the sensor exposed to the exhaust
4. Remove the retaining pin holding the fuel hose stream will have a white powdery coating.
fitting and remove fuel hose. Always be sure to eliminate the cause of
2. Place new O-rings on top of the Throttle Body.

3. Place Gasket and Throttle Body on intake adap-
Residual vapor pressure will be present in ter.
the fuel system. Ensure the work area is 4. Place Adapter and Mixer on top of Throttle Body
well ventilated before disconnecting any and align screw holes. Secure with the four re-
fuel line. taining screws and Torque to 80 in.lb. (9 Nm).
5. Install the fuel hose fitting into the Mixer and hold
with the retaining pin.
5. Remove the two hoses on the side of the Mix- 6. Install the air intake duct.
er. 7. Install the two hoses to the 90° fittings on Mixer.
6. Remove electrical connector on Throttle Body 8. Reconnect the negative battery cable.
7. Remove the four screws under the Mixer that 9. Open LPG tank valve.
secure the Mixer, Adapter and Throttle Body. 10. Turn ignition to ON for approximately 30
8. Remove the Mixer and Adapter. seconds, then OFF.
9. Remove Throttle Body. 11. Leak check the LPG fuel system at each ser-
viced fitting.
INSTALLATION PROCEDURE 12. Start the vehicle and leak check the LPG fuel
system at each serviced fitting.
1. Lightly lubricate new O-rings with Vaseline or 13. Test drive vehicle to ensure it operates correctly
petroleum jelly prior to installation. at all throttle ranges. If a DTC code is found, re-
fer to the Electrical Section for further diagnosis.
X. CRANKCASE VENTILATION SYSTEM

INSPECTION/DIAGNOSIS
RESULTS OF INCORRECT OPERATION
A plugged positive crankcase ventilation (PCV) ori-

fice or hose may cause the following conditions:
 Rough or unstable idle

462
 Stalling or low idle speed
 Oil leaks
 Oil in the air cleaner
 Sludge in the engine
A leaking PCV orifice or hose may cause the fol-

lowing problems:
 Rough Idle
 Stalling
 High idle speed Testing the PCV Action
FUNCTIONAL CHECK 4. If the plunger moves irregularly or fails to move,

the PCV is clogged and should be cleaned or
Any blow-by in excess of the system capacity, replaced.
from a badly worn engine, sustained heavy load, 5. Connect the PCV to the vacuum hose, leaving
etc., is exhausted into the air cleaner and is drawn the opposite end open.
back into the engine. 6. Start engine.
Proper operation of the crankcase ventilation sys-

tem depends on a sealed engine. If irregular oil
flow or dilution is noted and the crankcase ventila-
tion system is functioning properly, check the
engine for another possible cause. Correct any of
these problems first.
If an engine is idling rough, inspect for a clogged

PCV orifice, a dirty vent filter, air cleaner element,
or plugged hose. Replace any faulty items found.
Use the following procedure:
Testing the PCV for Vacuum
7. Place your finger over the end of the hose in or-

der to check for vacuum. If there is no vacuum
at the hose end, inspect for plugged hoses
and/or clogged or damaged manifold vacuum
port.
8. Turn the engine OFF.
9. Inspect the PCV orifice in the valve cover for de-
bris or blockage. Clean with carburetor cleaner
as necessary.
10. Reconnect hose to PCV.
The PCV is Located Between Two Hoses, as
11. Start the vehicle and let run until it reaches nor-
Shown Above.
mal operating temperature.
1. Locate the PCV connected to hoses as shown
above.
2. Remove the PCV.
XI. MIXER/ADAPTER/THROTTLE BODY &
3. Insert a thin rod into the PCV against the plun-
RELATED SEALS
ger and gently push.
REMOVAL PROCEDURE

463
2. Relieve the LPG fuel system pressure. Refer IMPORTANT
to III. LPG Fuel System Pressure Relief. Verify that the quad seals rest flat against the neck
3. Remove the air intake duct. of the Throttle Body with no twists.
4. Remove the retaining pin holding the fuel hose
fitting and remove fuel hose. 3. Carefully place the Adapter on top of the Throttle
5. Remove two hoses attached to the sides of the Body, ensuring the seals properly seat and are
Mixer. not twisted or pushed down.
6. Remove the electrical connector to the Throttle 4. Place Mixer on top of the Adapter.
Body. 5. Place gasket on top of Intake Manifold.
7. Remove four screws on Mixer that secure the 6. Align the holes of the Mixer, Adapter, Throttle
Mixer, Adapter and Throttle Body to the Intake Body, Gasket and Intake Manifold and secure
Manifold with four screws. Torque to 106 in. lbs. (12
8. Lift up Mixer and Adapter, noting the place- Nm).
ment of the O-rings on the neck or inlet of the 7. Attach the two hoses to Mixer.
Throttle Body. Three O-rings are used: two 8. Attach the air intake duct from the Mixer.
are quad seals with an “X” cross section and 9. Reconnect negative battery cable.
one has a round cross section. 10. Open LPG tank valve.
9. Remove gasket between Throttle Body and 11. Start the vehicle and let run until it reaches nor-
Intake Manifold. mal operating temperature.
10. Remove O-rings from the Throttle Body neck. 12. If a DTC code is found, refer to the Electrical
XII. FUEL VAPOR HOSE--(EPR) TO FUEL MIXER
1. Lightly lubricate new O-rings with Vaseline or REMOVAL PROCEDURE
petroleum jelly prior to installation.
1. Disconnect negative battery cable.
2. Remove retaining clip from EPR end of hose and
remove hose from EPR port with Port Fitting.
3. Remove retaining clip from Mixer end of hose
and remove hose from Mixer with Port Fitting.
4. Remove Port Fittings from both ends of the
hose.
IMPORTANT
Hoses are designed for specific applications, DO
NOT use hose material or length other than speci-
fied by the OEM.
then reduce the amount of fuel delivery to INSTALLATION PROCEDURE
problem. If silicone contamination is sus- 1. Lightly lubricate Port Fitting O-rings with Vase-
pected, remove and visually inspect the line or petroleum jelly prior to installation.
sensor element. If contaminated, the portion 2. Insert Port Fittings into each end of the hose and
of the sensor exposed to the exhaust secure with hose clamps.
stream will have a white powdery coating.
Always be sure to eliminate the cause of
2. Place the quad seals and third O-ring on the

neck of the Throttle Body, maintaining the
same order as before.
464
11. Replace Plug.
12. Reconnect negative battery cable.
13. Turn ignition to ON for approximately 30
seconds, then OFF.
Contamination of the HEGO sensor can re- 14. Check for leaks.
sealer or silicone spray products. Do not XIV. GASOLINE FUEL PRESSURE CHECK
sembled using silicone lubricants. Always ITK-3 or ITK-4 test kit gauge or J 34730-1A fuel
use “oxygen sensor safe” RTV sealant for pressure gauge or equivalent.
then reduce the amount of fuel delivery to
pected, remove and visually inspect the
of the sensor exposed to the exhaust
Fuel Pressure Gauge
3. Reinstall Port Fittings on both ends of the hose 1. Turn ignition to OFF.
and secure with retaining pins. Make sure 2. Disconnect the negative battery cable.
hose is correctly positioned and not twisted or 3. Refer to the Fuel Injection Pressure Tester
kinked. Owner’s Manual supplied in the IMPCO Test Kit
4. Reconnect negative battery cable. for instructions on relieving gasoline fuel pres-
5. Open valve on the LPG tank. sure for fuel systems without a Schrader valve or
6. Turn Key to the ON position for several test port.
seconds, then turn back to OFF. Using a liquid
or electronic leak detection tool, inspect the
EPR, fuel hoses and all serviced fittings for
leaks.
7. Start the vehicle and check for leaks. Let run
until it reaches normal operating temperature. Systems without test ports require that fuel
8. If a DTC code is found, refer to the Electrical lines be removed or disconnected. Be aware
Section for further diagnosis. that these lines may be UNDER PRESSURE and
when remove could cause fuel to spray and/or
XIII. LPG FUEL SYSTEM PRESSURE CHECK leakage onto hot engine parts.
1. Turn ignition to OFF.
3. Remove plug on EPR listed as “PRIMARY
PRESSURE TEST.”
4. Install Pressure Gauge.
6. Start engine and note value on gauge.
7. Turn engine OFF.
8. Relieve the LPG fuel system pressure. Refer to
III. LPG Fuel System Pressure Relief.
10. Remove Gauge.
465
XVII. ELECTRONIC PRESSURE REGULATOR
(EPR)
REMOVAL PROCEDURE
Remove the fuel tank cap and relieve the fuel
system pressure before servicing the fuel 1. Disconnect the negative battery cable.
system to reduce the risk of personal injury. 2. Relieve the LPG fuel system pressure. Refer to
After you relieve the fuel system pressure, a III. LPG Fuel System Pressure Relief.
small amount of fuel may still be released 3. Disconnect the LPG fuel inlet line from the Shut-
when servicing the fuel lines, the fuel injec- Off Valve fitting.
tion pump, or the connections. Always cover 4. Disconnect the EPR electrical connector.
the fuel system components with a shop to- 5. Disconnect the Shut-Off Valve electrical connec-
wel before disconnecting to absorb any fuel tor.
that may leak out. Dispose of towel in an ap- 6. Clamp both coolant lines near the EPR fittings.
proved container when the procedure is 7. Remove the retaining pins from the water inlet
completed. Follow any additional user rec- and outlet fittings, fuel hose and Temperature
ommendations in the manufacturer Sensor.
instructions for the fuel pressure gauge in 8. Remove coolant inlet and outlet Port Fittings and
use. fuel hose.
9. Remove the three nuts securing the Vibration
mounts to the EPR/ECM mounting bracket.
10. Remove Shutoff valve and fitting and Tempera-
ture Sensor.
11. Remove the three vibration mounts from the
EPR.
Do not drain fuel into an open container.
Never store the fuel in an open container due
to the possibility of a fire and/or explosion.
1. Apply Loctite 567 (or equivalent high-temp
4. Clean any spillage of gas with a shop towel thread locker/sealer) to the threads of the Shut-
and dispose of properly. Off valve 90° fitting. Install the Shut-Off valve fit-
5. Reconnect negative battery cable. ting to the EPR and turn until finger tight plus 1
6. Turn ON the ignition with the engine OFF for 2 to 2 turns, ensuring the Shut-Off Valve is in the
seconds. Inspect for leaks. Turn ON ignition correct clock position.
for 10 seconds and inspect for leaks.
7. Start and run fuel pressure test.
XV. LPG FUEL CONTROL SYSTEM CHECK
1. The fuel system can be thoroughly diagnosed Do not use Teflon tape on any fuel fitting. Use
by use of the DST tool. See section a liquid pipe thread sealant when installing
DIAGNOSTIC SCAN TOOL. threaded fittings.
XVI. LPG FUEL SYSTEM LEAK TEST 2. Connect the EPR electrical connector.
3. Install the fuel inlet line. Torque to 20 ft. lbs.
1. Use a commercially available liquid leak detector (27 Nm).
or an electronic leak detector and follow the 4. Connect the Shut-Off Valve electrical connector.
manufacturer’s instructions. 5. Lubricate the O-rings on each of the port fittings
and Temperature Sensor with petroleum jelly or
IMPORTANT Vaseline.
When using both methods, use the electronic leak
detector first to avoid contamination by the liquid
leak detector
466
Contamination of the HEGO sensor can result
from the use of an inappropriate RTV sealer or
silicone spray products. Do not use silicone
sprays or hoses which are assembled using
silicone lubricants. Always use “oxygen sen-
sor safe” RTV sealant for repair procedures.
Silicon contamination will cause a high but
false HEGO signal voltage (rich exhaust indi-
cation). The ECM will then reduce the amount
of fuel delivery to the engine, causing a severe
driveability problem. If silicone contamination
is suspected, remove and visually inspect the
sensor element. If contaminated, the portion of
the sensor exposed to the exhaust stream will
have a white powdery coating. Always be sure
to eliminate the cause of contamination before
replacing the sensor.
6. Install the inlet and outlet water fittings, Fuel

Hose and Temperature Sensor. Secure with
retaining pins.
7. Remove clamps from coolant hoses.
8. Inspect coolant level and add coolant as ne-
cessary.
9. Reconnect the negative battery cable.
10. Open LPG tank valve.
11. Turn ignition ON for approximately 30
seconds, then OFF.
12. Leak check the LPG fuel system at each ser-
viced fitting.
normal operating temperature. Leak check the
LPG fuel system at each serviced fitting.
15. Test drive vehicle to ensure correct operation.
467
XVIII. ELECTRONIC PRESSURE REGULATOR NOTE
(EPR) The Repair Kit consists of nine parts which are not
available separately. These are the only serviceable
A Repair Kit is available to service and replace the components of the EPR. Any attempt to service
following components in the Spectrum III Electron- other components may damage or cause the EPR to
ic Pressure Regulator (EPR): malfunction, and void warranty coverage.
1. Seal, Clamp Plate

2. Seat, Secondary
3. Gasket, Body Secondary
4. Pin, Primary The Repair Kit consists of the only serviceable
5. Spring, Primary
components for the Spectrum III EPR. Do not
6. Clip, Primary
use any other components or regulator repair
7. Diaphragm, Primary
kits to service the Spectrum III EPR. The Kit is
8. O-ring
specifically designed for the Spectrum III EPR
9. O-ring and is not compatible with other regulators.
Expanded View of the EPR Regulator and the Repair Kit Components.
REPAIR INSTRUCTIONS
5. Inspect the outside of the EPR assembly for

DISASSEMBLY OF EPR cracks, signs of leakage, corrosion, electro-
lysis, damage, stripped threads, etc. If
1. Disconnect negative battery cable. damage is found, the EPR assembly is not
2. Relieve the LPG fuel system pressure. Re- repairable and must be replaced.
fer to III.LPG Fuel System Pressure Relief. 6. Remove the six screws that connect the
3. Disconnect electrical connector from EPR. Regulator to the Actuator.
4. Remove three nuts securing EPR to Mount-
ing Bracket.
468
NOTE 11. Turn the Regulator over and remove the
Be sure to identify the type of screw and its loca- seven screws from the face of the Regulator.
tion during each stage of disassembly to ensure Remove cover.
proper placement during reassembly. 12. Remove the primary diaphragm.
13. Remove the body cover plate and C-clip
7. Gently pull the Regulator away from the Ac- from the primary valve pin.
tuator. If necessary, tap around the edge of 14. Turn the plate over and remove pin and
the face plate with the handle of a plastic spring. Discard pin and keep the spring.
screwdriver to break the regulator free. Note 15. Remove the secondary body gasket.
that the lever from the primary valve slides 16. Inspect the Regulator body and cover plates
into a slot of the secondary diaphragm, re- for debris, deposits or “heavy ends” and re-
quiring the Regulator to be moved sideways move using a Safety Solvent as necessary.
to free the tab from the diaphragm. Remove Ensure all mating surfaces are clean.
and discard Clamp Plate Seal.
Optional:
If leaks are detected or if the replacement of the
O-rings on the Coolant Hose(s), Fuel Tempera-
ture Sensor or the Fuel Vapor Hose is deemed
necessary, the follow the additional steps. Oth-
erwise, continue to Reassembly.
17. Release coolant pressure.

18. Clamp off the two radiator hoses near the
point where they connect to the EPR.
19. Remove Coolant Hoses, Fuel Temperature
Sensor and Fuel Vapor Hose by first remov-
ing Retaining Clips, then pulling each out of
the EPR ports.
20. Remove O-rings from the Temperature Sen-
sor, both Coolant Hose fittings, and the Fuel
Vapor Hose. Clean Temperature Sensor
EPR ports and hose fittings as necessary us-
The two major components of the EPR As-
ing a Safety Solvent.
sembly: Regulator and the Actuator.
Care must be used when removing regula- Use only Safety Solvents for the cleaning
tor from the actuator to prevent damage to of the regulator and its components. Sol-
the lever and diaphragm. Neither part is vents such as carburetor or brake cleaners
serviceable and if damaged, the entire may damage gaskets, seals, O-rings, di-
EPR assembly must be replaced. aphragms or other non-metal components.
8. Place Regulator face down and remove the REASSEMBLY OF EPR

retaining screw holding the secondary lever.
9. Remove secondary lever, fulcrum pin and 1. Inspect all parts to ensure the Repair Kit is
spring. complete and all components are free of de-
10. Inspect lever and fulcrum pin for excessive terioration, cracks, tears, etc.
wear. If the pin diameter is reduced at any 2. Place the new primary valve pin into the
point or if the holes in the lever are irregular cover plate orifice.
(oblong), the EPR assembly is not repairable 3. Holding the valve pin in place, turn the body
and must be replaced. cover plate over. Place the valve pin spring
469
over the valve pin and install C-clip or retain- face. Torque screws to 40 in. lbs. (4.5
ing clip. Nm).
4. Place a new secondary body gasket ensur-
ing the small hole in the gasket is aligned Optional:
with the small hole in the body cover. Place If hoses and O-rings were removed during the
body cover and gasket on the front of Regu- Removal Procedure, then follow the additional
lator body, ensuring the holes in the gasket steps 17-20; otherwise, continue to Step 21.
are aligned with all screw holes.
5. Set new primary diaphragm the face of the 16. Lubricate new O-rings using petroleum jelly
body cover using the screw hole for proper or Vaseline. Mount new O-rings on the
alignment. Temperature Sensor and hose fittings.
6. Place the Regular face over the diaphragm
and hand thread all seven screws through
the face plate and body cover into the Regu-
lator body. Torque the screws to 4.5 Nm
(40 in. lbs.) in a criss-cross pattern.
7. Using side-cutters, cut off the nose of the
soft secondary seat and remove from sec-
ondary lever.
8. Push the nose or button of the new second-
ary seat through the hole of the secondary
lever.
9. Set the secondary spring on its seat on the
back of the Regulator body, then position the
secondary lever and fulcrum pin assembly
on top of the secondary spring. Push down, then reduce the amount of fuel delivery to
compressing the spring until the fulcrum pin
can be slid into place.
10. Insert screw to hold lever and torque to 4.5 pected, remove and visually inspect the
Nm (40 in. lbs.).
11. Verify the secondary lever height by placing of the sensor exposed to the exhaust
a straight edge over the mating surface (rim)
of the Regular body. The distance between
the rim of the Regulator (as determined by a
straight edge) and lever should be 1/32”
(.794mm). If the measurement does not 17. Mount EPR assembly in vehicle and recon-
meet this specification, the EPR cannot be nect electrical connector to EPR.
repaired and must be replaced. 18. Insert Temperature Sensor and hose fittings
12. Place the EPR Actuator facing upward and into EPR and lock each into place using orig-
place the new clamp plate seal into the open inal retaining clips.
end of the Actuator. 19. Remove clamps on coolant hoses. Check
13. Place the Regulator above the Actuator, not- coolant fluid level.
ing the position of the lever tab and slot on 20. Clean Shut-Off Valve fitting, apply LPG com-
the secondary diaphragm. Carefully slide patible pipe thread sealer and install into
the lever tab into the slot of the secondary EPR assembly.
diaphragm and align the Regulator to the Ac-
tuator. Place the Regulator on top the
Actuator, aligning the screw holes.
14. Insert the six screws through the Actuator
holes and into the Regulator. Finger tighten Do not use Teflon tape to seal any LPG fit-
as many screws as possible. tings.
15. Holding the Regulator to the Actuator, turn
the assembly over so that it is resting on its 21. Reconnect negative battery cable.
22. Open valve on the LPG tank.
470
23. Turn Key to the ON position for several XX. SHUT-OFF VALVE REPLACEMENT
seconds, then turn back to OFF. Using a
liquid or electronic leak detection tool, in- REMOVAL PROCEDURE
spect the EPR, fuel hoses and all serviced
fittings for leaks. 1. Disconnect the negative battery cable.
24. Start the vehicle and let run until it reaches 2. Relieve the LPG fuel system pressure. Re-
normal operating temperature. fer to III. LPG Fuel System Pressure Relief.
XIX. EPR COOLANT HOSE REPLACEMENT

The LPG fuel system operates at pressure
REMOVAL PROCEDURE up to 21.5 bar (312 psi). To minimize per-
sonal injury, relieve the LPG fuel system
1. Drain coolant. pressure before servicing the LPG fuel sys-
2. Remove Retaining Pins securing Coolant tem components.
Hose Port Fittings and remove, still attached
to the Coolant Hose.
3. Remove the Coolant Hoses from opposite 3. Disconnect Shut-Off Valve electrical connector
ends, by removing hose clamp. and remove connector from bracket.
4. Disconnect the LPG fuel inlet line from the
Shut-Off Valve fitting.
5. Remove Shut-Off Valve and fitting as an as-
sembly.
6. Remove brass fitting from the Shut-Off
The coolant may be hot. Use caution when Valve.
removing hose(s) to prevent contact.
1. Add pipe thread sealer to male threads on
IMPORTANT the Shut-Off Valve and brass fitting.
Coolant hoses are specifically designed for their 2. Connect brass fitting to Shut-Off Valve.
application. DO NOT use hose material or 3. Connect elbow, Shut-Off Valve and fitting
length other than the OEM specified parts. DO assembly to the EPR.
NOT mix the inlet or outlet hoses when reinstal- 4. Connect electrical connector to the Shut-Off
ling Valve.
5. Connect the LPG fuel inlet line from the
1. Lightly lubricate Port Fitting O-rings with Shut-Off Valve fitting.
Vaseline or petroleum jelly prior to installa- 6. Reconnect negative battery cable.
tion. 7. Open LPG tank valve.
2. Insert Port Fittings into each end of the hose 8. Turn Key to the ON position for several
and secure with hose clamps. seconds, then turn back to OFF. Using a
3. Insert Coolant Hose Port Fittings into the liquid or electronic leak detection tool, in-
EPR and secure with Retaining Pins. spect the EPR, fuel hoses and all serviced
4. Install hose on both ends and secure with fittings for leaks.
hose clamps. Make sure the hoses are in 9. Start engine and check for leaks.
the proper position and are not twisted or
kinked. XXI. EPR/ECM MOUNTING BRACKET
5. Refill with coolant.
6. Start engine and run until operation tempera- REMOVAL PROCEDURE
ture is reached.
7. Let engine cool and check coolant level. 1. Disconnect the negative battery cable.
2. Relieve the LPG fuel system pressure. Re-
fer to III. LPG Fuel System Pressure Relief.
471
3. Remove ECM (Refer to I. Engine Control 4. Remove ECM/Mixer Bracket (Refer to XXII.
Module). EPR/ECM Mounting Bracket).
4. Remove EPR (Refer to XVIII Electronic 5. Remove the TMAP (Refer to VI. Tempera-
Pressure Regulator). ture Manifold Absolute Pressure Sensor).
5. Remove four screws securing the EPR/ECM 6. Remove Coolant Hose support brackets.
bracket to the Intake Manifold. 7. Remove two bolts securing the Manifold to
the bracket.
INSTALLATION PROCEDURE 8. Remove eight bolts securing the Manifold to
the side of the engine and remove.
1. Place EPR/ECM Mounting Bracket on adap- 9. Remove Gasket.
ter. Secure with four screws. Torque to 12
Nm (106 in. lbs.). INSTALLATION PROCEDURE
2. Mount EPR (Refer to XVIII. Electronic Pres-
sure Regulator). 1. Place bolt through Intake Manifold and
3. Mount ECM (Refer to I. Engine Control Mod- Gasket and mount on engine. Torque bolts
ule). to 11.6-16.6 ft.lbs. (15.7-22.6Nm).
4. Reconnect negative battery cable. 2. Install two bolts at bottom of the manifold,
5. Open valve on the LPG tank. securing the manifold to the bracket. Tor-
6. Start the vehicle and let run until it reaches que bolts to 11.6-16.6 ft.lbs. (15.7-
normal operating temperature. 22.6Nm).
7. If a DTC code is found, refer to the Electrical 3. Install TMAP (Refer to VI. Temperature Ma-
Section for further diagnosis. nifold Absolute Pressure Sensor).
4. Install ECM/Mixer Bracket (Refer to XXII.
XXII. INTAKE MANIFOLD EPR/ECM Mounting Bracket.)
5. Install Mixer, Adapter and Throttle Body as-
REMOVAL PROCEDURE sembly (Refer to IX. Mixer/Adapter/Throttle
Body & Related Seals).
6. Install ECM.
normal operating temperature.
XXIII. EXHAUST MANIFOLD
REMOVAL PROCEDURE
1. Remove three bolts securing exhaust mani-

fold cover.
2. Remove HEGO 1 (refer to VIII. Heated Ex-
haust Gas Oxygen Sensor).
3. Remove two screws securing the exhaust
pipe to the exhaust manifold.
4. Remove eight screws securing the exhaust
manifold to the engine block and remove the
Intake Manifold
manifold.
1. Remove ECM (Refer to I. Engine Control
Module).
2. Remove EPR (Refer to XVIII. Electronic
1. Place exhaust manifold against engine block.
Pressure Regulator).
Align holes and thread eight screws into the
3. Remove Mixer, Adapter and Throttle Body
block. Torque to 31.1-39.8ft.lbs. (42.2Nm-
Assembly (Refer to XI. Mixer/Adapter/
53.9).
Throttle Body & Related Seals)
472
2. Install the exhaust manifold cover with three
screws. Torque to 10.8-14.5ft.lbs. (14.7-
19.6Nm).
XXIV. RESTRICTED EXHAUST SYSTEM

DIAGNOSIS
PROCEDURE:
1. Carefully remove the HEGO 2(Refer to VIII.

Heated Exhaust Gas Oxygen Sensor).
2. Install Exhaust Back Pressure Test Gauge
(J35314-A) in place of the HEGO 2.
3. With the engine idling at normal operating
temperature, observe the exhaust system
back pressure reading on the gauge. Read-
ing should not exceed 8.6 kPa (1.25 psi).
4. Increase engine speed to 2000 RPM and
observe gauge. Reading should not exceed
20.7 kPa (3 psi).
5. If the back pressure at either speed exceeds
specification, a restricted exhaust system is 1. Back Pressure Gauge
indicated. 2. Heated Exhaust Gas Oxygen Sensor
6. Inspect the entire exhaust system for a col- (HEGO 1––Sensor between the engine
lapsed pipe, heat distress or possible internal and Catalytic Converter).
catalytic converter failure. 3. Exhaust Pipe/Muffler
7. If there are no obvious reasons for the ex-
cessive back pressure, the catalytic
Exhaust Back Pressure Test
converter is likely damaged and should be
replaced.
XXV. CATALYTIC CONVERTER
8. Check for MIL and clear using the DST.
Catalytic Muffler
REMOVAL PROCEDURE
1. Remove the Catalytic Converter using the

OEM end product processes
473
IMPORTANT
The Catalytic converter is specifically designed
to meet the emission control of the certified en-
gine. Use only the OEM specified part. Install
the Catalytic Converter using the OEM end
product processes.
1. Start engine
2. Check for any DTC codes and clear
3. Verify engine is in closed loop and no MIL
lights are present.
XXVI. VACUUM LINE
REMOVAL PROCEDURE

2. Remove the Vacuum Line from each fitting.
3. Start engine and check for leaks.
IMPORTANT
DO NOT use a hose other than the OEM
specified part.
1. Reinstall the Fuel Vapor Hose to each fitting

3. Start engine and check for leaks.
474
Definitions
475
Air Valve Vacuum (AVV): The vacuum signal tak- CNG: Compressed Natural Gas.
en from below the air valve assembly and above CKP: Crankshaft Position Sensor
the throttle butterfly valve. CMP: Camshaft Position Sensor
ADP: Adaptive Digital Processor. Conductor: A material, normally metallic, that
Air/Fuel Ratio: The amount or balance of air and permits easy passage of electricity.
fuel in the air fuel mixture that enters the engine. Contaminants: Impurities or foreign material
Analog Voltmeter: A meter that uses a mechani- present in fuel.
cal needle to point to a value on a scale of Control Module: One of several informal names
numbers. It is usually of the low impedance type for a solid state microcomputer which monitors
and used to measure voltage and resistance. engine conditions and controls certain engine
Aromatics: Pertaining to or containing the six- functions; i.e. air/fuel ratio, injection and ignition
carbon ring characteristic of the benzene series. time, etc. The formal name and the one used
Found in many petroleum distillates. throughout this manual is ECM, or Engine Control
Backfire: Combustion of the air/fuel mixture in the Module.
intake or exhaust manifolds. A backfire can occur Converter: A LPG fuel system component contain-
if the intake or exhaust valves are open when ing varying stages of fuel pressure regulation
there is a mis-timed ignition spark. combined with a vaporizer.
Benzene: An aromatic (C6H6). Often blended with Cryogen: A refrigerant used to obtain very low
gasoline to improve anti-knock value. Benzene is temperatures.
toxic and suspected of causing cancer. Current: The volume or flow of electrons through a
Bi-Fueled: A vehicle equipped to run on two fuels. conductor. Measured in amperes or amps.
Blow-By: Gases formed by the combustion of fuel DBW: Drive By Wire
and air, which ordinarily should exert pressure Dedicated Fuel System: A motor fuel system de-
only against the piston crown and first compres- signed to operate on only one fuel type.
sion ring. When rings do not seal, these gases Diaphragm: A thin, flexible membrane that sepa-
escape or “blow by” the side of the piston into the rates two chambers. When the pressure in one
crankcase. chamber is lower than in the other chamber, the
BTU: British Thermal Unit. A measurement of the diaphragm will move toward the side with the low
amount of heat required to raise the temperature pressure.
of 1lb. of water 1 degree F. Diaphragm Port: The external port located at the
Butane: An odorless, colorless gas, C4H10 found in fuel inlet assembly and connected to the vacuum
natural gas and petroleum. One of the five LP chamber above the air valve diaphragm.
gases. DLC: Data Link Connector.
CAFE: Corporate Average Fuel Economy. DTC: Diagnostic Trouble Code
CARB: California Air Resources Board. DST: Diagnostic Scan Tool.
Carbon Monoxide (CO): A chemical compound of DVOM: Digital Volt/ohm Meter. A meter that uses a
a highly toxic gas that is both odorless and color- numerical display in place of a gauge and is
less. usually of the high impedance type.
Carburetor: An apparatus for supplying an inter- ECT: Engine Coolant Temperature.
nal-combustion engine a mixture of vaporized fuel ECM: Electronic Control Module
and air. ECOM: A DLC cable supporting CAN and serial
Cathode Ray Tube: A vacuum tube in which ca- communication with a Spectrum II or III ECM.
thode rays usually in the form of a slender beam EFI: Electronic Fuel Injection. A fuel injection sys-
are projected on a fluorescent screen and pro- tem, which uses a microcomputer (ECM) to
duce a luminous spot. determine and control the amount of fuel, re-
Circuit: A path of conductors through which elec- quired by, and injected into, a particular engine.
tricity flows. EGO: Exhaust Gas Oxygen, used to describe a
Closed Loop Operation: Applies to systems utiliz- sensor. Also known as “HEGO” (Heat Exhaust
ing an oxygen sensor. In this mode of operation, Gas Oxygen) sensor, “O2” or “Oxygen sensor.
the system uses oxygen sensor information to de- EGR: Exhaust Gas Recirculation.
termine air/fuel ratio. Adjustments are made EPA: Environmental Protection Agency: A regulat-
accordingly and checked by comparing the new ing agency of the Federal government which,
oxygen sensor to previous signals. No stored in- among other duties, establishes and enforces au-
formation is used. tomotive emissions standards.
476
Ethanol: Grain alcohol (C2H5OH), generally pro- Hydrocarbon: A chemical compound made up of
duced by fermenting starch or sugar. hydrogen and carbon (HC). Gasoline and almost
Evaporative Emissions Controls: An automotive all other fuels are hydrocarbons.
emission control system designed to reduce hy- Hydrostatic Relief Valve: A pressure relief device
drocarbon emissions by trapping evaporated fuel installed in the liquid LPG hose on a LPG fuel
vapors from the fuel system. system.
Excess Flow Valve: A check valve that is caused IAT: Intake Air Temperature
to close by the fuel when the flow exceeds a pre- Ideal Mixture: The air/fuel ratio at which the best
determined rate. compromise of engine performance to exhaust
FTV: Fuel Trim Valve. emissions is obtained. Typically 14.7:1.
FFV: Flexible Fuel Vehicle. Ignition Reserve: The difference between availa-
Firing Line: The portion of an oscilloscope pattern ble voltage and the required voltage.
that represents the total amount of voltage being ILEV: Inherently Low Emission Vehicle.
expended through the secondary circuit. IMPCO: Imperial Machine Products Company.
FMVSS: Federal Motor Vehicle Safety Standards. IMPCO Technologies, Inc. A manufacturer of both
FPP: Foot Pedal Position Sensor LPG and Gasoline fuel systems.
Fuel Injector: a spring loaded, electromagnetic Impedance: A form of opposition of AC electrical
valve which delivers fuel into the intake manifold, current flow (resistance) measured in ohms.
in response to an electrical input from the control Insulation: A nonconductive material used to cover
module. wires in electrical circuits to prevent the leakage
Fuel Lock: A solenoid-controlled valve located in of electricity and to protect the wire from corro-
the fuel line to stop the flow when the engine sion.
stops or the ignition switch is off. Intercept: An electrical term for a type of splice
Gasohol: 10 percent ethanol, 90 percent gasoline. where the original circuit is interrupted and redi-
Often referred to as E-10. rected through another circuit.
Gasoline: A motor vehicle fuel that is a complex ITK: IMPCO Test Kit
blend of hydrocarbons and additives. Typical oc- Knock: Sound produced when an engine’s air/fuel
tane level is 89. mixture is ignited by something other than the
GCP: Spectrum III (90-pin) ECM. spark plug, such as a hot spot in the combustion
Greenhouse Effect: A scientific theory suggesting chamber. Also caused by a fuel with an octane
that carbon dioxide from the burning of fossil fuels rating that is too low and/or incorrect ignition tim-
is causing the atmosphere to trap heat and cause ing. Also called detonation or ping.
global warming. Lambda Sensor: A feedback device, usually lo-
HC: Hydrocarbon. An organic chemical compound. cated in the exhaust manifold, which detects the
HD 10: A fuel of not less than 80% liquid volume amount of oxygen present in exhaust gases in re-
propane and not more than 10% liquid volume lation to the surrounding atmosphere. (See
propylene. HEGO).
HD 5: A fuel of not less than 90% liquid volume LDV: Light Duty Vehicle.
propane and not more than 5% liquid volume Lean Mixture: An air to fuel ratio above the stoi-
propylene. chiometric ratio; too much air.
HDV: Heavy Duty Vehicle. LEV: Low Emission Vehicle.
Heavy Ends: A term used to describe the buildup Limp-in or Limp Home: A mode where the ECM
of wax-like impurities that fall out of LPG when or a component has failed, but the vehicle re-
vaporized. mains operational although the engine may
HEGO: Heated Exhaust Gas Oxygen, used to de- operate minimally. This term may also describe
scribe a sensor. Also known as “EGO” (Exhaust the drivability characteristics of a failed computer
Gas Oxygen sensor), “O2” or “Oxygen sensor. system.
Hg: Chemical symbol for the element mercury. Liquid Petroleum Gas (LPG): A fuel commonly
Used in reference to a measure of vacuum (inch- known as propane consisting mostly of propane
es of Hg). (C3H8), derived from the liquid components of
Histogram: The graphical version of a table which natural gas stripped out before the gas enters the
shows what proportion of values fall into specific pipeline, and the lightest hydrocarbons produced
categories over a specific period of time. during petroleum refining. Octane level of LPG is
107.
477
LPG: Liquified Petroleum Gas. content of the exhaust gas. (See Lambda Sen-
M85: A blend of gasoline and methanol consisting sor).
of 85% methanol and 15% gasoline. Oxygenate: Oxygenates (such as MTBE, ethanol
MSV: (Abbreviated MSV). Refers to the manually and methanol) added to gasoline to increase the
operated valve on the LPG tank. oxygen content and therefore reduce exhaust
Measurements of Pressure: 1 PSI=2.06” Hg emissions.
(mercury) = 27.72” H2O (water column). At sea Ozone: A radical oxygen module (O3) that is found
level atmospheric pressure is 29.92” Hg. in the upper atmosphere and filters out ultraviolet
Methanol: Known as wood alcohol (CH3OH), a radiation from the sun. Ground level ozone is
light, volatile, flammable alcohol commonly made formed by NOX, during the formation of photo-
from natural gas. chemical smog.
MIL: Malfunction Indicator Lamp. Particulates: Microscopic pieces of solid or liquid
Misfire: Failure of the air/fuel mixture to ignite dur- substances such as lead and carbon that are dis-
ing the power stroke. charged into the atmosphere by internal
Mixer: Fuel introduction device that does not in- combustion engines.
clude a throttle plate. Positive Crankcase Ventilation (PCV): An auto-
MFI: Multiport Fuel Injection. A fuel injection system motive emission control system designed to
that uses one injector per cylinder mounted on reduce hydrocarbon emissions by routing crank-
the engine to spray fuel near the intake valve case fumes into the intake manifold rather than to
area of combustion chamber. the atmosphere.
MSV: Manual Shut-Off Valve. Refers to the ma- Power Derate: A mode of reduced engine power
nually operated valve on the LPG tank. output for the purposes of protecting engine com-
MTBE: Methyl Tertiary Butyl Ether. Oxygenate add ponents during a failure or malfunction.
to gasoline to reduce harmful emissions and to Pressure Differential: The differential between
improve the octane rating. atmospheric pressure and intake manifold (re-
Multi-fuel System: A motor fuel system designed ferred to as vacuum) pressure.
to operate on two different fuels, such as LPG Pressure Regulator: A device to control the pres-
and gasoline. sure of fuel delivered to the fuel injector(s).
Natural Gas: A gas formed naturally from buried Primary Circuit: The low-voltage or input side of
organic material, composed of a mixture of hy- the ignition coil.
drocarbons, with methane (CH4) being the Propane: An odorless and colorless gas, C3H8,
dominant component. found in natural gas and petroleum.
NGV: Natural Gas Vehicle. Psia: pounds per square inch absolute
NOX: See Oxides of Nitrogen. PTV: Pressure Trim Valve
OBD: On Board Diagnostic Reactivity: Refers to the tendency of an HC in the
Octane Rating: The measurement of the antiknock presence of NOX and sunlight to cause a smog-
value of a motor fuel. forming reaction. The lighter the HC, the lower
OEM: Original Equipment Manufacturer, the vehicle reactivity tends to be.
manufacturer. Regulator: An assembly used to reduce and con-
Open-Loop: An operational mode during which trol the pressure of a liquid or vapor.
control module memory information is used to de- Resistance: The opposition to the flow of current in
termine air/fuel ratio, injection timing, etc., as an electrical circuit. Measured in ohms.
opposed to actual oxygen sensor input. Rest Pressure: Fuel pressure maintained within
Orifice: A port or passage with a calibrated open- the system after engine shutdown.
ing designed to control or limit the amount of flow Rich Mixture: An air to fuel ratio below the stoichi-
through it. ometric ratio; too much fuel.
Oscilloscope: An instrument that converts voltage SAE: Society of Automotive Engineers.
and frequency readings into traces on a cathode Secondary Circuit: The high-voltage output side of
ray tube (also see Cathode Ray Tube). the ignition coil.
Oxides of Nitrogen: Chemical compounds of ni- SEFI or SFI: Sequential Electronic Fuel Injection or
trogen bonded to various amounts of oxygen Sequential Fuel Injection.
(NOX). A chief smog forming-agent. Sensors: Devices that provide the control module
Oxygen Sensor: An automotive fuel system that with engine information as needed to properly
produces a signal in accordance with the oxygen control engine function.
478
Spark Line: The portion of an oscilloscope pattern TSB: Technical Service Bulletin.
that represents the time during which the air/fuel ULEV: Ultra Low Emission Vehicle.
mixture is being burned in the combustion cham- USB: Universal Serial Bus. A plug or interface sup-
ber. plied on most personal computers.
Splice: An electrical term for the joining of two or Vaporization: A process in which liquid changes
more conductors at a single point. states into gas.
Stoichiometric Ratio: An ideal fuel/air ratio for Venturi Air Valve Vacuum (VAVV): An amplified
combustion in which all of the fuel and most of air valve vacuum signal coming from the venturi
the oxygen will be burned. area of the mixer, directly exposed to airflow be-
Sulfur Oxides: Chemical compounds where sulfur fore the addition of vaporized LPG.
is bonded to oxygen produced by the combustion Volt/ohmmeter (VOM): A combination meter used
of gasoline or any other fuel that contains sulfur. to measure voltage and resistance in an electrical
As sulfur oxides combine with water in the at- circuit. Available in both analog and digital types.
mosphere to form sulfuric acid. May also referred to as AVOM and DVOM.
System Pressure: The fuel pressure maintained in Voltage: The electrical pressure that causes cur-
the system during normal engine operation. rent to flow in a circuit. Measured in volts.
Tap: An electrical term for a type of splice where Voltage Drop: A lowering of the voltage in a circuit
the original circuit is not interrupted. when resistance or electrical load is added.
TBI: Throttle Body Injection. Any of several injec- Voltmeter: A meter that uses a needle to point to a
tion systems that have the fuel injector(s) value on a scale of numbers usually of the low
mounted in a centrally located throttle body. impedance type; used to measure voltage and
Throttle Body: Controls engine RPM by adjusting resistance.
the engine manifold vacuum to the mixer. Con- VSS: Vehicle Speed Sensor.
sists of a housing shaft, throttle liner and butterfly Xylene: C6H4 (CH3)2. Any of three toxic,
valve. flammable, and oily isomeric aromatic hydrocar-
TLEV: Transitional Low Emission Vehicle. bons that are dimethyl homologues of benzene
TMAP: Combined Air Inlet and Manifold Pressure and usually obtained from petroleum or natural
Sensor. gas distillates.
Toluene: A liquid aromatic hydrocarbon C7H8. ZEV: Zero Emission Vehicle.
TPS: Throttle Position Sensor.
479
480
TOOL KIT & ACCESSORIES
1 2 3 4 5
6 7 8 9 10
11 12 13 14
481
TOOL KIT, IMPCO P/N ITK-4
Item Qty.
Description IMPCO Part Number
# Used
1 Test Kit Gauge 0-5 PSI (2-5205) 1 TG-005
2 Test Kit-Gage 0-10" WC (2-5010) 1 TG-010
3 Hose, 3/16" Id Vacuum, Bulk 1.5’ H1-11
4 Harness, Adapter Gen 2 DLC to Gen 1 DLC 1 E1557400
Fitting Assembly, Test Cap (System II LPR
5 1 AF4-31105
Secondary Pressure Test Adapter)
6 Fitting, 1/8 NPT 3/16Hs Nip Brass 2 F4-4
7 Assembly, Fitting Test Cap 3/4 1 AF4-50254-002
8 Pin, Retainer 10 P1-30559
9 Case, Metal, 14.25 x 9 x 4.25 1 C9-50724-001
10 Fitting, 1/8 NPT 1/4Hs El Nylon 2 F4-8
11 Tool, 20IPR Torx-Plus Bit 1 T7-50172
12 Fitting, ¼ UNF, ¼ HS Vac Nip 1 F4-2
13 Gauge, Test Gasoline Fuel System 1 TG-31119-001
14 ASM, CAN Dongle (ECOM Cable) 1 E2046002
482
Appendix
483
Altitude vs. Barometric Pressure
Altitude Measured Kilopascals Pounds Per Square

In Feet (ft) (kPa) Inch (PSIA)
14,000 56-64 8.1-9.2
13,000 58-66 8.4-9.6
12,000 61-69 8.8-10.0
11,000 64-72 9.3-10.4
10,000 66-74 9.6-10.7
9,000 69-77 10.0-11.2
8,000 71-79 10.3-11.4
7,000 74-82 10.7-11.9
6,000 77-85 11.2-12.3
5,000 80-88 11.6-12.8
4,000 83-91 12.0-13.2
3,000 87-95 12.6-13.8
2,000 90-98 13.0-14.2
1,000 94-102 13.6-14.8
0 96-104 13.9-15.0
-1,000 101-105 14.6-15.2
484
Ignition System Specifications
Firing Order 1-3-4-2
Hyundai 27410-23400
Spark Plug Type NGK PFRN6N
Champion RC8PYPB
Spark Plug Gap .028-.031 in (0.7-0.8mm)
485

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HHI

LPG Fuel System ................................................................................................

LPG Fuel System Diagnosis ................................................................

LPG Symptom Diagnostics tics................................................................

Gasoline Fuel System................................

Gasoline Fuel System Diagnosis................................................................

Gasoline Symptom Diagnostics ................................................................

Electrical Section ................................................................................................

Diagnostic Scan Tool ...........................................................................................

Engine Wire Harness Repair................................................................

Diagnosticic Trouble Codes (DTCs) ................................................................

Tool Kit & Accessories................................

INTRODUCTION ing technician and damage to the vehicle or

Note that LPG engines are designed to operate

IMPCO recommends the use of name brand

FUEL SYSTEM CAUTIONS This manual contains several different Warn-

Typical Warning Label:

Do not allow LPG to contact the skin.

Always leak check any fuel system

When performing maintenance on the engine,

Check coolant level in coolant recovery tank and OIL RECOMMENDATION

ENGINE ELECTRICAL SYSTEM MAINTNANCE

The engine’s electrical system incorporates com-

 Check Positive and Negative cables for corro-

 Check for leaks at the inlet and outlet ﬁttings,

LPG FUEL SYSTEM

Electronic Pressure Regulator

ENGINE CONTROL MODULE HEATED EXHAUST GAS OXYGEN SENSORS

The Engine Coolant Temperature sensor or ECT

OIL PRESSURE SENDER/SWITCH

The Oil Pressure Switch is Mounted on the

The Engine Oil Pressure switch or sender is de-

 7/16” Open end wrench (for test port plugs)

 Diagnostic Scan Tool (DST)

 0-10” Water Column Gauge

The numbers below refer to step numbers on

1. This step checks the base mechanical EPR

Check the ignition wires for the following conditions:

Check the wiring harness for the following conditions:

(Sample Only – Readings will vary)

Is the gauge secondary pressure within the specified percen-

NOTE: This action will cause a DTC to be set turning ON the

NOTE: At cranking speeds, the air valve movement will be mi-

 HEGO 1 for correct switching characteristics.

Step Action Value(s) Yes No

1. The ECM and MIL are operating correctly.

1. Verify the customer complaint.

 Check all ECM system fuses and circuit breakers.

Check the ignition wires for the following conditions:

Faulty electrical connections or wiring can cause most intermittent problems.

The following components can cause intermittent MIL and no DTC(s):

1. Disconnect the TMAP sensor.

Check the spark plugs for the following conditions:

Check for the following:

Check the exhaust system for a possible restriction:

Check the spark plugs for the following conditions:

Check for the following:

Check the intake and exhaust manifolds for casting ﬂash.