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1. TABLE 1 TEMPERATURE VAPOR PRESSURE deg F deg C PSIG kPa 130 54 257 1794 110 43 197 1358 100 38 172 1186 90 32 149 1027 80 27 128 883 60 16 92 637 30 1 51 356 0 18 24 162 20 29 11 14 44 42 propane begins to boil sea level 45 43 0 0 Because the LPG is stored under pressure the tank is equipped with a safety valves which are normally set at 25 8 bar 375 psi to prevent tank rupture due 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 equipped with a safety feature called an excess flow check valve This feature reduces the flow from the service valve in the event of a rupture of the fuel line or any downstream 21 Typical LPG Cylinder 1 Liquid Outage Fill Check Valve 2 Pressure Relief Valve 3 Liquid Outage Valve w quick disconnect coupl ing also referred to as the manual shut off valve or MSV Filler Valve Fuel Gauge Vapor Withdrawal Tube when applicable 80 Limiter Tube Fuel Level Float Liquid Withdrawal Tube 201002 SERVICE LINE LPG flows from the fuel tank to the electric LPG Shut Off Valve via the service line The service line is connected to the tank utilizing a quick coupler The other end of the service line is con nect
2. 406 407 DTC 2122 FPP 1 High Voltage Circuit Wire Color FPP IVS Sensor Interface CN25 Check OEM chassis wiring diagram for specific pin numbers and wire colors Conditions for Setting the DTC Foot Pedal Position Check Condition Key On Fault Condition FPP1 sensor voltage exceeds 4 00 volts MIL On during active fault Low rev limit Force idle 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 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 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 408 DTC 2122 FPP 1 Voltage High Value s Action Did you perform the On Board OBD System Check e Key ON Engine OFF e DST Diagnostic Scan Tool connected in
3. Conditions for Setting the DTC CAN Rx Check Condition Engine running 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 Action Did you perform the On Board OBD System Check Key On Engine Running DST Diagnostic Scan Tool connected in System Data Mode Clear system fault code Does DTC1628 reset with the engine idling Disconnect one CAN device Clear DTC 1628 Key ON start engine if possible if not contin ue cranking for at least 3 seconds Wait 5 seconds Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of
4. Injector Driver 3 Injector Driver 4 Ignition Fuse and Power Relay Conditions for Setting the DTC Injector coil shorted Check Condition key on and engine running 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 Adaptive Disabled Closed Loop Disabled Circuit Description System battery voltage is supplied to each fuel injector The ECM controls each fuel injector by 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 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 254 DTC 268 Injector Driver 3 Coil Shorted Value s Action Did you perform the On Board OBD System Check Key On Engine Running DST Diagnostic Scan Tool connected in System Data Mode Clear System DTC 268 Does DTC 268 reset with the engine idling Key OFF Disconnect the injector interface connector CN19 Using a high impedance DVOM measure the resistance between the fuel injector pins at the fuel metering body at an ambient tem perature of 50 to 90 degrees F Does the DVOM display a resistance value of
5. 150 151 DTC 113 IAT Voltage High Wire Color 120 Gr Circuit ECM Conditions for Setting the DTC Intake Air Temperature Check Condition Engine Running Fault Condition IAT Sensor Voltage greater than 4 95 volts Adaptive Disabled during active fault 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 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 Action Did you perform the On Board OBD System Check e Key On e DST Diagnostic Scan Tool connected in System Data Mode Does DST display IAT voltage of 4 950 or great er Key Off Disconnect the TMAP sensor connector CN4 and jump pins 1 and 2 together Key On 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 Key ON Does DST display IAT voltage of 0 10 volts or le
6. lt Shift Up Down Arrow gt 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 x Log Fie fesisog raw Sampling Interval ms 30 00 Time Inerval s 10 00 9 1 1 1 1 1 1 0 20 40 60 80 100 close 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 do
7. y TPS position J 0 0 2 Gov2 voltage 20 volts Engine Load 00 x 1PS1 00 x 25 Current governor target 800 pm ze Oilpressuevolage 50 vots 25 TPS2 percent T 1000 MAP voltage 7 00 volts 250 Vbat 145 volts Tps1 voltage 0005 vols ECT CHT voltage NEE vot Ta Vew 146 vots Tps2yoltage 0000 volts 50 IAT voltage 5 0 volts 250 Hour meter 0 428 hours Ee com se 250 Cumulative starts 6 starts patas OO ES 2 50 FPP1 voltage 0 010 volts FPP2 voltage 5 000 volts WS voltage SnapShot Base Definitions e Select Plot Tags to open the snapshot window Other functions available from the Plot Log menu include e Clear Tags Releases all plot log variables Plot Tags Ctrl P or P Graphically plot all tagged variables e Load Plot Setup Loads and tags variables for plotting logging that have been stored in a plot file plt e 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 Save Button Snapshot Button Start or stop plotting of selected variables Save plotted data displayed in the plot to a comma separated val ue file CSV on the PC hard drive Format must not be altered if the Load function is to be us
8. Favorite Links E Documents E Pictures E Music More Folders BZ Desktop I Top Tech de Public E Computer amp Local Disk C DVD RW Drive D 070413_0948 KINGSTON E P Network Control Panel E Recycle Bin Name Size Files Currently on the Disc 1 DST_Series II e Open the DST_Series III folder Date modified UGS Jr gt Computer DVD RW Drive D 070413 0948 gt DST Series BZASA wy Org Favorite Links En a anize Y m Views gt Y E Documents E Pictures MB Music More Folders BZ Desktop E Top Tech Ji Public Computer amp Local Disk C DVD RW Drive D 070413_0948 de DST_Series IM Ji ECOM Driver Ji Latest_GCP Display Je USB Driver KINGSTON E ry Network Control Panel El Recycle Bin Burn to disc Name Size Type Date modif Files Currently on the Disc 3 k ECOM_Driver i File Folder USB Driver File Folder J 3 items 94 Latest_GCP_Display File Folder e Open the USB Driver folder use Driver instmsi USB Driver Select an item to view its description See also My Documents My Network Places My Computer ReadMe Setup License Agreement NI Serial USB 111 instmsiw Setup Type Application Size 39 0 K
9. l 1 2 3 4 5 6 1 Engine fuel L LPG 2 Engine range 4 In line 4 cycle 4 cylinder 3 Engine development order G engine 4 Engine capacity C 1975CC B engine 5 Production year 1 2001 2 2002 4 2004 5 2005 3 2003 6 2006 6 Engine production sequence number 000001 999999 Engine Identification Number Table SERVICING YOUR EMISSIONS CERTIFIED ENGINE 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 GENERAL INFORMATION ing technician and damage to the vehicle or components Service repairs should always be performed in a safe environment and the technician should always wear protective clothing to prevent injury For parts or labor to be reimbursed under the IMPCO Technologies Inc emission warranty only work performed by IMPCO or OEM trained technicians using only IMPCO speci fied parts will qualify for reimbursement Refer to the IMPCO Labor Time Guide for ad ditional information For parts or labor not reimbursed under war ranty a repair shop or person of the owner s 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
10. 7 Did you find a problem 271 Value s Yes No Repair the circuit as ne cessary Refer to Wir Go as ing Repairs in Engine Elec trical Go to Step 10 Go to Step 11 System OK Go to Step 9 Go to OBD System OK System Check Inspect the ECM connector CN1 for damage corrosion or contamination Did you find a problem e Replace the CKP sensor Is the replacement complete e Replace ECM Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 337 check for any stored codes Does the engine operate normally with no stored codes Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 337 check for any stored codes Does the engine operate normally with no stored codes 272 273 DTC 341 Camshaft Sensor Sync Noi
11. Go to Step 10 Repair the open circuit as necessary Refer to Wir ing Repairs in Engine Elec trical Repair the open circuit as necessary Refer to Wir ing Repairs in Engine Elec trical e Inspect ECM connector terminals for damage corrosion or contamination Any problems found e Replace ECM Is the replacement complete Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 12 Go to Step 11 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 221 check for any stored codes Does the engine operate normally with no stored codes 224 System OK Go to OBD System Check 225 DTC 222 TPS 2 Signal Voltage Low Electronic Throttle Circuit Wire ECM Color L TPS 1 Signal Sensor Ground TPS 2 Signal 5 Volts Conditions for Setting the DTC Throttle Position Sensor 2 Check Condition Cranking or Running Fault Condition TPS 2 sensor voltage less than 0 200 volts MIL ON during active fault Engine shutdown Circuit Description Dual throttle Posi
12. Go to Step 28 NA 27 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 e Intake manifold for leaks e All throttle body and mixer gaskets or o rings for leaks e All vacuum hoses and fittings for leaks e Exhaust system for leaks NOTE Exhaust system leaks allow for excess O 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 e HEGO 1 for correct switching characteristics Are all actions complete Go to Step 28 NA 28 Repeat Step 20 NA NA 29 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 temperature e Observe the MIL e 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 NA NA 36 ADDITIONAL STEPS Action VENTO Yes No Go to Ap Perform the On Board Diagnostic OBD System check plicable Go to Are any DTCs present in the ECM DTC Ta Step 2 ble f Go to
13. e Replace MAP sensor Is the replacement complete 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 temperature Observe the MIL 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 Repair the circuit as necessary Refer to Wir ing Repairs in Engine Electrical Repair the circuit as necessary Refer to Wir ing Repairs in Engine Electrical Go to Step 18 Go to Step 18 System OK No Go to Step 15 Go to Step 16 Go to OBD System Check DTC 108 MAP High Pressure Wire Color 120 Gr Circuit ECM Conditions for Setting the DTC 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
14. system check Does the engine operate normally with no stored codes 264 265 DTC 336 Crank Sync Noise ECM Circuit Wire Color 5 volt reference Crank Sensor Sensor Ground Crank Conditions for setting the DTC 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 Value s Action Did you perform the On Board OBD System Check e Check that the ECM ground terminal CN28 is clean tight and in the proper location Are the ground terminals clean and tight e Key On Engine OFF e Disconnect the CKP Crankshaft position Sensor connector CN9 e Using A DVOM check for voltage at the CKP sensor connector CN9 circuit 119 pin A and engine ground Do you have voltage e Key OFF e Disconnect ECM connector CN1 e Using a DVOM check for continuity between CKP connector circuit 125 and ECM connec tor circuit 125 Do you have continuity between them e Using a DVOM check for continuity on sen sor ground c
15. 5 Volts Conditions for Setting the DTC Throttle Position Sensor 1 8 2 Check Condition Key On Fault Condition TPS 1 20 higher than TPS2 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 lower voltage when closed and TPS 2 will read higher 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 The TPS is not serviceable and in the event of a failure the electronic throttle assembly must be replaced This fault will set if 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 Step Action Did you perform the On Board OBD System Check e Key ON Engine OFF e DST Diagnostic Scan Tool connected in System Data Mode Does the DST display more than a 20 differ ence between TPS 1 and TPS 2 Value s Go to Step 3 Go to Step 5 Go to System Check Section Intermitt
16. REMOVAL PROCEDURE Intake Manifold Remove ECM Refer to Engine Control Module Remove EPR Refer to XVIII Electronic Pressure Regulator Remove Mixer Adapter and Throttle Body Assembly Refer to XI Mixer Adapter Throttle Body amp Related Seals 472 4 Remove ECM Mixer Bracket Refer to XXII EPR ECM Mounting Bracket 5 Remove the TMAP Refer to V Tempera ture Manifold Absolute Pressure Sensor 6 Remove Coolant Hose support brackets 7 Remove two bolts securing the Manifold to the bracket 8 Remove eight bolts securing the Manifold to the side of the engine and remove 9 Remove Gasket INSTALLATION PROCEDURE 1 Place bolt through Intake Manifold and Gasket and mount on engine Torque bolts to 11 6 16 6 ft Ibs 15 7 22 6Nm 2 Install two bolts at bottom of the manifold securing the manifold to the bracket Tor que bolts to 11 6 16 6 ft Ibs 15 7 22 6Nm 3 Install TMAP Refer to VI Temperature Ma nifold Absolute Pressure Sensor 4 Install ECM Mixer Bracket Refer to XXII EPR ECM Mounting Bracket 5 Install Mixer Adapter and Throttle Body as sembly Refer to IX Mixer Adapter Throttle Body amp Related Seals 6 Install ECM 7 Start the vehicle and let run until it reaches normal operating temperature 8 Ifa DTC code is found refer to the Electrical Section for further diagnosis XXIII EXHAUST MANIFOLD REMOVAL PROCEDURE 1 Remove three bolts securing exhaust
17. Y Refer to the symptom diag nostic charts Go to Step 9 Go to Step e 1 1 2 12 11 14 Is the fuel pressure more than the specified val TBD kPa Go to Step Go to Step ue TBD psi 15 Turn OFF the ignition 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 Place the open end of the flexible fuel hose into an approved gasoline container Turn ON the ignition with the engine OFF Monitor the fuel pressure gage while the fuel pump is operating Is the fuel pressure within the specified range 67 TBD kPa TBD psi s 15 17 Go to Step Go to Step 21 18 Go to Step Go to Step 20 13 Inspect the engine fuel return pipe and the chassis fuel return pipe for a restriction Did you find and correct the condition Go to Step 23 Go to Step 21 Turn OFF the ignition 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 Monitor the fuel pressure gage Caution DO NOT allow the fuel pressure to exceed TBD kPa TBD psi Excessive p
18. e Replace CKP sensor Go to Step 10 Is the replacement complete 10 e Replace ECM Go to Step 11 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 16 check for any stored codes Go to Step System OK 9 Does the engine operate normally with no stored codes Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 16 check for any stored codes Does the engine operate normally with no stored codes 132 133 DTC 92 FRP Hiah Voltage Bi fuel Gasoline Onl Wire Color ECM 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
19. ground relay control circuit as necessary See wiring harness re pairs Go to Step 7 Go to Step 7 System OK Go to OBD System Check DTC 629 Relay Coil Short to Power Bi Fuel Gasoline Onl Fuel Pump Relay Relay Control VSW fuse Battery Voltage F Pump Fuse Conditions for Setting the DTC e Fuel pump relay check e Check Condition Key ON e Fault Condition Relay coil shorted to power 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 a short circuit to power 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 310 DTC 629 Relay Coil Short to Power Bi Fuel Gasoline Onl Did you perform the On Board OBD System Check DST connected and in the System Data Mode Key OFF Remove the power relay from the fuse block Using a DVOM check the resistance of the relay coil between fuel pump relay terminals for circuits 178 and 144B Is the resistance value less than 60 ohms e Replace the power relay Is the replacement complete Using a DVOM check for continuity between relay terminals for circuits 178 and 144B Do you have continuity betw
20. 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 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 Action Did you perform the On Board OBD System Check DST connected and in the system data mode Check for any other current or active DTCs Does the DST show any other codes set Repair any other DTC s set starting with the lowest DTC number first Have the other DTC s set been corrected Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1176 check for any stored codes Does DTC 1176 still re set e Replace the EPR Is the replacement complete Remove all test equ
21. Coolant hoses are specifically designed for their application DO NOT use hose material or length other than the OEM specified parts DO NOT mix the inlet or outlet hoses when reinstal ling 1 Lightly lubricate Port Fitting O rings with Vaseline or petroleum jelly prior to installa tion 2 Insert Port Fittings into each end of the hose and secure with hose clamps 3 Insert Coolant Hose Port Fittings into the EPR and secure with Retaining Pins 4 Install hose on both ends and secure with hose clamps Make sure the hoses are in the proper position and are not twisted or kinked 5 Refill with coolant 6 Start engine and run until operation tempera ture is reached 7 Let engine cool and check coolant level 471 XX SHUT OFF VALVE REPLACEMENT REMOVAL PROCEDURE 1 Disconnect the negative battery cable Relieve the LPG fuel system pressure Re fer to Ill LPG Fuel System Pressure Relief N CAUTION The LPG fuel system operates at pressure up to 21 5 bar 312 psi To minimize per sonal injury relieve the LPG fuel system pressure before servicing the LPG fuel sys tem components 3 Disconnect Shut Off Valve electrical connector 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 Valve INSTALLATION PROCEDURE 1 Add pipe thread sealer to
22. Did the power and ground circuits check OK e Replace ECM Go to Step 5 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds nn the an and ae the vehicle to Go to OBD ull operating temperature Observe the MIL Sys OK pS Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 1614 check for any stored codes Does the engine operate normally with no stored codes 389 DTC 1615 A D Loss Microprocessor Conditions for Setting the DTC 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 limiting maximum power 390 DTC 1615 A D Loss Action Value s Go to OBD Did you perform the On Board OBD System Go to Step System Check 2 Check Sec tion e Key On Engine Runni
23. Did you find a problem 275 5 0 volts Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 6 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check Sec tion Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 7 Go to Step 8 Value s Yes e Replace CMP sensor Go to Step 10 Is the replacement complete 10 e Replace ECM Go to Step 11 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 341 check for any stored codes Go to Step System OK 9 Does the engine operate normally with no stored codes Remove all test equipment except
24. Do you have continuity between them 243 Value s 20 ohms or less 5 Ohms or less Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 8 Repair the shorted to ground injec tor control circuit See wire har ness repair section Go to Step 7 Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent electrical sec tion Go to Step 4 Go to Step 6 Repair the open injector control circuit See wire har ness repair section Value s Yes e Replace the ECM Go to Step 8 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 264 check for any stored codes Does the engine operate normally with no stored codes 244 245 DTC 265 Injector Driver 2 Coil Shorted Circuit Wire Color 164 L Injector Driver 1 Injector Driver 2 Injector Driver 3 Injector Driver 4 Ignition Fuse and Power Relay Conditions for Setting the DTC Injector coil shorted Check Condition key on
25. File Folder y 3 items e Open the Latest_GCP_Display folder 89 Latest_GCP_Display ES GO DST_Series III Latest GCP Display X 44 Search A By Organize y Views Y Burn to disc a Fate Name Size Type Date modified Loc E Dacumenis Files Currently on the Disc 7 E Pictures B DistFile 3 779 KB Cabinet File 3 30 2007 12 51 PM Filey p Mnie 5 Impco GCP Display 884 KB Windows Installer 3 30 2007 12 51 PM Files 3 Edinstmsi 1 460 KB Application 3 30 200712 51 PM Filed Bee Edinstmsiw 1 470KB Application 3 30 2007 12 51 PM Filed Folders Vv setup 68KB Application 3 30 2007 12 51 PM Fileg HZ Desktop a lt j setup 1KB Configuration Sett 3 30 2007 12 51 PM Files Top Tech usertech_gcp_reprogra 1KB Text Document 11 3 2005 7 06 AM File Public ME Computer amp Local Disk C DVD RW Drive D 070413_0948 de DST_Series M E Ji ECOM Driver Ji Latest_GCP_Display Ji USB Driver KINGSTON E Y Network a Control Panel A amp Recycle Bin bdil m 7 l 7 items e 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 bella Ea Welcome to the Impco GCP Display Installation Wizard It is strongly recommended that you exit all Windows progra
26. 12 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2309 check for any stored codes Does the engine operate normally with no stored codes 452 Go to OBD system check System OK 453 DTC 2310 Primary Coil Shorted to Voltage Cylinder 1 Cylinder 4 Cylinder 3 Ignition Coil Pack Puse Interface Power Relay Fuse Block CN25 Conditions for Setting the DTC Ignition Control Check Check condition Engine running or cranking Fault condition Adaptive dwell less than 2 0ms or total dwell less than 4 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers the ignition coil 1 ignition by providing ground to the ignition connector circuit 104 This code will set if the ECM low side driver circuit 104 remains high or is shorted to vol tage 454 DTC 2310 Primary Coil Shorted to Voltage Action Did you perform the On Board OBD System Check Key ON Engine OFF DST Diagnostic Scan Tool connected in System Data Mode Clear DTC 2310 Crank the engine Does DTC 2310 re set Key OFF Disconnect
27. 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 Value s Action Did you perform the On Board OBD System Check Did you run the fuel pressure diagnostic test in the fuel system diagnostic section with no prob lems found Run the EPR pressure test in the fuel system diagnostic section Did the EPR pass the fuel pressure test specifi cations Inspect the EPR electrical connector pins C018 for damage corrosion or contamina Did you find a problem Replace or repair the EPR Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1171 check for any stored codes Does the engine operate normally with no stored codes 365 Go to Step 2 Go to Step 4 Go to Step 4 Repair the circuit as ne cessary Refer to wire harness re pair section Go to Step 6 System OK Go to OBD System Check Sec tion Go to Step
28. Four Pin DLC 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 e 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 e 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 Connected at 19200 bps Within several seconds the system Gauge screen should now appear and a green banner in the upper left hand will read Connected e Connecting to the PC using the ECOM cable Automatic COM comi So COM Global ContolP ons System Variables MIL Manifold Engine Speed 0 m Min Govemor Setpoint 0 mm Max Govemor Setpoint 0 mm Current govemor target 0 pm Pulse width
29. Go to Step 10 Is the replacement complete 10 e Replace ECM Go to Step 11 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 342 check for any stored codes Go to Step System OK 9 Does the engine operate normally with no stored codes Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds ie the engine and operate the vehicle to Go to OBD ull operating temperature Observe the MIL syste OK ES Ha Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 342 check for any stored codes Does the engine operate normally with no stored codes 280 281 DTC 359 Fuel Run out Longer Than Expected Circuit 177 Lockoff Control Wire Color W L LPG shut off valve Circuit 821 Wire Color R System Interface Connector CN21 Conditions for Setting the DTC LPG shut off valve Check Condition Key OFF Fault Condition Engine run down time greate
30. Has the Fuel system diagnosis been performed m Step 3 1 Replace the Engine Control Unit ECM Refer to Engine Go to Goto Control Unit ECM replacement Steb 5 Steb 4 Is this action complete p p 1 Repair the open or damaged circuit Go to Go to 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 Raise the engine speed to approximately 2500 rpm 15 Step 9 Step 6 Is the Adaptive 1 fuel correction within the specified range at p P idle and 2500 rpms 1 Check all vacuum hoses and mixer connections for lea Go to Goto Step 5 Step 7 1 Replace Mixer Go to Go to 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 Sala If you were sent to this routine by another diagnostic chart x retune to the previous diagnostic procedure Is this action complete Disconnect all test equipment System OK Was a problem found 2 Start the engine Using a liquid leak detection solution leak check any fuel system repairs made Is this action complete 37 38 LPG Symptom Diagnostics Checks Before Using This Section LPG Fuel System Check Visual and Physical Checks LPG SYMPTOM DIAGNOSTICS Action Before using this section you should have performed On Board Diagnostic OBD Check and determined that 1 Th
31. Heated Exhaust Gas Oxygen Sensor HEGO 1 Sensor between the engine and Catalytic Converter Exhaust Pipe Muffler Exhaust Back Pressure Test XXV CATALYTIC CONVERTER Catalytic Muffler REMOVAL PROCEDURE 1 Remove the Catalytic Converter using the OEM end product processes 473 INSTALLATION PROCEDURE 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 Disconnect the negative battery cable Remove the Vacuum Line from each fitting Start engine and check for leaks ON gt INSTALLATION PROCEDURE IMPORTANT DO NOT use a hose other than the OEM specified part 1 Reinstall the Fuel Vapor Hose to each fitting 2 Reconnect negative battery cable 3 Start engine and check for leaks 474 Definitions Air Valve Vacuum AVV The vacuum signal tak en from below the air valve assembly and above the throttle butterfly valve ADP Adaptive Digital Processor Air Fuel Ratio The amount or balance of air and fuel in the air fuel mixture that enters the engine Analog Voltmeter A meter that uses a mechani cal needle to point to a value on a scale of numbers It is usually of the low impe
32. Ignition System Checks Burned electrodes Heavy deposits Preliminary Checks Check the ignition wires for the following items e Cracking e Hardness e Proper connections Cooling System Checks elsa the engine thermostat to see if it is stuck open or for the wrong heat Check the transmission shift pattern Additional Check Refer to the OEM Transmission Controls section the Service Manual Check for dragging brakes 81 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 Preliminary Check None Check the Heated Exhaust Gas Oxygen Sensors HEGO performance e 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 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 Sensor Checks 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 Check the in line fuel filter for restrictions Refer to the Gas Fuel System Diagnosis
33. See Intermittent problems in the electrical section Go to Step 4 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2304 check for any stored codes Does the engine operate normally with no stored codes e Replace the ECM Is the replacement complete e Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2304 check for any stored codes Does the engine operate normally with no stored codes 440 Value s Yes No System OK Go to Step 7 System OK Go to Step 6 Go to OBD system check 441 DTC 2306 Primary Loop Open Low Side Short to Ground Cylinder 1 Cylinder 4 Cylinder 3 Ignition Coil Pack Puse Interface Power Relay Fuse Block CN25 Conditions for Setting the DTC Ignition Control Check Ch
34. Start the vehicle and let run until it reaches normal operating temperature 10 If a DTC code is found refer to the Electrical Section for further diagnosis lll LPG FUEL SYSTEM PRESSURE RELIEF N CAUTION The LPG fuel system operates at pressure up to 21 5 bar 312 psi To minimize per sonal injury relieve the LPG fuel system pressure before servicing the LPG fuel sys tem components 1 Close the valve on the LPG tank 2 Start and run the vehicle until the engine stalls running out of fuel 3 Turn the ignition switch to OFF N WARNING IV FUEL TEMPERATURE FT SENSOR REPLACEMENT LPG ONLY Fuel Temperature Sensor Relieve the LPG fuel system pressure Refer to Ill LPG Fuel System Pressure Relief on page 459 Disconnect the negative battery cable Locate the Fuel Temperature Sensor on the EPR port Remove retaining clip holding the Fuel Temp Sensor and remove the Sensor from the EPR port Remove electrical connector 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 N CAUTION Never use an open flame of any type to check for LPG leaks IMPORTANT Always inspect the LPG fuel system for leaks after performing service Check for leaks at the fittings of the serviced or
35. TBD psi TBD TBD kPa TBD TBD psi TBD TBD kPa TBD TBD psi Go to Step coto Step 5 8 Go to Step Go to Step 6 Go to Step Go to Step 7 ou Step Operate the vehicle within the conditions of the customer concern Monitor the adaptive parameters with the DST Do any of the DST readings indicate a lean con dition Turn OFF the ignition 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 adapters Turn ON the ignition with the engine OFF 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 Turn OFF the ignition Open the fuel feed pipe shut off valve Turn ON the ignition with the engine OFF Command the fuel pump relay ON and then OFF with the DST or fuel pump test circuit 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 ue Value s TBD kPa TBD psi
36. 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 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 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 DTC 123 TPS 1 Signal Voltage Step Action Did you perform the On Board OBD System Check e Key ON Engine OFF e DST Diagnostic Scan Tool connected Does the DST display TPS 1 voltage of 4 800 volts or greater with the throttle closed Slowly depress Foot Pedal while observing TPS 1 voltage Does TPS 1 voltage ever exceed 4 800 volts Disconnect electronic throttle connector C017 Does DST display TPS 1 voltage less than 0 2 volts Key OFF Disconnect ECM wire harness connector CN1 Key ON Using a DVOM check for voltage between TPS 1 signal circuit 147 at the ECM connec tor CN1 and engine ground Do you have voltage Replace ECM Is the replacement complete Back probe sensor ground circuit at the ECM side of the wire harness circuit 120 with a test light connected to
37. open power circuit See wiring har ness repairs Go To Step 8 Repair the open ignition module cir cuit See wiring har ness repairs Replace the ignition module Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2300 check for any stored codes Does the engine operate normally with no stored Value s _ Yes No Go to Step 10 System OK Go to Step 11 7 e Replace the ECM Go to Step Is the replacement complete 12 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2300 check for any stored codes Does the engine operate normally with no stored codes 428 Go to OBD system check System OK 429 DTC 2301 Primary Coil Shorted to Voltage Cylinder 1 Cylinder 4 Cylinder 3 Ignition
38. to Wiring Re pairs in Engine Elec trical Go to Step 9 e Inspect the throttle wire harness connector terminals for damage corrosion or contami nation Did you find a problem e Replace the electronic throttle Is the replacement complete 171 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 8 Go to Step 9 Action VENTO Yes Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature System OK Go to OBD Observe the MIL System Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 122 check for any stored codes Does the engine operate normally with no stored codes 172 173 DTC 123 TPS 1 Signal Voltage High Electronic Throttle Circuit Wire ECM Color L TPS 1 Signal Sensor Ground TPS 2 Signal 5 Volts Conditions for Setting the DTC Throttle Position Sensor 1 Check Condition Cranking or Running Fault Condition TPS sensor voltage exceeds 4 800 volts MIL On during active fault Engine shutdown Circuit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to deter
39. 0 00 ms EGO1 0 000 volts i E EGO2 0 000 vots y Configure CAN 0 deg F 0 degF System State Configure ECOM Pedal Position Throttle Position Run Mode Stopped Power Mode Sleep Batter Show Stats Fuel Type Gasoline Fuel Supply Off Fuel Spark inhibit input Inactive Normal Fuel Control Mode 0 Oil pressure state Active govemortype Customer Configuration Information Cust hardware name number Software and Hardware Information Cust software name number Software model Hardware model nitial cal model e To connect using the ECOM cable you must select ECOM from the COM Port drop down menu 101 Automatic COM COML com2 COM3 Intake Air Temperature System Variables ML _ COM4 250 f Engine Speed COM5 200 COM6 COM7 coms _ CAN Configure CAN D deg F v ECOM Pedal Position Throttle Position 100 80 60 40 FueVSpark inhibit input Inactive Normal 20 Fuel Control Mode Open Loop 0 Govemor switch state None 0 Oil pressure state OK Active govemor type None Active govemor mode Disabled Customer Configuration Information Cust hardware name number Sofware and Hardware Information Cust software name number Software model Hardware model e You will now need to configure the ECOM communication protocol XJ EDIS ECI Target Communications EEA File Page Flash Comm Port Plot Log Help Error opening com port 8 in HandleConnect
40. 0 000 volts AUX_PUD3 raw 5 000 volts ee om 4 00 33 volts Neutral_SW_rew 0 000 vols 5 00 35 4 Pedal_INH_raw 0 000 volts 6 0 0 419 Eng_Brake_raw 0 000 volts 7 00 482 8 00 407 AUX_DIG1 volts 2 70 volts AUX_DIG2 volts 2 70 volts AUX_DIG3 volts 2 73 volts 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 File Page Flash Comm Port Plot Log Help i Service e RUM UM S Connected at 19200 bps ATA Service Screen Clear Faults EE A Engine Speed Y RPM Rich Coolant Temperature SO Spark Advance cab Broc Lean Mixture Fuel Control O T Mode penaaoR Adaptive Learn State Fuel Type Propane 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 MS EDIS ECI Target Communications lo Ex File Page Flash Comm Port Plot Log Help Tests SPI UM Connected at 19200 bps El Toggle Page F9 ECIRUM SIT ne User Tests MIL System States Monitored Driver Status Throttle IAC Variables
41. 0H a light volatile flammable alcohol commonly made from natural gas MIL Malfunction Indicator Lamp Misfire Failure of the air fuel mixture to ignite dur ing the power stroke Mixer Fuel introduction device that does not in clude a throttle plate MFI Multiport Fuel Injection A fuel injection system that uses one injector per cylinder mounted on the engine to spray fuel near the intake valve area of combustion chamber MSV Manual Shut Off Valve Refers to the ma nually operated valve on the LPG tank MTBE Methyl Tertiary Butyl Ether Oxygenate add to gasoline to reduce harmful emissions and to improve the octane rating Multi fuel System A motor fuel system designed to operate on two different fuels such as LPG and gasoline Natural Gas A gas formed naturally from buried organic material composed of a mixture of hy drocarbons with methane CH being the dominant component NGV Natural Gas Vehicle NOX See Oxides of Nitrogen OBD On Board Diagnostic Octane Rating The measurement of the antiknock value of a motor fuel OEM Original Equipment Manufacturer the vehicle manufacturer Open Loop An operational mode during which control module memory information is used to de termine air fuel ratio injection timing etc as opposed to actual oxygen sensor input Orifice A port or passage with a calibrated open ing designed to control or limit the amount of flow through it Oscilloscope An instru
42. 121 and engine ground trical Do you have continuity 339 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 or ignition wires 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 set first Using a high impedance DVOM check for continuity at the EGO 1 connector CN11 be tween signal circuit 121 and sensor ground circuit 120 Do you have continuity e Using a high impedance DVOM check for continuity on the EGO 1 heater circuit 162 be tween EGO 1 connector CN11 and ECM connector CN1 Do you have continuity e Replace EGO 1 sensor Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine withi
43. 5 ohms or more e Replace the Fuel Injector Is the replacement complete Disconnect the ECM wire harness connector CN1 Key ON Using a DVOM check for voltage between the ECM connector CN1 injector control cir Greater than 5 0 Ohms Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 8 Repair the shorted to voltage injec tor driver circuit as ne cessary Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 4 Go to Step 6 Refer to Wir ing Repairs in Engine Elec trical cuit 165 and engine ground Does the DVOM display voltage e Replace the ECM Go to Step 7 Is the replacement complete 255 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature System OK Go to OBD Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC268 check for any stored codes system check Does the engine operate normally with no stored codes 256 257 D TC 270 Injector Driver 4 Open or Low Side Short to Ground Circuit Wire Color 164 Injector Driver 1 Injector Driver 2 Injector Driver 3 Inj
44. 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 Action Did you perform the On Board OBD System e Key ON Engine OFF e DST Diagnostic Scan Tool connected in System Data Mode Does the DST display more than a 20 differ ence between TPS 1 and TPS 2 voltage Key OFF Disconnect electronic throttle connector CN3 Key ON Change DST mode to DBW drive by wire test mode Is the voltage for TPS 1 less than 0 1 volts Value s Yes Go to Step 2 Go to Step 3 Go to Step 5 No Go to OBD System Check Section Intermittent problem Go to Intermit tent section Go to Step 4 e Key OFF e Disconnect ECM wiring harness connector CN1 e Key ON e Us
45. Coil Pack Fiss 7 Interface Power Relay Fuse Block CN25 Conditions for Setting the DTC Ignition Control Check Check condition Engine running or cranking Fault condition Adaptive dwell less than 2 0ms or total dwell less than 4 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled 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 DTC 2301 Primary Coil Shorted to Voltage Action Value s Yes Go to OBD Did you perform the On Board OBD System Go to Step System Check 2 Check Sec tion Key ON Engine OFF l DST Diagnostic Scan Tool connected in nl System Data Mode id Pa a Clear DTC 2301 o to otep ntermitten Crank the engine 3 problems in the electrical section Does DTC 2301 re set Key OFF Disconnect ECM connector CN1 Disconnect ignition module connector CN6 Repair the Using aDVOM check for voltage between shorted to Go to Step ignition module connector CN6 circuit 101 voltage coil 1 4 and engine ground circuit Do you have voltage e Replace the ignition module Go to Step 6 Is the replacement complete 431 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition
46. 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 Onl Action Value s Yes No J Perform the On Board OBD System Check Go to Step Go to Step 3 2 Go to Step Go to Step 4 Have any other DTC codes been detected diag 3 9 Go to Step Go to Step 9 4 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 Goto Step as necessary tage 5 Refer to Wir CHECK MUST BE MADE WITHIN 30 SECONDS ing Repairs in OR BEFORE POWER RELAY SHUTS DOWN Engine Elec trical Do you have voltage e Key OFF e Disconnect EGO 1 sensor wire harness connector CN11 ry the A Disconnect ECM wire harness connector CN1 a Key ON Refer to Wir 0 to Step Using a high impedance DVOM check for ing Repairs in 6 continuity between EGO 1 connector signal Engine Elec circuit 121 and engine ground trical Do you have continuity 193 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 manifol
47. 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 f 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 Value s Action Did you perform the On Board OBD System Check e Key On e DST Diagnostic Scan Tool connected in System Data Mode Does DST display ECT voltage of 4 90 or great er Key Off Disconnect the ECT sensor connector CN5 and Jump circuits 120 and 137 together Key On Does the DST display ECT voltage of 0 10 volts or less e Read the ECT voltage on the DST and com pare the reading at a known temperature to the chart Is the resistance value correct e Replace ECT sensor Is the replacement complete e Inspect the ECT wire harness connector ter minals for damage corrosion or contamination Did you find a problem Key OFF Disconnect ECM wire harness connector CN1 Inspect ECM connector CN1 c
48. Disconnect the System Interface connector CN21 e Check for continuity between circuits 154 and 120 at the system interface connector CN21 Do you have continuity e Disconnect the ECM connector CN1 e Check for continuity on the sensor ground circuit 120 between the system interface connector CN21 and the ECM connector CN1 Do you have continuity on the circuit e Inspect the FPP IVS connector the ECM connector CN1 and the system interface connector CN21 for damage corrosion or contamination Any damage found 421 Value s Go to Step 2 Go to Step 5 Greater than 1 00 volt FPP less than 0 85 volts AND IVS less than 1 0 volt Go to Step 4 Repair circuit See wiring harness re pair section Repair circuit See wiring harness re pair section Go to Step 7 Repair circuit See wiring harness re pair section as necessary as necessary as necessary Go to OBD System Check Sec tion Go to Step 3 Intermittent problem Go to Inter mittent section Go to Step 6 Go to Step 6 Repair circuit as necessary See wiring harness re pair section Go to Step 8 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MI
49. Gauges NO specrrun SIT error atempang reconnect Not Connected Araon Global Control Platform Coolant Temperature Intake Air Temperature System Variables MiL _ 250 jj 250 jj Engine Speed 9 m Min Govemor Setpoint 0 mm Max Govemor Setpoint Fo rpm Current govemortarget 0 mm Pulse width 0 00 ms 20 150 25 0 EGO1 0 000 vots EGO2 0 000 vots System State Run Mode Stopped Power Mode Sleep Battery Voltage Fuel Type Gasoline 10 0 200 Fuel Supply J 00 eo 300 FueUSpark inhibit input Inactive Normal Pl Fuel Control Mode Open Loop 0 0 volts Govemor switch state None Oil pressure state OK Active govemor type None Active govemor mode Disabled Customer Configuration Information Cust hardware name number Sofware and Hardware Information Cust software name number Software model DD Hardwaremodel DD e 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 File Page Flash CommPort Plot Log Help Gauges L6 SPECTRUM sH Connected at 19200 bps ei Toggle Page F9 by PCO z Global Control Platform Coolant Temperature Intake Air Temperature System Variables MiL Manifold Pressure 250 250 i 200 200 150 150 Bas H 2 pm 100 100 Curent govemor target 1200 pm il rol Pulse width 000 ms EGO1 0 559 volts R E EGO2 0 619 volts 40 deg F 22 de
50. MIL light in the dash By monitoring output from the sensor upstream and the sensor downstream of the catalytic con verter the ECM can determine the performance of the converter The Heat Exhaust Gas Oxygen HEGO Sensor HEGO1 volts HEGO 2 volts ss Time sec HEGO1 upstream or before the catalytic con verter and HEGO2 downstream voltage output N CAUTION The Heated Exhaust Gas Oxygen Sensor HEGO is an emissions control compo 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 TMAP SENSOR E T MAP Senso 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 The intake air temperature or IAT sensor is a variable resistance thermistor located in the air intake passage which measures the tempera tu
51. OBD System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 187 check for any stored codes Does the engine operate normally with no stored codes 210 211 DTC 188 LP Temp Voltage High Circuit Wire Color ECT CHT Signal Sensor Ground Conditions for Setting the DTC e LP Temperature e Check Condition Engine Running e Fault Condition FT sensor voltage exceeds 4 90 e MIL On e Adaptive Disabled during active fault Sensor Resistance Circuit Description Be n oe The LP Temp Fuel Temperature sensor is a temperature sensi 50 eso tive resistor located near the fuel outlet of the electronic pressure 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 Value s Action Did you perform the On Board OBD System Check DST Diagnostic Scan Tool connected in System Data Mode Does DST display FT voltage of 4 90 or greater Disconnect the FT sensor connector CN14 and jump
52. OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 129 check for any stored codes Does the engine operate normally with no stored codes 183 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 18 Go to Step 18 System OK Go to Step 16 Go to OBD System Check DTC 134 EGO 1 Open Inactive Wire Color G B EGO 1 Signal Circuit Signal Ground EGO 1 Heater Ground Power Relay Fuse Block CN25 7 Ignition Fuse Conditions for Setting the DTC Heated Oxygen Sensor Check condition Engine running Fault condition EGO 1 pre catalyst persistently cold for more than 55 seconds MIL On during active fault Adaptive Disabled during active fault 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 DTC 134 EGO 1 Open Inactive Action Did you perform the On Board OBD System Check VENTO Go to
53. On e Adaptive Disabled during active fault e 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 DTC 111 IAT Higher Than Expected 1 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 all
54. Open Low Side Short to Ground Cylinder 1 Cylinder 4 Cylinder 3 Ignition Coil Pack Fiss 7 Interface Power Relay Fuse Block CN25 Conditions for Setting the DTC Ignition Control Check Check condition Engine running or cranking Fault condition Adaptive dwell greater than 2 0ms or total dwell greater than 14 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers ignition by providing ground to the ignition circuit 104 This code will set if the ECM low side driver circuit 104 is open or shorted to ground 450 DTC 2309 Primary Loop Open Low Side Short to Ground Action Did you perform the On Board OBD System Check Key ON Engine OFF DST Diagnostic Scan Tool connected in System Data Mode Clear DTC 2309 Crank the engine Does DTC 2309 re set e Remove and check the ignition fuse Is the fuse OK e Replace the ignition fuse Is the replacement complete e Key ON e Using a DVOM check for voltage at the igni tion fuse terminal circuit 927 CHECK THIS BEFORE THE POWER RELAY CIRCUIT SHUTS DOWN Do you have voltage e Key OFF e Disconnect the ignition module connector CN6 e Using a DVOM check for voltage between ignition module connector circuit 812 and engine ground Do you have voltage e Disconnect ECM wire harness connector CN1 e Using a DVOM check for continuity on the coil control circuit 104 between ECM conn
55. PUMP 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 N CAUTION The fuel pump is an emission control com ponent If the fuel pump fails to operate replace only with an OEM replacement part The fuel pump is calibrated to supply the correct amount of fuel to the injectors Re placing the pump with anything other than the recommended OEM replacement pump could cause damage to the fuel system and or fuel tank FUEL FILTER The fuel is drawn into the fuel pump and then through the fuel filter to trap and remove small par ticles and prevent injectors from becoming damaged Maintenance of the fuel filter is required 57 as indicated in the Recommended Maintenance Schedule A more frequent replacement of the filter may be required if the equipment operates in a dus ty or dirty environment FUEL METERING BODY AND PRESSURE REGULATOR The gas flows from the fuel filter to the fuel pres sure regulator block Regulated fuel is then sent to the fuel inlet pipe and through the fuel metering body to the injectors Excess fuel is return
56. 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 communication with the ECM is lost The MIL command is on 368 DTC 1173 EPR Communication Lost Action Did you perform the On Board OBD System Check Key ON DST Diagnostic Scan Tool connected in the system data mode Clear DTC1173 Key OFF Key ON and attempt to start the engine Does DTC1173 re set 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 Be sure to activate relay control ON using the DST function or check before ECM relay control times out Do you have power e Check the fuses Is the fuse open e Replace damaged fuse Is the replacement complete e Using a DVOM check for system power at power relay terminal 3 Be sure to activate relay control ON using the DST function or check before ECM relay control times out Do you have power e Using a DVOM check for continuity between EPR connector circuit 181 and engine ground Do you have continuity 369 Value s System bat tery voltage System bat tery voltage Go to Step 2 Go to Step 3 Go to Step 7 Go to
57. Regulator Assembly EPR Shown with Port Fittings and Shut off Valve FUEL SYSTEM DESCRIPTION The Engine Control Module ECM receives in formation from various engine sensors in order to control the operation of the Electronic Pres sure Regulator EPR and Shut Off Valve The Shut Off Valve solenoid prevents fuel flow un less the engine is cranking or running LPG is stored in the tank as a liquid and deli vered under pressure of up to 21 5 BAR 312 psi At Key ON the EPR receives a two 2 second prime pulse from the ECM allowing time for the LPG to flow from the tank through the fuel filter and fuel lines to the EPR Inside of the EPR fuel is vaporized and reduced in pres sure in two stages The first stage reduces the tank pressure to approximately 20 68 kilopas cals 3 0 psi The second stage then reduces the pressure to approximately negative 38 1 mm 1 5 of water column when vacuum from the engine draws in fuel The fuel is then drawn in from the secondary chamber of the EPR by the vacuum generated by air flowing through the Mixer This vacuum is also generates lift for the mixer air valve and is commonly referred to as air valve vacuum Once in the mixer the fuel is combined with air and is drawn into the engine for combustion DIAGNOSTIC AIDS This procedure is intended to diagnose a ve hicle operating on LPG If the vehicle will not continue to run on LPG refer to Hard Start for preliminary checks B
58. Replace ECM Is the replacement complete Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 12 Go to Step 11 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 121 check for any stored codes Does the engine operate normally with no stored codes 168 System OK Go to OBD System Check 169 DTC 122 TPS 1 Signal Voltage Low Electronic Throttle Circuit Wire ECM TPS 1 Signal Sensor Ground TPS 2 Signal 5 Volts Conditions for Setting the DTC e Throttle Position Sensor 1 e Check Condition Cranking or Running e Fault Condition TPS sensor less than 0 200 volts e MIL On during active fault e 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 TPS1 will read lower voltage when closed and TPS2 will read higher voltage when closed The TPS1 and TPS2 percentages are calcu lated from these voltages Although the voltages are differe
59. SECF11F34 mL Y e Turn the ignition key to the ON position e Verify the DST is connected to the ECM e From the File menu select Reprogram target Select S record Mot File Directory History Look in E 3 Floppy 4 ea ej Er F2_LPG_2700LPG_7613200B 009 mot AS File name F2_LPG_2700LPG_761 32008 009 Files of type mot E e Navigate to the media where you have stored the MOT file was stored on the on the floppy A drive e Highlight the correct mat file using the left mouse button e Click on Load 114 Cancel In the example above the MOT file Configuration ET Perform standard application code download e Click Yes to continue Attention Ready to begin reprogramming Download type APPLICATION CODE AND DATA ONLY Current target application code checksum 4BB1 Current buffer application code checksum 4BB1 Current buffer total memory checksum 19D9 Buffer source file a 1F2_LPG_2700LPG_7613200B 009 mot NOTE Any interruption of the reprogramming procedure will require another reprogram attempt Continue with program download e Click the Yes box to continue with the update Refrain from using other functions on the computer while the download takes place A CAUTION Do not disconnect the DLC remove power or use the PC for any other func tion during this process Any interruption during this r
60. Step 2 Go to OBD System Check Sec tion Key ON Engine Running DST Diagnostic Scan Tool connected in System Data Mode Run engine to full operating temperature and then idle for a minimum of 1 minute Does DST display EGO 1 voltage fixed between 0 40 and 0 50 volts after at least 1 minute of idle 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 162 Check must be made within 30 seconds or before power relay shuts down Do you have voltage Go to Step 3 Go to Step 8 Intermittent problem See Electrical Section In termittent Electrical Di agnosis Go To Step 4 Key OFF Using a DVOM check for voltage between EGO 1 connector CN11 circuit 812 and en gine ground Key ON Check must be made within 30 seconds or before power relay shuts down Do you have voltage Disconnect ECM connector CN 1 Using a DVOM check for continuity on EGO heater 1 circuit 162 between EGO 1 connec tor CN11 and ECM connector CN1 Do you have continuity 185 System Vol tage Go to Step 5 Go to Step 6 Repair sys tem power relay open circuit Repair open heater ground circuit Inspect wire harness connector CN5 pins and CN1 pins for damage corrosion or con tamination Did you find a problem e Replace ECM Is the replacement complete e Key OFF e Disconnect ECM wire harne
61. Step 5 Go to Step 17 Repair the open circuit between power relay pin 3 and EPR pin 7 Go to Step 17 Go to Step 8 Go to OBD System Check Sec tion Intermittent problem Go to Intermittent Problem sec tion in the electrical sec tion of this manual Go to Step 4 Go to Step 6 Repair the power relay circuit as re quired Go to Step 17 Repair the open ground circuit as ne cessary Refer to wir ing repairs in engine elec trical Key OFF Disconnect the EPR connector CN15 Disconnect the ECM connector CN1 Using a DVOM check for continuity on the CAN circuit 115 between EPR connector CN15 and ECM connector CN1 Do you have continuity e Using a DVOM check for continuity on the CAN circuit 114 between EPR connector CN15 and ECM connector CN1 Do you have continuity e Using a DVOM check for continuity between EPR CAN termination circuit 312 and circuit 114 on the EPR connector Do you have continuity e Using a DVOM check for continuity on the EPR ground circuit 181 between EPR con nector CN15 and ECM connector CN1 Do you have continuity e Using a DVOM check for continuity on the EPR ground circuit between EPR connector circuit 181 and ECM circuit 169 Do you have continuity e Disconnect DST from the DLC connector CN7 e Using a DVOM check for continuity between engine ground and EPR connector circuits 114 and 115 Do you have continuity e Replace
62. Step 6 Go to Step 7 Repair the shorted to ground coil 1 circuit Go to Step 9 Repair the open power circuit See wiring har ness repairs Repair the open power circuit See wiring har ness repairs Go To Step 8 Repair the open ignition module circuit See wiring harness re pairs e Replace the ignition module Go to Step a Is the replacement complete 10 435 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2303 check for any stored codes Does the engine operate normally with no stored codes e Replace the ECM 11 Is the replacement complete e Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2303 check for any stored codes Does the engine operate normally with no stored codes 436 Value s Yes No
63. System Data Mode Does the DST display FPP voltage of 4 00 volts or greater with the foot pedal in the idle position e Slowly increase FPP while observing FPP 1 voltage Does DST FPP voltage ever exceed 4 00 volts e Disconnect the FPP sensor connector Does the DST now show FPP 1 voltage below 0 200 volts e Replace FPP sensor Is the replacement complete e Key OFF e Disconnect ECM connector CN1 e Disconnect system interface connector CN21 e Using a DVOM check continuity between connector CN circuit 120 and ECM connector CN1 circuit 120 Do you have continuity e Key ON e Using a DVOM check for voltage between the System Interface connector CN21 circuit 153 and engine ground Do you have voltage Greater than 4 00 volts 0 200 volts or less No voltage Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 10 Go to Step 7 Repair the signal shorted to voltage cir cuit Go to OBD System Check Sec tion Go to Step 3 Intermittent problem Go to Inter mittent section Go to Step 6 Repair the open ground circuit as re quired Go to Step 8 e Inspect ECM and FPP connectors for dam age corrosion or contamination Did you find a problem e Replace ECM Is the replacement complete 409 Repair the circuit as re quired See wire harness repair section Go to Step 10 Go to Step 9 Remove all test equi
64. Value s _ Yes Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 12 Go to Step 6 Go to Step 7 Repair the shorted to ground coil 1 circuit Go to Step 9 Go to OBD System Check Sec tion Intermittent problem See Electrical Section In termittent Electrical Di agnosis Go to Step 4 Repair the open power circuit See wiring har ness repairs Repair the open power circuit See wiring har ness repairs Go To Step 8 Repair the open ignition module cir cuit See wiring har ness repairs Replace the ignition module Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2306 check for any stored codes Does the engine operate normally with no stored Value s _ Yes No Go to Step 10 System OK Go to Step 11 7 e Replace the ECM Go to Step Is the replacement complete 12 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and opera
65. a Er Run Mode Stopped IAC electrical status OK iE command 12 m ti Manifold Pressure 24 pala Power Mode Standby Power relay electical status JOK position 00 el ee el ee Bees voltage Coolant Temperature 200 Fuel Control Mode Loop Ep Sey us Open loa y volts Active govemor type Min Buzzer electrical status Open load IVS voltage 5 000 vols aair ead Teme 1908 MIL electrical status Open load us Manifold Temperature 190 0 F Active govemor mode tsochronous TPS command 300 nn Tach output electrical status OK pane 3 Intake Air Temperature 220 F pms amp position 00 f H prosmar Contig 3 Crank Cam Datalog TPS1 percent 00 ern 35 BTDC IVS state Oide oa TINTE TPS2 percent 1000 Pulse width 00 ms Cylinder numbering Firing Order TPS1 voltage 0 005 volts Vbat 147 vols TPS2 voltage 0 000 volts Vsw 14 8 volts Crank Alam data log IAC driver power Off AC command position 300 Distributor Alignment ag IAC actual position 00 Cam position 0 CADBTDC Cam position desired value 0 CAD BTDC Spark Kill Test Injector Kill Test DBW Test Spark kill command Normal bd Injector kill command Normal v DBW test command Off vj Spark kill test status Test Not Started Injector kil test status Test Not Started DBW test status Test Not Started Spak kE treed f 0 sec rjocdor kil imeut DT sec IAC Test Spark Advance Test Injector Fire Test Disabled w Spark advance lest command Enabled D irector fring teat command it Er Test Not Started Spark adv
66. a severe driveability problem If silicone contamination is sus pected remove and visually inspect the sensor element If contaminated the por tion 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 A N WARNING Residual vapor pressure will be present in the fuel system Ensure the work area is well ventilated before disconnecting any fuel line 5 Remove the two hoses on the side of the Mix er 6 Remove electrical connector on Throttle Body 7 Remove the four screws under the Mixer that secure the Mixer Adapter and Throttle Body 8 Remove the Mixer and Adapter 9 Remove Throttle Body INSTALLATION PROCEDURE Lightly lubricate new O rings with Vaseline or petroleum jelly prior to installation 2 Place new O rings on top of the Throttle Body 3 Place Gasket and Throttle Body on intake adap ter 4 Place Adapter and Mixer on top of Throttle Body and align screw holes Secure with the four re taining screws and Torque to 80 in lb 9 Nm Install the fuel hose fitting into the Mixer and hold with the retaining pin Install the air intake duct Install the two hoses to the 90 fittings on Mixer Reconnect the negative battery cable Open LPG tank valve 0 Turn ignition to ON for approximately 30 seconds then OFF 11 Leak check the LPG fuel system at each ser vic
67. 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 Action Value s Yes Go to OBD Go to Step System 2 Check Sec Did you perform the On Board OBD System Check tion Go to Step Go to Step 3 4 Go to Step 4 e Key ON Engine OFF e DST connected Are any other DTC codes present with DTC 1112 e Diagnose any other DTC codes before pro ceeding with this chart Have any other DTC codes been diagnosed and repaired e Replace ECM with correct service part Num ber Go to Step 9 Go to Step Go to Step 8 7 Go to Step 9 Is the replacement complete e Check the mechanical operation of the throttle Is the mechanical operation of the throttle OK e Correct mechanical operation of the throttle Refer to Engine amp Component section Has the mechanical operation of the throttle been corrected e Check engine for large manifold vacuum leaks Refer to Fuel Systems section Symp tom Diagnostics Goto OBD Go to Step System 9 Check Sec tion e Check the service part number on the ECM to ensure correct calibration is in use Go o7 Go to Step 5 Is the service part number Correct Did you find and correct the vacuum leak 335 Remove all test equipment except the DST Connec
68. and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1175 check for any stored codes Does DTC 1175 still re set e Replace the ECM Is the replacement complete e Remove all test equipment except the DST e Connect any disconnected components fus es etc e Using the DST clear DTC information from the ECM e Turn the ignition OFF and wait 30 seconds e Start the engine and operate the vehicle to full operating temperature e Observe the MIL e Observe engine performance and driveability e After operating the engine within the test pa rameters of DTC1175 check for any stored codes Does the engine operate normally with no stored codes Less than Go to Step 0 5 Ohms 7 Go to Step 8 Go to Step 9 Go to Step 10 System OK Repair the poor EPR power ground circuit See wiring har ness repair in the electrical section of this manual System OK Go to OBD System Check 376 377 DTC 1176 EPR Internal Actuator Fault Circuit Wire Color 115 G Br Ground Ground To Power Relay Fuse Block CN25 Conditions for Setting the DTC EPR internal actuator test Check condition Engine running or cranking MIL On during active fault Fault condition Failed actuator Adaptive disabled
69. 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 lt Single left click on trace gt Snap closest cursor to data lt Ctrl Up Down Arrows gt Move pan plot along y axis lt Ctrl Left Right Arrows gt Move pan plot along t axis lt Ctrl Shift Up Down Arrows gt Zoom plot in and out in y axis lt Ctrl Shift Left Right Arrows gt Zoom plot in and out in t axis lt Ctrl Home gt Resize plot to default settings lt Ctrl Page Up gt Zoom out by 10 lt Ctrl Page Down gt Zoom in by 10 lt Page Up gt Toggle to previous cursor lt Page Down gt Toggle to next cursor lt Left Right Arrow gt Follow selected data along trace lt Up Down Arrow gt Follow selected data along trace lt Shift Left Right Arrow gt Move 10 points along trace lt Shift Up Down Arrow gt Move 10 points along trace lt Home gt Go to first visible point on current plot lt End gt Advance to last visible point on current plot
70. connector circuits 120 and 139 Does the DST display FT voltage of 0 05 volts or Using a DVOM check the resistance be tween the two terminals of the FT sensor and compare the resistance reading to the chart Is the resistance value correct e Replace FT sensor Is the replacement complete e Inspect the FT sensor connector terminals for damage corrosion or contamination Did you find a problem Key OFF Disconnect ECM wire harness connector CN1 Inspect ECM connector pins for damage cor rosion or contamination Did you find a problem 213 See tem perature vs resistance chart in the DTC 188 schematic page Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 6 Go to Step 14 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 8 Go to Step 5 Go to Step 7 Intermittent problem Go to Inter mittent section e Jump the fuel temperature sensor connector signal circuit 139 to engine ground Does DST display FT voltage of 0 05 or less Key OFF Disconnect ECM wire harness connector CN1 Using a DVOM check for continuity on the sensor ground circuit 120 between fuel tem perature sensor and ECM connector Do you have continuity
71. contamina tion and performance Check for proper operation of the TMAP sensor Check for proper operation of the TPS and FPP sensors Check the exhaust system for a possible restriction Inspect the exhaust system for damaged or collapsed pipes Inspect the muffler for signs of heat distress or for possible internal fail ure Check for possible plugged catalytic converter Check the engine for the following Engine compression Valve timing 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 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 e Excessive idling or stop and go driving e Carrying of very heavy load
72. downstream Disconnect the Oxygen sensor electrical connec tor HEGO and Connector Using an Oxygen Sensor socket remove the Oxygen Sensor INSTALLATION PROCEDURE IMPORTANT Before install the Oxygen sensor lubricate threads with anti seize compound P N 5613695 or equiva lent Avoid contaminating sensor tip with compound Install Oxygen Sensor Torque to 36 2 43 4 ft Ibs 49 0 58 8 Nm 2 Reconnect electrical connector to the Oxygen Sensor 3 Reconnect the negative battery cable 4 Start the vehicle and let run until it reaches normal operating temperature 5 Ifa DTC code is found refer to the Electrical Section for further diagnosis IX MIXER ADAPTER THROTTLE BODY amp RELATED SEALS REMOVAL PROCEDURE Disconnect the negative battery cable 2 Relieve the LPG fuel system pressure Refer to lll LPG Fuel System Pressure Relief 3 Remove the air intake duct 4 Remove the retaining pin holding the fuel hose fitting and remove fuel hose AN WARNING 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
73. especially at light load Fuel Mixer System can be lean due to faulty EPR Electronic Pressure Regulator or faulty fuel mixer 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 338 DTC 1151 Closed Loop Multiplier High LPG Action Value s Yes No J Perform the On Board OBD System Check Go to Step Go to Step 3 2 Go to Step Go to Step 4 Have any other DTC codes been detected diag 3 9 Go to Step Go to Step 9 4 nosed and repaired Disconnect EGO1 connector C005 Using a DVOM check for voltage between es se EGO 1 connector pin B and engine ground PEN EI Kev ON power circuit y System vol Goto Step as necessary tage 5 Refer to Wir CHECK MUST BE MADE WITHIN 30 SECONDS ing Repairs in OR BEFORE POWER RELAY SHUTS DOWN Engine Elec trical Do you have voltage Key OFF Disconnect EGO 1 sensor wire harness con j nector CN11 Repair the Disconnect ECM wire harness connector CN1 an Key ON Refer to A Go to Step Using a high impedance DVOM check for ing Repairs in 6 continuity between EGO 1 connector signal Engine Elec circuit
74. ex ceed TBD kPa TBD psi as damage to the fuel pressure regulator may result 17 Fuel pressure above TBD kPa TBD psi may cause a rich starting condition followed by black smoke and a strong fuel odor in the exhaust 18 This test is to determine if the high fuel pressure is due to a restricted fuel return pipe or a faulty fuel pressure regulator 21 The pressure regulator may be fitted with a screen which is designed to trap contami nants introduced during engine assembly If dirty it can be removed and cleaned if re quired 23 A system that does not hold pressure is caused by one of the following e Leaking fuel pump check e Leaking fuel feed hose e Leaking valve seat within the pressure regulator e Leaking injector fuel metering block as sembly 26 A leaking injector can best be determined by checking for a fouled or saturated spark plug s If a leaking injector cannot be de termined by a fouled or saturated plug the following procedure should be used e Remove the fuel metering body but leave the lines connected e Inspect the injector tips for leakage un der pressure 65 GASOLINE FUEL SYSTEM DIAGNOSTIC CHART Go to ES a a System Check Section Check all sys tem power Go to Step fuses and 3 power relay circuit Refer to wiring harness schematic Go to Step Go to Step 4 10 Did you perform the On Board OBD System Check Important Inspect the fuel system for damage o
75. 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 Verify that the spark plugs are the correct type and properly gapped Remove the plugs and inspect them for the following conditions Wet plugs Cracks Ignition System Checks Wear Improper gap Burned electrodes 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 Important The LPG Fuel system is more sensitive to intake manifold lea kage than the gasoline fuel supply system e Check for vacuum leaks Vacuum leaks can cause a higher than normal Additional Checks idle and low throttle ang
76. flow 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 chat Diagnostic Aid Oxygen Sensor Wire Heated Oxygen sensor wires may be mis routed and contacting the ex 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 Fuel Pressure Low fuel pressure faulty fuel regulator or contaminated fuel filter can cause fuel the system to run lean Exhaust Leaks lf 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 354 DTC 1161 Adaptive Learn High LPG Action Value s No Yes a 2 Perform the On Board OBD System Check Go to Step Go to Step 3 2 Go to Step Go to Step 9 4 Have any other DTC codes been detected diag Go to Step Go to Step 9 4 nosed and repaired e Disconnect EGO1 connector CN11 e Using a DVOM check for voltage between Repair the EGO 1 connector pin B and engine ground open EGO e Key ON power circuit System vol Goto Step
77. ground circuits Are the power and ground circuits OK e Replace ECM Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 606 check for any stored codes Does the engine operate normally with no stored codes 303 Value s Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 System OK Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check DTC 627 Fuel Pump Relay Coil Open Bi Fuel Gasoline Onl Fuel Pump Relay Relay Control VSW fuse Battery Voltage F Pump Fuse Conditions for Setting the DTC e Fuel pump relay check e Check Condition Key ON e 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 diagnost
78. 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 e Inspect the exhaust system for visual signs of damage leaks or modification and repair if necessary e Insure the pre catalyst and post catalyst oxygen sensors are mounted correctly and wiring is not damaged melted or corroded and repair if necessary e f none of the above problems are found replace the catalyst 287 DTC 524 Oil Pressure Low ECM 5 volts Circuit 135 Oil Pressure Wire Color G W Voltage CN8 Oil Pressure Switch Conditions for Setting the DTC 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 Engine Shut Down 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 r
79. level being too high can cause an oil leak a fluctuation or drop in oil pressure When overfilled the en gine crankshafts splash and agitate the oil causing it to aerate or foam IMPORTANT Change oil when engine is warm and the old oil flows more freely 2 Stop engine IMPORTANT Engine oil will be hot Use protective gloves to prevent burns Engine oil contains chemicals which may be harmful to your health Avoid skin contact 3 Remove drain plug and allow the oil to drain 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 manufacturers instructions Do not over tigh ten 6 Check sealing ring on drain plug for any dam age replace if necessary wipe plug with clean rag wipe pan sealing surface with clean rag and re install plug into the pan Tighten to 25 3 32 4 ft lbs 34 3 44 1 Nm IMPORTANT Always use a new drain plug gasket when chang ing the oil 7 Fill crankcase with oil 8 Start engine and check for oil leaks 9 Dispose of oil and filter in a safe manner FUEL SYSTEM INSPECTION AND MAINTENANCE LPG FUEL SYSTEM The LPG fuel system installed on this industrial engine has been designed to meet the emission standard applicable for the 2007 2009 model years To ensure compliance to these s
80. male threads on the Shut Off Valve and brass fitting 2 Connect brass fitting to Shut Off Valve 3 Connect elbow Shut Off Valve and fitting assembly to the EPR 4 Connect electrical connector to the Shut Off Valve 5 Connect the LPG fuel inlet line from the Shut Off Valve fitting Reconnect negative battery cable Open LPG tank valve Turn Key to the ON position for several seconds then turn back to OFF Using a liquid or electronic leak detection tool in spect the EPR fuel hoses and all serviced fittings for leaks 9 Start engine and check for leaks COON OD XXI EPR ECM MOUNTING BRACKET REMOVAL PROCEDURE 1 Disconnect the negative battery cable Relieve the LPG fuel system pressure Re fer to Ill LPG Fuel System Pressure Relief Dar Remove ECM Refer to I Engine Control Module Remove EPR Refer to XVIII Electronic Pressure Regulator Remove four screws securing the EPR ECM bracket to the Intake Manifold INSTALLATION PROCEDURE Place EPR ECM Mounting Bracket on adap ter Secure with four screws Torque to 12 Nm 106 in Ibs Mount EPR Refer to XVIII Electronic Pres sure Regulator Mount ECM Refer to I Engine Control Mod ule Reconnect negative battery cable Open valve on the LPG tank Start the vehicle and let run until it reaches normal operating temperature If a DTC code is found refer to the Electrical Section for further diagnosis XXII INTAKE MANIFOLD 1
81. mechanical damage Any problems found e Key OFF e Disconnect ECM connector CN1 e Check for continuity on MAP signal circuit 123 between MAP sensor connector CN4 and ECM connector CN1 Do you have continuity between them e Check for continuity on 5 volts supply cir cuit 119 between MAP sensor connector CN4 and ECM connector CN1 Do you have continuity between them 139 Value s Go to Step 3 Go to Step 4 Repair the circuit as necessary Refer to Wir ing Repairs in Engine Electrical Go to Step 6 Go to Step 7 Yes Go to Step 2 Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 8 Go to Step 5 Repair the circuit as necessary Refer to Wir ing Repairs in Engine Electrical Repair the circuit as necessary Refer to Wir ing Repairs in Engine Electrical Check for continuity on MAP sensor ground circuit 120 between MAP sensor connector CN4 and ECM connector CN1 Do you have continuity between them e Probe MAP signal circuit 119 on MAP connector CN4 with a test light connected to battery voltage Does the DST display MAP voltage of 4 0 or greater e Key OFF e Disconnect ECM connector e Check for continuity on 5 volts supply cir cuit 119 between MAP sensor connector CN4 and ECM connector CN1 Do you have continuity between them e Check for continuity between MAP sensor connector CN4 5 volt r
82. 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 e Diagnose any other DTC codes before pro ceeding with this chart Always repair existing codes starting with the lowest numerical code set first Value s Yes Key OFF Disconnect EGO 1 sensor wire harness con nector CN11 Disconnect ECM wire harness connector CN1 Key ON Using a high impedance DVOM check for continuity between EGO 1 connector signal circuit 121 and engine ground Repair the shorted circuit as necessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 6 Do you have continuity Repair the shorted circuit as necessary Refer to Wir ing Repairs in Engine Elec trical e Using a high impedance DVOM check for continuity between EGO 1 heater ground pin Repair the A Go to Step D and ECM pin 72 open EGO i 8 o ground Do you have continuity e Using a high impedance DVOM check for continuity on the EGO1 connector between the signal circuit 121 and ground circuit 120 Go to Step 7 Do you have continuity e Replace EGO 1 sensor Go to Step 9 Go to OBD System OK System Check Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start th
83. 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 412 DTC 2123 FPP 1 Low Voltage Value s Action Did you perform the On Board OBD System Check e Key ON Engine OFF e DST Diagnostic Scan Tool connected in System Data Mode Does the DST display FPP 1 voltage of 0 300 volts or less with the foot pedal in the idle posi tion e Slowly increase FPP while observing the FPP 1 voltage Does the DST ever display FPP voltage below 0 300 volts e Disconnect the System Interface connector CN21 e Jump the FPP 1 circuit 153 and 5 volt refer ence circuit 119 Does the DST now show FPP 1 voltage above 0 300 volts e Inspect FPP 1 and CN21 connectors for damage corrosion or contamination Did you find a problem e Replace FPP 1 sensor Is the replacement complete e Key OFF e Disconnect ECM connector CN1 e Using a DVOM check for continuity on the 5 volt reference circuit 119 between system in terface connector CN21 and ECM connector CN1 Do you have continuity e Using a DVOM check for continuity of the FPP1 circuit 153 between ECM connector CN1 and system interface connector CN21 Do you have continuity 413 0 300 volts or less Greater than
84. of AVV generated is a direct result of the throttle position At low engine speed the air valve vacuum and the air valve position is low thus creating a small venturi for the fuel to flow As the engine speed increases the AVV increases and the air valve is lifted higher thus creating a much larger venturi This air valve vacuum is communicated from the mixer venturi to the EPR secondary chamber via the low pressure fuel supply hose As the AVV increases in the secondary chamber the secondary diaphragm is drawn further down forcing the secondary valve lever to open wider The mixer is equipped with a low speed mixture adjustment retained in a tamper proof housing 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 N CAUTION The air fuel mixer is an emission control device Components inside the mixer are specifically calibrated to meet the engine s emissions requirements and should never be disassembled or rebuilt If the mixer fails to function correctly replace with an OEM replacement part THROTTLE CONTROL DEVICE DRIVE BY WIRE Drive By Wire Engine speed control is maintained by the amount of pressure applied to the foot pedal located in the engine compartment Ina Drive By Wire DBW application there is no di rect connection between the operator pedal and
85. of fuel injectors Refer to the Gasoline Fuel System Diagnosis Fuel System Checks 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 Check the spark plugs for the following conditions 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 Ignition System Checks Check for the following Improper valve timing Engine Mechanical Low compression Checks 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 Inspect the catalytic converter and muffler for signs of heat distress or for possible internal failure Check for possible plugged catalytic converter Refer to Restricted Ex haust System Diagnosis Exhaust System Checks 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 c
86. operating the engine within the test pa rameters of DTC 629 check for any stored codes Does the engine operate normally with no stored codes 312 313 DTC 642 External 5 Volt Reference Low Circuit 119 49 Lt 5 Volts Wire Color RW ECM Conditions for Setting the DTC External 5 volt reference Check Condition Engine cranking or running Fault Condition 5 volt reference voltage lower than 4 60 volts MIL On during active fault Adaptive Disabled during active fault 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 Action Did you perform the On Board OBD System Check e Key ON Engine Running e DST Diagnostic Scan Tool connected in System Fault Mode Does DST display DTC 642 Key OFF Disconnect ECM connector CN1 Using DVOM check for continuity between ECM 5 volt reference circuit 119 and engine ground Do you have continuity e Replace ECM Is the replacement complete While monitoring DVOM for continuity be t
87. 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 N WARNING 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 INSTALLATION Lubricate O rings on the sensor with petroleum jelly or Vaseline N WARNING 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 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 2 Install the sensor into the EPR port Lock in place with retaining clip 3 Reconnect electrical connector 4 Reconnect the negati
88. replacement in the Engine Controls Section Is the replacement complete e Disconnect ECM connector CN1 e Check for continuity between TMAP sensor connector CN4 circuit 123 and ECM connec tor CN1 circuit 123 Do you have continuity between them e Check for continuity between TMAP sensor connector CN4 MAP circuit 123 and engine ground Do you have continuity 182 Go to Step 9 Go to Step 10 Repair the open ground circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 14 Repair the open ground circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 13 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 11 Go to Step 16 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 15 Inspect ECM connector and wire harness connector pins for corrosion contamination or mechanical damage Any problems found e Replace ECM Refer to ECM replacement in the Engine Controls Section Is the replacement complete e Replace TMAP sensor Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition
89. sche dule When inspecting the fuel filter check the following e Check for leaks at the inlet and outlet fittings 15 using a soapy solution or an electronic leak detector and repair if necessary e Check to make sure filter is securely mounted e Check filter housing for external damage or distortion If damaged replace fuel filter REPLACING THE LPG FUEL FILTER 1 Move the equipment to a well ventilated area and verify that sparks ignition and any heat sources are not present Start the engine Close the LPG tank valve When the engine stalls when it runs out of fuel turn the ignition key to the OFF position and disconnect the battery negative cable ee IMPORTANT A small amount of fuel may still be present in the fuel line Use gloves and proper eye protection to prevent burns If liquid fuel continues to flow from the connections when removed make sure the manual valve is fully closed 5 Slowly loosen the inlet fitting and disconnect 6 Slowly loosen the outlet fitting and disconnect 7 Remove the filter housing form the equipment 8 Check for contamination 9 Tap the opening of the filter on a clean cloth 10 Check for debris 11 Check canister for proper mounting direction 12 Reinstall the filter housing to the equipment 13 Tighten the inlet and outlet fittings to specifica tion 14 Open the LPG tank valve IMPORTANT The fuel cylinder manual valve contains an Excess Flow Check Valv
90. 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 17 18 19 20 Mount EPR assembly in vehicle and recon nect electrical connector to EPR Insert Temperature Sensor and hose fittings into EPR and lock each into place using orig inal retaining clips Remove clamps on coolant hoses Check coolant fluid level Clean Shut Off Valve fitting apply LPG com patible pipe thread sealer and install into EPR assembly N WARNING Do not use Teflon tape to seal any LPG fit tings 21 Reconnect negative battery cable 22 Open valve on the LPG tank 23 Turn Key to the ON position for several seconds then turn back to OFF Using a liquid or electronic leak detection tool in spect the EPR fuel hoses and all serviced fittings for leaks 24 Start the vehicle and let run until it reaches normal operating temperature 25 If a DTC code is found refer to the Electrical Section for further diagnosis XIX EPR COOLANT HOSE REPLACEMENT REMOVAL PROCEDURE Drain coolant Remove Retaining Pins securing Coolant Hose Port Fittings and remove still attached to the Coolant Hose 3 Remove the Coolant Hoses from opposite ends by removing hose clamp Na N CAUTION The coolant may be hot Use caution when removing hose s to prevent contact INSTALLATION PROCEDURE IMPORTANT
91. sensor uses a variable resistor to determine signal voltage based on 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 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 420 DTC 2139 FPP 1 Lower Than IVS Limit Action Did you perform the On Board OBD System Check e Key ON Engine OFF e DST Diagnostic Scan Tool connected in System Data Mode Does the DST display IVS voltage less than 1 00 volts with the foot pedal in the idle position e Observe the FPP and IVS voltages e Stroke the pedal while observing the voltage readings Does FPP voltage drop below 0 85 volts at any time while the IVS reads less than 1 0 volt e Disconnect the System Interface connector CN21 e Check for continuity between circuits 153 and 120 at the system interface connector CN21 Do you have continuity e
92. 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 Improper gap Burned electrodes Heavy deposits Ignition System Checks Visually Physically inspect the secondary ignition for the following e Ignition wires for arcing and proper routing e Cross firing e Primary ignition coil wires for cracks or carbon tracking Perform a cylinder compression check Check the engine for the following Improper valve timing Engine Mechanical Improper valve clearance Checks Worn rocker arms Worn camshaft lobes Broken or weak valve springs Check the intake and exhaust manifold passages for casting flash Check the fuel system Fuel System Checks e Plugged fuel filter e 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 moni
93. take effect Click Yes to restart now or E You must restart pour system for the configuration changes made Noif you plan to manually restart later e Click Yes to restart your computer 92 Computer Internet Explorer AOL 9 0 E Default Programs er Windows Update New Office Document Open Office Document Mer gt Accessories bl Je ADSTech Instant DVD Wireles AOL Autodesk Volo View Je CyberLink PowerDVD Extras and Upgrades J Games MR Impco GCP Display Maintenance McAfee Microsoft Office Tools National Instruments En Programs Microsoft Excel Microsoft Word y Search Windows Calendar 2 Windows Contacts gt O Help and Support MJ Windows Defend LE Run B Windows DVD Maker 1 Window 533 Windows Fax and Scan amp Windows Live Messenger Download A Windows Mail Windows Media Center EAS Ae 5 Windows Media Player Windows Meeting Space E Windows Movie Maker 1 Windows Photo Gallery A A EZ X edis_saplot Impco GCP Display 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. terminal reshape the locking tab 2 WEATHER PACK A Weather Pack connector can be identified by a rubber seal at the rear ofthe 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 protection is necessary to ensure a good connec tion 127 WEATHER PACK TERMINAL REPAIR FEMALE MALE CONNECTOR CONNECTOR SECONDARY J LOCK HINGE 1 Open secondary lock hinge on connector dl release TERMINAL TOOL J 28742 BT8234 A 2 Remove terminal using tool Pay X Wire Seal 3 Cut wire immediately behind cable seal 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 backup or secondary locking feature for the con
95. than in the other chamber the diaphragm will move toward the side with the low pressure Diaphragm Port The external port located at the fuel inlet assembly and connected to the vacuum chamber above the air valve diaphragm DLC Data Link Connector DTC Diagnostic Trouble Code DST Diagnostic Scan Tool DVOM Digital Volt ohm Meter A meter that uses a numerical display in place of a gauge and is usually of the high impedance type ECT Engine Coolant Temperature ECM Electronic Control Module ECOM A DLC cable supporting CAN and serial communication with a Spectrum II or III ECM EFI Electronic Fuel Injection A fuel injection sys tem which uses a microcomputer ECM to determine and control the amount of fuel re quired by and injected into a particular engine EGO Exhaust Gas Oxygen used to describe a sensor Also known as HEGO Heat Exhaust Gas Oxygen sensor O or Oxygen sensor EGR Exhaust Gas Recirculation EPA Environmental Protection Agency A regulat ing agency of the Federal government which among other duties establishes and enforces au tomotive emissions standards Ethanol Grain alcohol C2H50H generally pro duced by fermenting starch or sugar Evaporative Emissions Controls An automotive emission control system designed to reduce hy drocarbon emissions by trapping evaporated fuel vapors from the fuel system Excess Flow Valve A check valve that is caused to close by the
96. 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 No Yes fo Go to Step Go to Step 3 2 Go to Step Go to Step 6 4 Was a repair made e Diagnose any other DTC codes before pro ceeding with this chart Go to Step Go to Step 6 4 Have any other DTC codes been detected diag 18 a nosed and repaired Action Value s Perform the On Board OBD System Check 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 The EGO sensor installed securely and the wire leads not damaged contacting the sec ondary ignition wires ECM grounds for being clean and tight Run the fuel system diagnostic checks Key OFF Disconnect EGO sensor wire harness connec tor Disconnect ECM wire harness connector Key ON Using a DVOM check for voltage between EGO 1 connector CN11 signal circuit 121 and engine ground Repair the circuit short to voltage as Go to Step necessary 5 Refer to wir ing harness repair Do you have voltage e Replace EGO sensor Go to Step 6 Is the replacement complete 343 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM
97. the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 341 check for any stored codes Does the engine operate normally with no stored codes 276 277 DTC 342 Camshaft Sensor Loss Wire RAV 5 volts Dist Cam Sensor Conditions for Setting the DTC 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 MIL On for active fault Adaptive Disabled 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 Action Did you perform the On Board OBD System Check e Check that the ECM ground terminal CN28 is clean tight and in the proper location Is the ground terminal clean tight and in the proper location Key OFF Disconnect the CMP Camshaft Position Sensor connector CN2 Key ON Using A DVOM check for
98. the EPR Is the replacement complete 370 Go to Step 9 Go to Step 10 Go to Step 11 Go to Step 12 Go to Step 13 Repair the shorted to ground CAN circuit as ne cessary Refer to wir ing repairs in engine elec trical Go to Step 15 Repair the open circuit as necessary Refer to wir ing repairs in engine elec trical Repair the open circuit as necessary Refer to wir ing repairs in engine elec trical Repair the open circuit as necessary Refer to wir ing repairs in engine elec trical Repair the open circuit as necessary Refer to wir ing repairs in engine elec trical Repair the open circuit as necessary Refer to wir ing repairs in engine elec trical Go to Step 14 Remove all test equipment and reconnect the DST Connect any disconnected components fus es 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 Go to Step System OK full operating temperature 16 Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1173 check for any stored codes Does DTC1173 still re set e Replace the ECM Go to Step 17 Is the replacement complete 2 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from
99. the O rings on the neck or inlet of the Throttle Body Three O rings are used two are quad seals with an X cross section and one has a round cross section 9 Remove gasket between Throttle Body and Intake Manifold 10 Remove O rings from the Throttle Body neck INSTALLATION PROCEDURE 1 Lightly lubricate new O rings with Vaseline or petroleum jelly prior to installation N WARNING 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 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 2 Place the quad seals and third O ring on the neck of the Throttle Body maintaining the same order as before IMPORTANT Verify that the quad seals rest flat against the neck of the Throttle Body with no twists 3 Carefully place the Adapter on top of the Throttle Body e
100. the engine within the test pa rameters of DTC 270 check for any stored codes Does the engine operate normally with no stored codes 260 261 DTC 271 Injector Driver 4 Coil Shorted Circuit Wire Color 164 L Injector Driver 1 Injector Driver 2 Injector Driver 3 Injector Driver 4 Ignition Fuse and Power Relay Conditions for Setting the DTC Injector coil shorted Check Condition key on and engine running Fault Condition Battery voltage at ECM less than 16 volts and injector on state low side greater than 4 volts for 10 injector firings MIL On Adaptive Disabled Closed Loop Disabled Circuit Description System battery voltage is supplied to each fuel injector The ECM controls each fuel injector by 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 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 262 DTC 271 Injector Driver 4 Coil Shorted Value s Action Did you perform the On Board OBD System Check e Key On Engine Running e DST Diagnostic Scan Tool connected in System Data Mode e Clear System DTC 271 Does DTC
101. ure Check for possible plugged catalytic converter Refer to Restricted Ex haust System Diagnosis Exhaust System Checks 43 Checks HARD START 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 Sensor Checks Fuel System Checks Ignition System Checks e 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 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 e Verify the excess flow valve is not tripped or that the LPG tank valve is not closed Check mixer assembly for proper installation and leakage e Verify proper operation of the low pressure lock off solenoid e Verify proper operation of the EPR e 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 Note LPG being a gaseous fuel requires highe
102. voltage between CMP sensor connector circuit 119 and en gine ground RUN THIS VOLTAGE CHECK BEFORE THE POWER RELAY SHUTS OFF Do you have voltage e Key OFF e Disconnect ECM connector CN1 e Using a DVOM check for continuity on the CMP signal circuit 127 between CMP con nector CN2 and ECM connector CN1 Do you have continuity between them e Using a DVOM check for continuity on the sensor ground circuit between CMP connec tor CN2 and ECM connector CN1 Do you have continuity between them e Inspect the CMP connector CN2 terminals for damage corrosion or contamination Did you find a problem 279 Value s Go to Step 2 Go to Step 3 Go to Step 5 0 volts 4 Go to Step 5 Go to Step 6 Repair the circuit as ne cessary Refer to wir ing harness repair sec tion Go to OBD System Check Sec tion Repair the circuit as ne cessary Refer to wir ing harness repair sec tion Repair the circuit as ne cessary Refer to wir ing harness repair sec tion Repair the circuit as ne cessary Refer to wir ing harness repair sec tion Repair the circuit as ne cessary Refer to wir ing harness repair sec tion Go to Step 7 Repair the circuit as ne cessary Refer to wir ing harness repair sec tion Inspect the ECM connector terminals for damage corrosion or contamination Go to Step 8 Did you find a problem e Replace the CMP
103. 0 4 15614 0 32 5887 20 68 2510 40 104 2000 60 140 612 70 158 446 80 176 330 100 212 186 120 248 110 130 266 85 45 DTC 182 FRT Voltage Low Gasoline Bi Fuel Only Value s Action Did you perform the On Board OBD System Check e Key On e DST Diagnostic Scan Tool connected in System Data Mode Does DST display FT voltage of 0 050 or less e Key Off e Disconnect the FT wire harness connector CN16 e Key ON Does the DST display FT voltage of 4 90 volts or greater e Replace FT sensor Is the replacement complete e Key OFF e Disconnect ECM wire harness connector CN1 e Check for continuity between fuel tempera ture sensor connector CN16 circuits 120 and 138 Do you have continuity between them e Check for continuity between the fuel tem perature sensor connector signal circuit 138 and engine ground Do you have continuity 201 Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 8 Repair the shorted circuit as required See Repairs in Engine Electrical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 5 Go to Step 6 Go to Step 7 Value s Yes e Replace ECM Refer to ECM replacement in the Engine Controls Section Go to Step 8 Is the replacement complete Remove all test eq
104. 0 300 volts Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 Repair the circuit as re quired See wiring har ness repair section Go to Step 12 Go to Step 8 Go to Step 9 Go to OBD System Check Sec tion Go to Step 3 Intermittent problem Go to Inter mittent section Go to Step 7 Go to Step 6 Repair the open circuit as required See wiring harness re pair section Repair the open circuit as required See wiring harness re pair section Repair the Key ON signal shorted to ground cir cuit as Go to Step required See 10 ae 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 wiring har 11 ness repair section Go to Step 12 e Using a DVOM check for continuity between ECM connector circuit153 and engine ground Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds aa the nn and ae the vehicle to Co to OBD ull operating temperature Observe the MIL System Oks id Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2123 check for any stored codes Does the engine operate normally with no stored codes
105. 20 920 4500 300 680 750 815 825 ssf eso 900 905 s1o 910 910 910 910 910 910 TEF A 5000 300 6sof 700 750 780 810 820 850 e60 870 870 870 870 870 870 870 empereiure 5200 300 680 00 750 780 810 830 eso eso 870 s7o ezo 870 870 870 870 IAT min contribution 00 VE IAT max contribution 95 0 MAT estimati E Ewesosd EEE m o IE m a Manifold Pressure BO psia VE final St Pulse width offset 032 ms AED learag iza ms Een 98 Fuel rail pressure 539 psia Throttle estimated MAP 830 ling ESD sr peca 47 E Fuel pressure comection 1 000 fraction Throttle estimated MAPA 0 9 psi sec Coolant Tonpens re rection 00 Cylinder Head Temp 1850 deg F en rn ah MAP CAD project 270 CAD Manifold Temperature 165 0 deg F ER rau kun pod 700 mo intake MAP effective 200 psa Intake Air Temperature 110 0 degF 1 Bank2 mdot air port 00 9 sec 00 00 I Global Adv Offset 0 0 CADBTDC a te mdotfuelpot 0 00 g sec Exhaust Back Pressure Esitmate Total Spark Advance 95 caDeToc moot air throttle 0 EBP estimate _ Exhaust flow rte estimate _ Phi global offset 00 el 00 gt mdot fuel throtle 000 EBP default gauge mu EBP flow rate constant 7 400 upsig V s 2 Phi command UEGO phi x ss Inn ee EGO1 70069 vots EBP gauge 000 psig 70096 vots 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
106. 266 85 45 DTC 183 FT Voltage High Gasoline Bi Fuel Only Value s Action Did you perform the On Board OBD System Check e Key On e DST Diagnostic Scan Tool connected in System Data Mode Does DST display FT voltage of 4 90 or greater e Key Off e Disconnect the FT sensor connector CN16 and jump connector circuits 120 and 138 e Key On Does the DST display FT voltage of 0 05 volts or less e Using a DVOM check the resistance be tween the two terminals of the FT sensor and compare the resistance reading to the chart Is the resistance value correct e Replace FT sensor Is the replacement complete e Inspect the FT sensor connector terminals for damage corrosion or contamination Did you find a problem Key OFF Disconnect ECM wire harness connector CN1 Inspect ECM connector pins for damage cor rosion or contamination Did you find a problem 205 Go to Step 2 Go to Step 3 Go to Step 4 See tem perature vs resistance chart in the DTC 183 schematic page Go to Step 6 Go to Step 14 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 8 Go to Step 5 Go to Step 7 Intermittent problem Go to In
107. 271 reset with the engine idling Key OFF Disconnect the injector interface connector CN20 Using a high impedance DVOM measure the resistance between the fuel injector pins at the fuel metering body at an ambient tem perature of 50 to 90 degrees F Does the DVOM display a resistance value of 5 ohms or more e Replace the Fuel Injector Is the replacement complete Disconnect the ECM wire harness connector CN1 Key ON Using a DVOM check for voltage between the ECM connector CN1 injector control cir cuit 166 and engine ground Does the DVOM display voltage e Replace the ECM Is the replacement complete Go to Step 2 Go to Step 3 Greater than Go to Step 5 0 Ohms 5 Go to Step 8 Repair the shorted to voltage injec tor driver circuit as ne cessary Refer to Wir Engine Elec trical Go to Step 7 ing Repairs in Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 4 Go to Step 6 263 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature System OK Go to OBD Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC271 check for any stored codes
108. 3 Follow the EPR service recommenda tions from the fuel pressure test chart Go to Step 5 Go to OBD System Check DTC 1172 EPR Pressure Lower Than Expected Circuit Wire Color G Br Ground Ground To Power Relay Fuse Block CN25 Conditions for Setting the DTC EPR delivery pressure Check condition Engine running or cranking MIL On during active fault Fault condition EPR actual pressure less than 1 0 inches below 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 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 Value s Action Did you perform the On Board OBD System Check Did you run the fuel pressure diagnostic test in the fuel system diagnostic section
109. 414 415 DTC 2135 TPS 1 2 Voltages Out Of Range Electronic Throttle Circuit Wire ECM Color L TPS 1 Signal Sensor Ground TPS 2 Signal 5 Volts Conditions for Setting the DTC Throttle Position Sensor Check Condition Cranking or Running Fault Condition TPS 1 and TPS 2 signals simultaneously out of range MIL On during active fault 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 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 _ Action Did you perform the On Board OBD System Key ON Engine OFF DST Diagnostic Scan Tool connected in DBW Drive By Wire test mode Depress foot pedal until the throttle com mand is 63 68 Is the TPS voltage less than 2 0 volts Key OFF Disconnect electronic throttle connector CN3
110. 5 Greater than 4 80 volts Less than 0 10 volts Less than 0 10 volts Yes Go to OBD System Check Sec tion Go to Step 2 Intermittent problem Go to Inter mittent section Go to Step 6 Go to Step 5 Go to Step 7 Go to Step 3 Go to Step 4 Repair the circuit as ne cessary See wire harness repair sec tion Go to Step 11 Go to Step 8 Repair the circuit as ne cessary See wire harness repair section Go to Step 9 Disconnect the ECM wire harness connector CN1 Check for continuity on the sensor ground circuit 120 between FRP sensor connector CN16 and ECM connector CN1 Do you have continuity between them Re check wire harness and FRP sensor connector for damage corrosion or contami nation Any problems found e Replace the ECM Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveabili ty Does the engine operate normally with no stored codes 136 Go to Step 9 Repair the circuit as ne cessary See wire harness repair sec tion Go to Step 11 System OK Repair the circuit as ne cessary See wire harness repair sec
111. 7 Cilindernumbering Fring Order Manifold Temperature 1900 F Adaptive2 00 po Intake Air Temperature 220 F Pan Lop y LA 235 Derates Warnings EGO3 0 000 volts Govemor switch state None 5 0 0 32 4 MS Spark Advance 35 BTDC Postcat CL offset 0 000 phi z 6 0 0 422 a Pulse width 0 0 ms Altemate Fuel er Me 7 te temate p a ca 0 0 48 2 00 Active govemor mode Isochronous Fuel rail pressure 108 9 psa tim duty cycle mm ri Low Rev Lim Fuel temperature 770 degF Brake input level MIL output pin Gaseous pressure target 0 00 H20 Ts Variables Oil pressure state S Sh Spel Buzzer output pin Gaseous pressure actual 0 00 H20 e 00 Of presse cont AN ren posten 00 vsstate Current govemor target 1200 rpm x 2 250 TPS1 percent 00 Engine Load 00 F h Volta 3 250 TPS2 percent 100 0 Input Voltages Current estimated torque 0 0 Nm 4 250 2 a TPS1 voltage 0 005 volts Gov voltage 2 0 volts Curent estimated torque 00 5 250 E a TPS2 voltage 0 000 volts Gov2 voltage 2 0 volts E atte me vots FPP command 12 Oil pressure voltage 5 0 vots z ama V switched 14 7 volts gt Y 7 250 FPP position 00 MAP voltage 0 0 volts Hour meter 0 079 hous FPP voltage 0 015 vots ECT CHT voltage 5 0 vols Cumulative starts 3 starts FPP voltage 5 005 vols IAT voltage 50 vols IVS voltage 5 000 vols SnapShot Base Definitions CL_BM1 EGO1_voks Po ee re pos Double click fault for information our
112. 77 check for any stored codes Does the engine operate normally with no stored codes 381 DTC 1178 EPR Internal Communication Error Circuit Wire Color G Br Ground Ground To Power Relay Fuse Block CN25 Conditions for Setting the DTC EPR internal communication test Check condition Engine running or cranking MIL On during active fault Fault condition 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 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 Action Value s Go to OBD Did you perform the On Board OBD System Go to Step System Check 2 Check Sec tion DST connected and in the system data mode Check for any other current or active DTCs Go to Step Go to Step 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 4 Have the other DTC s s
113. 8 e Replace the ECM Go to Step 9 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 685 check for any stored codes Does the engine operate normally with no stored codes 322 323 DTC 686 Relay Control Ground Short Power Relay Relay Control VSW fuse Battery Voltage EPR lgnition Fuses Conditions for Setting the DTC e Power relay ground control e Check Condition Key ON e Fault Condition Relay control shorted to ground 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 a short to ground 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 324 DTC 686 Relay Control Ground Short Action Did you perform the On Board OBD System Chec
114. 8 Go to Step 6 Go to Step 7 Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature Observe the MIL Zul en Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 562 check for any stored codes System Does the engine operate normally with no stored codes 294 295 DTC 563 System Voltage High Circuit Wire Color ECM GROUND 181 E 181 179 R VBAT 179 Conditions for Setting the DTC System Voltage to ECM Check Condition Cranking or Running Fault Condition System battery voltage at ECM greater than 16 volts MIL On for active fault Adaptive Disabled 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 Action Did you perform the On Board OBD System Check e Key On Engine Runni
115. B e 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 ll and series III DST software pro grams Favorite Links E Documents E Pictures BB Music More Folders BZ Desktop E Top Tech Je Public ME Computer amp Local Disk C DVD RW Drive D 070413_0948 e KINGSTON E Network Control Panel E Recycle Bin Es 1 item e Open the DST_Series Ill folder v 4 search Name Size Date modified Location Files Currently on the Disc 1 Type DST_Series I 95 Favorite Links E Documents E Pictures E Music More Folders BZ Desktop Top Tech J Public jE Computer amp Local Disk C DVD RW Drive D 0704130948 Ji DST_Series I J ECOM Driver Latest_GCP_Display Ji USB Driver e KINGSTON Es MY Network Control Panel Name Size Type Date modif Location Files Currently on the Disc 1 Setup ECOM Drivers and Software EControls Inc 1E Recycle Bin A 1 item e Double click on setup exe application file Welcome to the ECOM Drivers and Software Setup Wizard This will i
116. C codes were found e f 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 EDIS ECI Target Communications File Page Flash Comm Port Plot Log Help Link error attempting reconnect Faults Connected at 19200 bps Fau Access MIL OlasecHL age Cantal SSE States Mentared Drivers Engine Speed EGO1 0 401 volts Run Mode Stopped Injector Injector on Injector off Manifold Pressure Closed loop 1 I nn Power Mode Standby ve Pisa Tyc BERS Barometric Pressure Adaptive Historic Fault Information xj Coolant Temperature 40 0 I EGO2 Fauk Description Cylinder Head Temp 165 0 Closed lo a E e a DTC 2128 FPP2 voltage high Manifold Temperature 165 0 Adaptive 11939 SPN 0 FMI 0 Intake Air Temperature 40 0 EGO3 Spark Advance Ts Post cat Pulse width 2 8 Alternate Fuel rail pressure 479 trim duty Fuel temperature 770 Gaseous pressure target 0 00 Gaseous pressure actual 0 00 Current governor target 800 Enare Load Laz TPS1 pe IV Fault occurred during current key cycle ade TPS cor TPS posi TPS2 pe F Fault caused current engine shutdown TPS1 vo TPS2 vo volts FPP com volts FPP posi E i Clear All Faults J View Snap Shot Data J FPP1 vol Moteros f ren Data Cumulative starts 0 stats Epp yol IVS voltage 5 000 volts SnapShot Base Definitions Historic Faults Active Faults run_tmi_
117. C 123 check for any stored codes Does the engine operate normally with no stored codes 176 177 DTC 127 IAT Higher Than Expected 2 Wire Color ECM Conditions for Setting the DTC Intake Air Temperature Check Condition Engine Running 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 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 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 DTC 127 IAT Higher Than Expected 2 Diagnostic Aid e 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 e Inspect the air inlet system for cracks or breaks tha
118. Check for the proper ignition output voltage using the spark tester J26792 or the equivalent Remove the plugs and inspect them for the following conditions Verify that the spark plugs are the correct type and properly gapped Wet plugs Cracks Wear Improper gap Burned electrodes 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 Ignition System Checks Check for vacuum leaks Vacuum leaks can cause a higher than normal idle and low throttle angle control command ve Check the ECM grounds for being clean tight and in their proper loca apena cheeks 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 Improper valve timing Engine Mechanical Improper valve clearance Check Low compression Worn rocker arms Broken or weak valve springs Worn camshaft lobes 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 Preliminary Checks None Sensor Checks Check the Heated Exhaust Gas Oxygen Sensors HEGO performance Check for Rich or Lean symptom that causes the condit
119. Condition System voltage greater than 9 volts and injector low side less than 4 0 volts for 10 injector firings e MIL On for active fault e Adaptive Disabled e 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 ifthe 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 250 DTC 267 Injector Driver 3 Open or Low Side Short to Ground Step Action Did you perform the On Board OBD System Check Key On Engine Running DST Diagnostic Scan Tool connected in system data mode Clear System DTC 267 Does DTC 267 reset with the engine idling at the fuel metering body at an ambient tem perature of 50 to 90 degrees F e Replace the Fuel Injector Key OFF Disconnect the injector interface connector CN19 Using a high impedance DVOM measure 3 the resistance between the fuel injector pins Does the DVOM display a resistance value of 20 ohms or less Is the replacement complete e Disconnect the ECM connector CN1 e Using a DVOM measure the resistance be tween the in
120. D System Check e Key On e DST Diagnostic Scan Tool connected in System Data Mode Does DST display FT voltage of 0 050 or less e Key Off e Disconnect the FT wire harness connector CN14 e Key ON Does the DST display FT voltage of 4 90 volts or greater e Replace FT sensor Is the replacement complete e Key OFF e Disconnect ECM wire harness connector CN1 e Check for continuity between fuel tempera ture sensor connector CN14 circuits 120 and 139 Do you have continuity between them e Check for continuity between the fuel tem perature sensor connector signal circuit 139 and engine ground Do you have continuity 209 Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 8 Repair the shorted circuit as required See Repairs in Engine Electrical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 5 Go to Step 6 Go to Step 7 Value s Yes e Replace ECM Refer to ECM replacement in the Engine Controls Section Go to Step 8 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Go to
121. 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 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 Intermittent MIL Illumination To check for the loss of the DTC Memory Disconnect the TMAP sensor Loss of DTC Memory Idle the engine until the MIL illuminates 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 Use the DST to e Check for proper communication with both the ECM e Check all system fuses engine fuse holder Refer to Engine Controls ECM Checks Schematics e Check battery power ignition power and ground circuits to the ECM Re fer to Engine Control Schematics Verify voltage and or continuity for each Sensor Checks e Check the TMAP sensor e Check the cam angle sensor for output RPM Important A closed LPG manual fuel shut off val
122. DTC 1628 check for any stored codes Does the engine operate normally with no stored codes 395 Value s Go to Step 2 Go to Step 3 Repeat Step 3 until all CAN devices have been disconnected one ata time Go to Step 5 System OK Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Contact the CAN device manufacturer for additional CAN address information Go to Step 4 Go to OBD System Check DTC 2111 Unable To Reach Lower TPS Electronic Throttle Circuit Wire ECM Color L TPS 1 Signal Sensor Ground TPS 2 Signal 5 Volts Conditions for Setting the DTC Throttle Position Sensor Check Condition Cranking or Running Fault Condition Actual throttle position is 20 greater than the throttle command MIL On during active fault 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 wil
123. DVOM display a resistance value of 20 ohms or less e Replace the Fuel Injector Is the replacement complete Disconnect the injector interface connector CN20 Disconnect the ECM connector CN1 Using a DVOM measure the resistance be tween the injector control circuit 166 and engine ground Does the DVOM display a resistance of 5 Ohms or less e Using a DVOM check for continuity on the injector control circuit 166 between the CN20 connector and the ECM connector CN1 Do you have continuity between them 259 Value s 20 ohms or less 5 Ohms or less Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 8 Repair the shorted to ground injec tor control circuit See wire har ness repair section Go to Step 7 Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent electrical sec tion Go to Step 4 Go to Step 6 Repair the open injector control circuit See wire har ness repair section Value s Yes e Replace the ECM Go to Step 8 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After operating
124. ECM connector CN1 Disconnect ignition module connector CN6 Using a DVOM check for voltage between ignition module connector CN6 circuit 104 and engine ground Do you have voltage e Replace the ignition module 4 Is the replacement complete 455 Value s _ Yes Go to Step 2 Go to Step 3 Repair the shorted to voltage coil 1 circuit Go to Step 6 Go to OBD System Check Sec tion Intermittent problem See Intermittent problems in the electrical section Go to Step 4 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2310 check for any stored codes Does the engine operate normally with no stored codes e Replace the ECM Is the replacement complete e Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2310 check for any stor
125. F 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 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
126. Go to Step 7 Do you have continuity e Replace EGO 1 sensor Go to Step 9 Go to OBD System OK System Check Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 1161 check for any stored codes Does the engine operate normally with no stored codes Using a high impedance DVOM check for continuity on the EGO 1 heater control circuit Repair th 162 between EGO 1 connector CN11 and Go to Step EGO ECM connector CN1 8 nung Do you have continuity 356 397 DTC 1162 Adaptive Learn Low LPG Circuit Wire Color G B EGO 1 Signal Signal Ground EGO 1 Heater Ground Power Relay Fuse Block CN25 7 Ignition Fuse Conditions for Setting the DTC Heated Oxygen Sensor Check Condition Engine running 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 Thi
127. Key ON Using a DVOM check the voltage between circuit 119 and engine ground Is the voltage greater than 4 5 volts e Using a DVOM check the voltage between circuit 119 and circuit 120 at the throttle con nector CN3 Is the voltage greater than 4 5 volts e Disconnect ECM connector CN1 e Using a DVOM check continuity on circuit 147 between connector CN1 and CN3 Do you have continuity e Using a DVOM check continuity on circuit 148 between connector CN1 and CN3 Do you have continuity 417 Value s Go to Step 3 Greater than 4 5 volts Greater than 4 5 volts Go to Step 4 Go to Step 5 Go to Step 6 Go to Step 7 Go to System Check Section Intermittent problem Go to Intermit tent section Repair circuit 119 as neces sary Refer to Wiring Re pairs in Engine Elec trical Repair circuit 120 as neces sary Refer to Wiring Re pairs in Engine Elec trical Repair circuit 147 as neces sary Refer to Wiring Re pairs in Engine Elec trical Repair circuit 148 as neces sary Refer to Wiring Re pairs in Engine Elec trical Value s _ Yes Repair circuit Using a DVOM check continuity on circuit 120 as neces 120 between connector CN1 and CN3 Go to Step sary Refer to 8 Wiring Re Do you have continuity pairs in Engine Elec trical e Replace throttle Go to Step 9 Is the replacement complete 9 Remove all test equipment except the DST C
128. L Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2123 check for any stored codes Does the engine operate normally with no stored codes Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2123 check for any stored codes Does the engine operate normally with no stored codes 422 Yes Go to Step 10 Go to Step 11 System OK System OK Go to Step 9 Go to OBD System Check 423 DTC 2229 BP High Pressure Wire Color 120 Gr Circuit ECM Conditions for Setting the DTC Barometric Pressure Check Condition Key On Fault Condition BP greater than 16 psia MIL On for active fault Adaptive Disabled 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 Value s Yes Action Did you perform the On Board OBD System Check DST Diagnostic Scan Tool connected in Syst
129. M 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 Action Did you perform the On Board OBD System Check e Key On Engine Running e DST Diagnostic Scan Tool connected in System Data Mode e Clear system fault code Does DTC 601 reset with the engine idling e Check ECM power and ground circuits Did the power and ground circuits check OK e Replace ECM Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 601 check for any stored codes Does the engine operate normally with no stored codes 299 Value s Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 System OK Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent sec
130. N1 Key ON Using a DVOM check for voltage at EGO 1 connector signal circuit 121 and engine ground Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 5 Do you have voltage e Replace EGO sensor Go to Step 6 Is the replacement complete 359 Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD operating temperature Observe the MIL SYPIE OR oe Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 1162 check for any stored codes Does the engine operate normally with no stored codes 360 361 DTC 1165 Catalyst Monitor Test Circuit Wire Color G B EGO 1 Signal Signal Ground EGO 1 Heater Ground Power Relay Fuse Block CN25 T Ignition Fuse Conditions for Setting the DTC Heated Oxygen Sensor Check condition Engine running Fault condition Catalyst monitor test failed MIL On during active fault 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
131. NANCE REQUIREMENTS Perform the following maintenance on the engine at the hours indicated and at equivalent hour intervals thereafter Interval Hours Daily 1000 11500 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 R
132. O2 downstream voltage output CAUTION The Heated Exhaust Gas Oxygen Sensor HEGO is an emissions control compo 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 TMAP SENSOR T MAP 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 The intake air temperature or IAT sensor is a variable resistance thermistor located in the air intake passage which measures the tempera ture of the incoming air The ECM uses the resistance value to monitor incoming air tem 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 60 COOLANT TEMPERATURE SENSOR The En
133. OBD ull operating temperature Observe the MIL Sys OK pS Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 1613 check for any stored codes Does the engine operate normally with no stored codes 387 DTC 1614 RTI 3 Loss Microprocessor Conditions for Setting the DTC 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 limiting maximum power 388 DTC 1614 RTI 3 Loss Action Value s Go to OBD Did you perform the On Board OBD System Go to Step System Check 2 Check Sec tion e Key On Engine Running f e DST Diagnostic Scan Tool connected in intermittent System Data Mode Go to Step proniem e Clear system fault code 3 E section Does DTC 1614 reset with the engine idling Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical e Check ECM power and ground circuits Go to Step 4
134. OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2301 check for any stored codes Does the engine operate normally with no stored codes e Replace the ECM Is the replacement complete e Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2301 check for any stored codes Does the engine operate normally with no stored codes 432 Value s Yes No System OK Go to Step 7 System OK Go to Step 6 Go to OBD system check 433 DTC 2303 Primary Loop Open Low Side Short to Ground Cylinder 1 Cylinder 4 Cylinder 3 Ignition Coil Pack Puse Interface Power Relay Fuse Block CN25 Conditions for Setting the DTC Ignition Control Check Check condition Engine running or cranking Fault condition Adaptive dwell greater than 2 0ms or total dwell greater than 14 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers ignition b
135. Replace EGO sensor Go to Step 6 Is the replacement complete 197 Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD operating temperature Observe the MIL SYPIE OR oe Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 172 check for any stored codes Does the engine operate normally with no stored codes 198 199 DTC 182 FRT Voltage Low Gasoline Bi Fuel Onl Wire Color ECM Conditions for Setting the DTC Fuel Rail Temperature Check Condition Engine Running Fault Condition FT sensor voltage less than 0 050 volts MIL On Adaptive Disabled Circuit Description The FRT Fuel Rail Temperature sensor is a temperature sensitive resistor located near the fuel outlet of the elec tronic pressure regulator It is used to help determine fuel charge density for accurate fuel mixture control The ECM provides a voltage divider circuit so that when the sensor is cool the signal reads a higher voltage and lower when warm This fault will set if the signal voltage is less than 0 050 volts anytime the engine is running 200 Rail Sensor Temp Resistance in Ohms Degrees Degrees 6 40 40 48153 2
136. System OK Go to Step 12 System OK Go to Step 11 Go to OBD system check 437 DTC 2304 Primary Coil Shorted to Voltage Cylinder 1 Cylinder 4 Cylinder 3 Ignition Coil Pack Puse Interface Power Relay Fuse Block CN25 Conditions for Setting the DTC Ignition Control Check Check condition Engine running or cranking Fault condition Adaptive dwell less than 2 0ms or total dwell less than 4 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers the ignition coil 2 ignition by providing ground to the ignition connector circuit 102 This code will set if the ECM low side driver circuit 102 remains high or is shorted to vol tage 438 DTC 2304 Primary Coil Shorted to Voltage Action Did you perform the On Board OBD System Check Key ON Engine OFF DST Diagnostic Scan Tool connected in System Data Mode Clear DTC 2304 Crank the engine Does DTC 2304 re set Key OFF Disconnect ECM connector CN1 Disconnect ignition module connector CN6 Using a DVOM check for voltage between ignition module connector CN6 circuit 102 and engine ground Do you have voltage e Replace the ignition module 4 Is the replacement complete 439 Value s _ Yes Go to Step 2 Go to Step 3 Repair the shorted to voltage coil 1 circuit Go to Step 6 Go to OBD System Check Sec tion Intermittent problem
137. T OFF VALVE The LPG Shut Off Valve is an integrated assembly consisting of a 12 volt solenoid and a normally closed valve When energized the solenoid opens the valve and allows the LPG fuel to flow through the device The valve opens during cranking and engine run cycles LPG Shut Off Valve 22 Voltage to the LPG Shut Off Valve is controlled by the engine control module ECM ELECTRONIC PRESSURE REGULATOR EPR The EPR is a combination vaporizer and pressure regulating device The EPR functions as a nega tive pressure two stage regulator that is normally closed with the ability to supply additional fuel by command from the ECM When the engine is cranking or running a partial vacuum is created in the fuel line which connects the regulator to the mixer This partial vacuum opens the regulator permitting fuel to flow to the mixer LPG fuel enters the primary port of the EPR and 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 into the secondary chamber from the mixer draw ing the secondary diaphragm down onto the spring loaded lever and opening t
138. 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 Step Action Did you perform the On Board OBD System Check Key On Engine running at full operating temperature DST Diagnostic Scan Tool connected in the System Data Mode Does DST display MAP pressure of 16 00 psia or greater with the engine running above 1000 RPM and a TPS value less than 3 0 e Key OFF e Disconnect the MAP sensor connector CN4 e Key ON Does the DST display MAP pressure less than 0 05 psia tage e Check MAP mechanical vacuum connection for correct mounting or possible damage causing vacuum leakage Is the MAP sensor mechanical connection OK e Key OFF e Disconnect ECM connector CN1 and inspect terminals for damage corrosion or contami nation Is the connection OK e Replace MAP sensor e Probe MAP connector CN4 ground circuit 120 with a test light connected to battery vol 4 Does the test light come on Is the repair complete 143 Value s Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 6 Go to Step 7 Go to Step 11 Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 6 Go to Step 8 Go to Step 10 Repair the circuit as
139. Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full Go to OBD operating temperature Observe the MIL SYPIE OR oe Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 1152 check for any stored codes Does the engine operate normally with no stored codes 344 345 DTC 1155 Closed Loop High Bi Fuel Gasoline Onl Circuit Wire Color G B EGO 1 Signal Signal Ground EGO 1 Heater Ground Power Relay Fuse Block CN25 7 Ignition Fuse Conditions for Setting the DTC Heated Oxygen Sensor Check Condition Engine Running Fault Condition Closed Loop multiplier out of range greater than 35 0 MIL On 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 Adaptive multiplier This fault will set if the adaptive multip lier exceeds the limits of normal operation Always run 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 contaminate
140. Voltage The electrical pressure that causes cur rent to flow in a circuit Measured in volts Voltage Drop A lowering of the voltage in a circuit when resistance or electrical load is added Voltmeter A meter that uses a needle to point to a value on a scale of numbers usually of the low impedance type used to measure voltage and resistance VSS Vehicle Speed Sensor Xylene CH CH3 2 Any of three toxic flammable and oily isomeric aromatic hydrocar bons that are dimethyl homologues of benzene and usually obtained from petroleum or natural gas distillates ZEV Zero Emission Vehicle 480 TOOL KIT amp ACCESSORIES WV yy oy eed fe PSID e 7 INCHES wc Y 11 12 481 TOOL KIT IMPCO P N ITK 4 A Description A IMPCO Part Number 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 9 onda er Adale 4 Pparat 0S 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 UN
141. a DTC exists 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 Verify the customer complaint Locate the correct symptom table Check the items indicated under that symptom Operate the vehicle under the conditions the symptom occurs Verify HEGO switching between lean and rich IMPORTANT Normal HEGO switching indicates the fuel system is in closed loop and operating cor rectly at that time 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 Check the ignition wires for the following conditions e Cracking e Hardening e Proper routing e Carbon tracking Check the wiring for the following items e Proper connections e 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 log
142. ace the Regulator above the Actuator not ing the position of the lever tab and slot on the secondary diaphragm Carefully slide the lever tab into the slot of the secondary diaphragm and align the Regulator to the Ac tuator Place the Regulator on top the Actuator aligning the screw holes Insert the six screws through the Actuator holes and into the Regulator Finger tighten as many screws as possible Holding the Regulator to the Actuator turn the assembly over so that it is resting on its 470 face Torque screws to 40 in Ibs 4 5 Nm Optional If hoses and O rings were removed during the Removal Procedure then follow the additional steps 17 20 otherwise continue to Step 21 16 Lubricate new O rings using petroleum jelly or Vaseline Mount new O rings on the Temperature Sensor and hose fittings N WARNING 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 sensor element If contaminated the portion of the
143. agnostic 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 Action Value s Go to OBD Did you perform the On Board OBD System Go to Step System Check 2 Check Sec tion DST connected and in the system data mode Check for any other current or active DTCs Go to Step Go to Step 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 4 Have the other DTC s set been corrected Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature 20 ae System OK Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1177 check for any stored codes Go to Step 6 Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC11
144. akage 12 y and Go to Step 20 e Turn OFF the manual fuel shut off valve e Start the engine and let it run until it dies e Remove the LPG Temperature Sensor from the EPR DO 9 NOT disconnect the electrical connector Goto Step Goto e 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 10 Action e Insert the Secondary Pressure Test Adapter into the EPR port from which you removed the LPG Temp Sensor e Connect a CALIBRATED 0 10 water column WC vacuum gauge or manometer to the secondary pressure test port of the EPR e Connect the DST to the vehicle DLC connector and open the GCP Display software e 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 pressure on the DST Faults Screen Gaseous pressure target 2 76 H20 PA 194 Current governor target 844 pm Engine Load 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 MATS 0 75 WC Yes Go to Step 19 No Go to Step 11 11 With the engine still running e Disconnect the EPR electrical connector NOTE This action will cause a DTC to be set turning ON the MIL
145. al 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 o o HHI 2007 2009 Emission Certified LPG amp Bi Fuel System 2 0L Engine CN10 ALTERNATOR CN31 ALTERNATOR MAXI FUSE OIL S W CN25 FUSE BOX 1 ONLY BI FUEL STARTER RLY F PUMP RLY CN7 DIAGNOSTIC 50 150 p7 Acne IGNITION A 19 340 CN19 CN20 INJECTOR4 INJECTORS ACN21 E system INTERFACE O CN18 INJECTOR2 INJECTO CN13 LOCK OFF Sor 1 AB3LIV8 O 2 AYILLVE 910 CN27 STARTER SOL 122 CN16 MANIFOLD ASSY a 0 CN29 7 70 COM FUEL PUMP 70 CN30 O 08 FUEL PUMP ONLY Bl FUEL CN28 GROUND CN17 RI O CN12 POST CAT HHI 2007 2009 Emission Certified LPG 8 Bi Fuel System 2 0L Engine Connector a Manufacturer Description Type Manufacturer Remarks Number CN Number 2 6 Gm Ffemalesp amp 85205 3 3 3 Electronic Throttle Control Female6P amp vo676161 4 gt Twe gt _ Ffemaleap amp 3681621 5 ecr_ Femalesp Kum
146. ance test status Test Not Started Injector firing test status Test Not Started E Gwich v iye idle Speed Test CAD BTDC command 4 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 Ifthe 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 Ifthe 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 outpu
147. and engine running 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 Adaptive Disabled Closed Loop Disabled Circuit Description System battery voltage is supplied to each fuel injector The ECM controls each fuel injector by 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 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 246 DTC 265 Injector Driver 2 Coil Shorted Value s Action Did you perform the On Board OBD System Check Key On Engine Running DST Diagnostic Scan Tool connected in System Data Mode Clear System DTC 265 Does DTC 265 reset with the engine idling Key OFF Disconnect the injector interface connector CN18 Using a high impedance DVOM measure the resistance between the fuel injector pins at the fuel metering body at an ambient tem perature of 50 to 90 degrees F Does the DVOM display a resistance value of 5 ohms or more e Replace the Fuel Injector Is the replacement complete Disconnect the ECM wire harness connector CN1 Key ON Using a DVOM check for voltage between the ECM
148. 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 Disconnect the MAP sensor 1 Loss of DTC Memory 2 Idle the engine until the MIL illuminates 3 The ECM should store aMAP DTC which should remain in the memory l 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 Preliminary Checks Using the DST Check for proper communication with both the ECM ECM Checks Check all system fuses located in the engine fuse holder Refer to En 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 Sensor Checks e Check the MAP sensor e Check cam angle sensor RPM Check for fuel pump electrical circuit Verify proper fuel pump pressure Verify proper Fuel rail pressure Check the in line fuel filter for restrictions Check electrical connections
149. ar the EPR fittings Remove the retaining pins from the water inlet and outlet fittings fuel hose and Temperature Sensor Remove coolant inlet and outlet Port Fittings and fuel hose Remove the three nuts securing the Vibration mounts to the EPR ECM mounting bracket Remove Shutoff valve and fitting and Tempera ture Sensor Remove the three vibration mounts from the EPR INSTALLATION PROCEDURE Apply Loctite 567 or equivalent high temp thread locker sealer to the threads of the Shut Off valve 90 fitting Install the Shut Off valve fit ting to the EPR and turn until finger tight plus 1 to 2 turns ensuring the Shut Off Valve is in the correct clock position N CAUTION a Do not use Teflon tape on any fuel fitting Use liquid pipe thread sealant when installing threaded fittings o gt 466 Connect the EPR electrical connector Install the fuel inlet line Torque to 20 ft Ibs 27 Nm Connect the Shut Off Valve electrical connector Lubricate the O rings on each of the port fittings and Temperature Sensor with petroleum jelly or Vaseline A N WARNING 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 si
150. as necessary CHECK MUST BE MADE WITHIN 30 tage 5 Refer to Wir SECONDS OR BEFORE POWER RELAY ing Repairs in SHUTS DOWN Engine Elec trical Do you have voltage 355 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 or ignition wires 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 e Diagnose any other DTC codes before pro ceeding with this chart Always repair existing codes starting with the lowest numerical code set first Value s Yes Key OFF Disconnect EGO 1 sensor wire harness con nector CN11 Disconnect ECM wire harness connector CN1 Key ON Using a high impedance DVOM check for continuity between EGO 1 connector signal circuit 121 and engine ground Repair the shorted circuit as necessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 6 Do you have continuity Repair the shorted circuit as necessary Refer to Wir ing Repairs in Engine Elec trical Using a high impedance DVOM check for continuity on the EGO connector CN11 be tween signal circuit 121 and ground circuit 120
151. ase 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 drive feel characteristics Remove the air filter and check for dirt or restriction Check the vehicle transmission Refer to the OEM transmission diagnostics Preliminary Checks 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 pump pressure Verify proper fuel rail pressure Check the Heated Exhaust Gas Oxygen Sensor HEGO for contamina tion and performance Check for proper operation of the MAP sensor Check for proper operation of the TPS and FPP sensors Sensor Checks Check the exhaust system for a possible restriction e Inspect the exhaust system for damaged or collapsed pipes e Inspect the muffler for signs of heat distress or for possible internal failure e Check for possible plugged catalytic converter Exhaust System Checks Check the engine for the following e Engine compression Valve timing Engine Mechanical Improper or worn camshaft Check Refer to Engine Mechanical in the Service Manual Check for the proper ignition outpu
152. ator 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 Electronic Throttle Circuit Wire ECM Color L TPS 1 Signal Sensor Ground TPS 2 Signal 5 Volts Conditions for Setting the DTC Max Govern Speed Override Check Condition Engine Running Fault Condition Engine rpm greater than 3900 MIL On during active fault 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 Action Value s Yes Go to OBD Did you perform the On Board OBD System Go to Step System Check 2 Check Sec tion Go to Step Go to Step 3 4 Go to Step 4 e Key ON Engine OFF e DST connected Are any other DTC codes present with DTC 219 e Diagnose and repair any other DTC codes stored before proceeding with this chart Have any other DTC codes been diagnose
153. battery voltage Does the test light come on Inspect the electronic throttle connector ter minals for damage corrosion or contamination Did you find a problem Replace the electronic throttle Is the replacement complete 175 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Value s Go to arr Go i ae System Check Section Go to Step Goto Step 3 4 Intermittent Go to Step problem 4 Go to Intermit tent section Go E Step Go to Step 5 7 Go to Step 6 Go to Step 11 Go to Step Go to Step 8 10 Repair the circuit as ne cessary Refer to Wir Go to Step 9 ing Repairs in Engine Elec trical Go to Step 11 Step Action Key OFF Disconnect ECM connector C001 Using a DVOM check for continuity on the sensor ground circuit 120 between the elec Go to Step tronic throttle connector CN3 and ECM 6 connector CN1 Repair the circuit as ne cessary Refer to Wiring Re pairs in Engine Elec trical have continuity between them Remove all test equipment except the DST Connect any disconnected components fus es 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 z E full operating temperature o to OBD Observe the MIL System OK System Check Observe engine performance and driveability After operating the engine within the test pa rameters of DT
154. between them e Inspect ECM connector pins for damage corrosion or contamination Did you find a problem 214 Go to Step 9 Go to Step 10 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 12 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 11 e Replace ECM Is the replacement complete Go to Step 14 e Key OFF e Disconnect ECM wire harness connector CN1 e Using a DVOM check for continuity between the fuel temperature connector CN14 signal circuit 139 and ECM connector circuit 139 Do you have continuity between them e Inspect ECM connector pins for damage corrosion or contamination Did you find a problem Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 188 check for any stored codes Does the engine operate normally with no stored codes 215 Go to Step 13 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical System OK Repair the circuit as ne cessary Refer to Wir ing Repairs i
155. ble the Mixer The Mixer is calibrated and disassembly may alter its calibra tion and adversely affect engine performance and or emissions Are all actions complete Values Yes Go to Step 20 No NA 17 Replace the ECM Is the action complete Go to Step 20 NA 18 Replace the Lock off Valve Is the action complete Go to Step 20 NA 19 System working correctly at this time Vehicle may have inter mittent electrical connection conditions e Return vehicle to original condition but leave the diagnostic equipment connected e Start the engine and wiggle test the harness while observing the DST Faults Screen and the pressure gauge readings e Repair any conditions encountered Is the action complete Go to Step 20 NA 20 e Clear any active or historic DTCs DST Service or Faults Screen e Clear Adaptive from memory DST Service Screen e Return the vehicle to original condition e Operate the vehicle under all load and driving conditions for at least 10 minutes e Park the vehicle with the engine running and connect the DST to the vehicle s DLC connector e Open the GCP software and switch to the Faults Screen e 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 15 to 15 Go to Step 21 Go to Step 24 21 With engine still
156. by IMPCO O SPECTRUM HHI 2007 2009 Emission Certified LPG amp Bi Fuel System 2 0L Engine Service Manual Revision A June 2009 O SPECTRUM by IMPCO Table of Contents General Information 24 u u0 00400 000000 aan ann ann rr 5 An overview of this Service Manual Maintenance ana ad ii cad 11 General maintenance and maintenance interval information LPG FUE System siii nee ee 19 An overview of the LPG fuel system and its components LPG Fuel System Diagn sls ses aaa 29 How to identify a general problem LPG Symptom Diagnostie sense een 39 How to correct a specific problem Gasoline Fuel Sy StoM coria 55 An overview of the Gasoline fuel system bi fuel models only and its components Gasoline Fuel System DiagnoSIS ooocccccccccccnononnonanannnnananancnn nn nn nnnnnnnnnnnnnn nn 63 How to identify a general problem with the Gasoline fuel system bi fuel models only Gasoline Symptom Diagnostics cccoccocanconoonanananennonaonanianennononasnnncrnennaconn nro nonaanaarancanzs 71 How to correct a specific problem with the Gasoline fuel system bi fuel models only Electrical Section wiiseicesccicsiceccteccacdecsdicscedeuaccosceeuacetieeasscededactccuaceaccecavedseddeaaschcuecascecdeves 85 Diagnostic Scan Tool 87 Using the DST for testing and trouble shooting Wire SCM abl O iccatsees cos cains 121 Engine wiring schematic Engine Wire Harness Repa
157. 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 384 DTC 1612 RT 1 Loss Action Value s Go to OBD Did you perform the On Board OBD System Go to Step System Check 2 Check Sec tion e Key On Engine Running f e DST Diagnostic Scan Tool connected in intermittent System Data Mode Go to Step proniem e Clear system fault code 3 E section Does DTC 1612 reset with the engine idling Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical e Check ECM power and ground circuits Go to Step 4 Did the power and ground circuits check OK e Replace ECM Go to Step 5 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds nn the an and ae the vehicle to Go to OBD ull operating temperature Observe the MIL Sys OK pS Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 1612 check for any stored codes Does the engine operate normally with no stored codes 385 DTC 1613 RTI 2 Loss Microprocessor Conditions for Setting
158. connector circuit167 and engine Greater than 5 0 Ohms Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 8 Repair the shorted to voltage injec tor driver circuit as ne cessary Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 4 Go to Step 6 Refer to Wir ing Repairs in Engine Elec trical ground Does the DVOM display voltage e Replace the ECM Go to Step 7 Is the replacement complete 247 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature System OK Go to OBD Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC265 check for any stored codes system check Does the engine operate normally with no stored codes 248 249 D TC 267 Injector Driver 3 Open or Low Side Short to Ground Circuit Wire Color 164 Injector Driver 1 Injector Driver 2 Injector Driver 3 Injector Driver 4 Ignition Fuse and Power Relay Conditions for Setting the DTC e Injector loop open or low side short to ground e Check Condition key on and engine running e Fault
159. ctor CN9 e Using A DVOM check for voltage at the CKP sensor connector circuit 119 and engine ground Do you have voltage e Key OFF e Disconnect ECM connector CN1 e Using a DVOM check for continuity on the crank signal circuit 125 between CKP con nector CN9 and ECM connector CN1 Do you have continuity between them e Using a DVOM check for continuity on the sensor ground circuit 120 between CKP con nector and ECM connector Do you have continuity between them e Inspect the CKP connector CN9 terminals for damage corrosion or contamination Did you find a problem e Inspect the ECM connector CN1 terminals for damage corrosion or contamination Did you find a problem 131 5 0 volts Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 6 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check Sec tion Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 7 Go to Step 8 Value s Yes
160. cuit 120 and ECM connector signal ground circuit 120 Do you have continuity between them e Replace ECM Is the replacement complete 397 Repair the circuit as ne cessary Refer to Wiring Re pairs in Engine Elec trical Go to Step 13 Go to Step 8 e Check throttle for foreign object in bore Did you find a foreign object in the bore Go to Step 10 e Remove foreign object Is the removal complete Inspect the throttle wire harness connector terminals for damage corrosion or contami nation Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2111 check for any stored codes Does the engine operate normally with no stored 398 Go to Step 13 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical System OK No Go to Step 11 Go to Step 12 Go to OBD System Check 399 DTC 2112 Unable To Reach Higher TPS Electronic Throttle Circuit Wire ECM Color L TPS 1 Signal Sensor Ground TPS 2 Signal 5 Volts Conditions for Setting the DTC Throttle Po
161. d or ignition wires 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 set first Step No Repair the shorted circuit as necessary Refer to Wir ing Repairs in Engine Elec e Using a high impedance DVOM check for continuity between EGO 1 connector signal ground circuit 120 and EGO 1 signal circuit 121 Go to Step 7 Do you have continuity e Using a high impedance DVOM check for continuity between EGO 1 heater ground cir Go to Ste Repair the 7 cuit 162 and ECM connector CN1 circuit 162 8 p open EGO heater ground Do you have continuity e Replace EGO 1 sensor Go to Step Is the replacement complete 9 e Remove all test equipment except the DST e Connect any disconnected components fus es etc e Using the DST clear DTC information from the ECM e Turn the ignition OFF and wait 30 seconds e Start piis Eia a operate the vehicle to full Go to OBD operating temperature e Observe Ihe Kil OR Pe e Observe engine performance and driveability e After operating the engine within the test pa rameters of DTC 171 check for any stored codes Does the engine operate normally with no stored codes 194 195 DTC 172 Adaptive Learn Lo
162. d and repaired e Replace ECM with correct service part num ber Is the replacement complete e Check the mechanical operation of the throttle Go to Step 9 Go to Step Go to Step 8 7 Is the mechanical operation of the throttle OK e Correct mechanical operation of the throttle Refer to Engine amp Component section Go to Step 9 Has the mechanical operation of the throttle been corrected e Check engine for large manifold vacuum leaks Refer to Symptom Diagnostic section Go to OBD Go to Step System 9 Check Sec tion e Check the service part number on the ECM to ensure the correct calibration is in use Go to Step Go to Step 6 5 Is the Service Part Number Correct Did you find and correct the vacuum leak 219 Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD operating temperature Observe the MIL SYPIE OR oe Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 219 check for any stored codes Does the engine operate normally with no stored codes 220 221 DTC 221 TPS 1 Higher Than TPS 2 Electronic Throttle Circuit Wire ECM Color L TPS 1 Signal Sensor Ground TPS 2 Signal
163. d 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 lf 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 346 DTC 1155 Closed Loop High Bi Fuel Gasoline Onl N Yes fo Go to Step Go to Step 3 2 Go to Step Go to Step 9 4 Have any other DTC codes been detected diag Go to Step Go to Step 9 4 nosed and repaired Disconnect EGO1 connector CN11 Using a DVOM check for voltage between EGO 1 connector CN11 circuit 812 and en Repair the gine ground open EGO Key ON power circuit System vol Goto Step as necessary tage 5 Refer to Wir CHECK MUST BE MADE WITHIN 30 ing Repairs in SECONDS OR BEFORE POWER RELAY Engine Elec SHUTS DOWN trical Do you have voltage 347 Action Value s Perform the On Board OBD System Check 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 or ignition wires ECM grounds
164. d persistently more than 55 seconds MIL On during active fault Adaptive Disabled during active fault Closed Loop Disabled during active fault 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 DTC 154 EGO 2 Open Inactive Action Did you perform the On Board OBD System Check Key ON Engine Running DST Diagnostic Scan Tool connected in System Data Mode Run engine to full operating temperature and then idle for a minimum of 1 minute Does DST display EGO 2 voltage fixed between 0 4 and 0 5 volts after at least 1 minute of idle run time Key OFF Disconnect EGO 2 connector CN12 Key ON Using a DVOM check for voltage between EGO 2 connector CN12 circuits 812 and 161 Check must be made within 30 seconds or before power relay shuts down Do you have voltage Key OFF Using a DVOM check for voltage between EGO 2 connector CN12 circuit 812 and en gine ground Key ON Check must be made within 30 seconds or before power relay shuts down Do you have voltage Value s Go to Step 3 Go to Step 8 Yes Go to Step 2 Go to Step 5 System Vol tage Go to OBD System Check Sec tion Intermittent problem See Electrical Section In termittent Electrical Di agnosis Go To Step 4 Repair sys tem power relay open circ
165. d with a mixture of metals such as platinum palladium and rhodium to oxidize and reduce CO HC and NOX emission gases L Catalytic Converter Muffler ENGINE CONTROL MODULE To obtain maximum effect from the catalyst and accurate control of the air fuel ratio the emission certified engine is equipped with an onboard computer or Engine Control Module ECM The ECM is a 32 bit controller which receives input data from sensors mounted to the engine and fuel system and then outputs various signals to con trol engine operation Inputs Outputs TS ECTHAT Timing Distributor Timing Distributor gt Speed Control 02 Sensors gt Gauges gt MiL__o qx5 ENGINE CONTROL MODULE yoo Cam Signal _ gt Cranksignal Engine Control Module ECM One specific function of the controller is to main tain a closed loop fuel control which is accomplished by use of the Heated Exhaust Gas 24 Oxygen sensor HEGO mounted in the exhaust system The HEGO sensor sends a voltage sig nal to the controller which then outputs signals to the EPR to change the amount of fuel being deli vered from the regulator or mixer to the engine 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 i
166. dance type and used to measure voltage and resistance Aromatics Pertaining to or containing the six carbon ring characteristic of the benzene series Found in many petroleum distillates Backfire Combustion of the air fuel mixture in the intake or exhaust manifolds A backfire can occur if the intake or exhaust valves are open when there is a mis timed ignition spark Benzene An aromatic CsHe Often blended with gasoline to improve anti knock value Benzene is toxic and suspected of causing cancer Bi Fueled A vehicle equipped to run on two fuels Blow By Gases formed by the combustion of fuel and air which ordinarily should exert pressure only against the piston crown and first compres sion ring When rings do not seal these gases escape or blow by the side of the piston into the crankcase BTU British Thermal Unit A measurement of the amount of heat required to raise the temperature of 1lb of water 1 degree F Butane An odorless colorless gas C4H19 found in natural gas and petroleum One of the five LP gases CAFE Corporate Average Fuel Economy CARB California Air Resources Board Carbon Monoxide CO A chemical compound of a highly toxic gas that is both odorless and color less Carburetor An apparatus for supplying an inter nal combustion engine a mixture of vaporized fuel and air Cathode Ray Tube A vacuum tube in which ca thode rays usually in the form of a slender beam are projected on a fl
167. e Open the valve slowly to prevent activating the Excess Flow Check Valve 15 Check for leaks at the inlet and outlet fittings and the filter housing end connection using a soapy solution or an electronic leak detector if leaks are detected make repairs ELECTRONIC PRESSURE REGULATOR EPR MAINTENANCE AND INSPECTION IMPORTANT The Electronic Pressure Regulator EPR com ponents have been specifically designed and calibrated to meet the fuel system requirements of the emission certified engine Ifthe EPR fails to operate or develops a leak it should be repaired or replaced with the OEM recommended replacement parts When inspect ing the regulator check for the following items e Check for any fuel leaks at the inlet and outlet fittings e Check for any fuel leaks in the regulator body e Check the inlet and outlet fittings of the coo lant supply lines for water leaks e Check the coolant supply lines for hardening cracking chafing or splits If any of these con ditions exist replace coolant lines e Check coolant supply hose clamp connec tions ensure they are tight e Check to ensure the EPR is securely mounted and the mounting bolts are tight e Check EPR for external damage e Check EPR electrical connection to ensure the connector is seated and locked CHECKING DRAINING OIL BUILD UP IN THE ELECTRONIC PRESSURE REGULATOR During the course of normal operation oil or heavy ends may build inside the sec
168. e Diagnose any other DTC codes before pro ceeding with this chart Go to Step Go to Step 6 4 Have any other DTC codes been detected diag 6 e nosed and repaired Repair the shorted circuit as necessary Refer to Wir Cote SER ing Repairs in 5 Engine Elec trical Do you have voltage e Replace EGO sensor Go to Step 6 Is the replacement complete 351 Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD operating temperature Observe the MIL SYPIE OR oe Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 1156 check for any stored codes Does the engine operate normally with no stored codes 352 353 DTC 1161 Adaptive Learn High LPG Circuit Wire Color G B EGO 1 Signal Signal Ground EGO 1 Heater Ground Power Relay Fuse Block CN25 7 Ignition Fuse Conditions for Setting the DTC Heated Oxygen Sensor Check Condition Engine Running Fault Condition Adaptive multiplier out of range greater than 30 MIL On 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
169. e ECM and MIL are operating correctly 2 There are no Diagnostic Trouble Codes DTCs stored or a DTC exists 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 Verify the customer complaint Locate the correct symptom table Check the items indicated under that symptom Operate the vehicle under the conditions the symptom occurs Verify 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 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 e Check for proper installation of the mixer assembly e Check for air leaks at the mixer assembly Check the ignition wires for the following conditions e Cracking e Hardening e Proper routing e Carbon tracking Check the wiring for the following items proper connections pinches or cuts The following symptom tables contain groups of possible ca
170. e Short to Ground Action Did you perform the On Board OBD System Check Key ON Engine OFF DST Diagnostic Scan Tool connected in System Data Mode Clear DTC 2300 Crank the engine Does DTC 2300 re set e Remove and check the ignition fuse Is the fuse OK e Replace the ignition fuse Is the replacement complete e Key ON e Using a DVOM check for voltage at the igni tion fuse terminal circuit 927 CHECK THIS BEFORE THE POWER RELAY CIRCUIT SHUTS DOWN Do you have voltage e Key OFF e Disconnect the ignition module connector CN6 e Using a DVOM check for voltage between ignition module connector circuit 812 and engine ground Do you have voltage e Disconnect ECM wire harness connector CN1 e Using a DVOM check for continuity on the coil control circuit 101 between ECM connec tor CN1 and engine ground Do you have continuity e Using a DVOM check for continuity on the coil control circuit 101 between ECM connec tor CN1 and ignition module connector CN6 Do you have continuity 427 Value s _ Yes Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 12 Go to Step 6 Go to Step 7 Repair the shorted to ground coil 1 circuit Go to Step 9 Go to OBD System Check Sec tion Intermittent problem See Electrical Section In termittent Electrical Di agnosis Go to Step 4 Repair the open power circuit See wiring har ness repairs Repair the
171. e With the engine idling observe the pressure reading on the secondary pressure test port gauge Is the pressure reading within specifications 1 0 to 2 0 WC Go to Step 15 Go to Step 13 12 e Turn OFF the manual shut off valve and let the engine run until it dies e Turn the ignition OFF e Remove the Air induction hose from the mixer e Crank the engine and observe the air valve for movement while the engine is cranking NOTE At cranking speeds the air valve movement will be mi nimal Is there movement in the air valve when the engine is cranking Go to Step 14 Go to Step 13 13 Replace the mixer assembly refer to Fuel Mixer Replacement Is the action complete Go to Step 20 NA 14 e Ifturned OFF turn ON the manual shut off valve e Disconnect the Lock off valve electrical connector e Apply 12V to the lock off valve terminals and observe the pressure gauge Does the pressure gauge indicate pressure Above 1 0 PSI Go to Step 17 Go to Step 18 15 Repair or replace the EPR refer to EPR Repair Instructions Is the action complete Go to Step 20 NA 34 Step 16 Action Inspect the following for heavy end deposits e Electronic Pressure Regulator Inspect clean and or repair as necessary refer to EPR Repair Instructions e Inspect the diaphragm through the Mixer air inlet for any de posits or contaminants DO NOT disassem
172. e a sensor Also known as EGO Exhaust Gas Oxygen sensor O or Oxygen sensor Hg Chemical symbol for the element mercury Used in reference to a measure of vacuum inch es of Hg Histogram The graphical version of a table which shows what proportion of values fall into specific categories over a specific period of time 477 Hydrocarbon A chemical compound made up of hydrogen and carbon HC Gasoline and almost all other fuels are hydrocarbons Hydrostatic Relief Valve A pressure relief device installed in the liquid LPG hose on a LPG fuel system IAT Intake Air Temperature Ideal Mixture The air fuel ratio at which the best compromise of engine performance to exhaust emissions is obtained Typically 14 7 1 Ignition Reserve The difference between availa ble voltage and the required voltage ILEV Inherently Low Emission Vehicle IMPCO Imperial Machine Products Company IMPCO Technologies Inc A manufacturer of both LPG and Gasoline fuel systems Impedance A form of opposition of AC electrical current flow resistance measured in ohms Insulation A nonconductive material used to cover wires in electrical circuits to prevent the leakage of electricity and to protect the wire from corro sion Intercept An electrical term for a type of splice where the original circuit is interrupted and redi rected through another circuit ITK IMPCO Test Kit Knock Sound produced when an engine s air fuel m
173. e engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 1155 check for any stored codes Does the engine operate normally with no stored codes 348 349 DTC 1156 Closed Loop Low Bi Fuel Gasoline Onl Circuit Wire Color G B EGO 1 Signal Signal Ground EGO 1 Heater Ground Power Relay Fuse Block CN25 7 Ignition Fuse Conditions for Setting the DTC Heated Oxygen Sensor Check Condition Engine Running Fault Condition Closed loop multiplier out of range greater than 35 MIL On 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 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 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 i
174. e fuel connection to absorb any small amount of fuel leakage that may occur when installing the gage With ignition ON engine OFF and the fuel pump running pressure should be TBD TBD kPa TBD TBD psi When the engine is idling manifold pres sure is low High Vacuum and is applied to the pressure regulator diaphragm This va cuum will offset spring pressure and result in a lower pressure Fuel pressure at idle will vary somewhat depending on barome tric pressure but should be less than the pressure noted in step 4 Fuel pressure that drops off during accele ration or cruise may cause a lean condition and result in a loss of power surging or misfire This condition can be diagnosed us ing the Diagnostic Scan Tool If the fuel in the system is very lean the Heated Exhaust Gas Oxygen HEGO will stop toggling and output voltage may drop below 100 mV and stay low during the lean condition Fuel pressure below TBD TBD kPa TBD TBD psi under full load may cause a lean condition and may set a DTC Drivability conditions can include hard starting when cold hesitation and lack of power or misfire Restricting the fuel return pipe may cause the fuel pressure to build above the regu lated pressure and permanently damage the pressure regulator With battery voltage applied to the pump pressure should rise above TBD TBD kPa TBD TBD psi as the valve in the return pipe is partially closed NOTICE Do not allow the pressure to
175. e small hole in the gasket is aligned with the small hole in the body cover Place body cover and gasket on the front of Regu lator body ensuring the holes in the gasket are aligned with all screw holes Set new primary diaphragm the face of the body cover using the screw hole for proper alignment 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 Ibs in a criss cross pattern Using side cutters cut off the nose of the soft secondary seat and remove from sec ondary lever Push the nose or button of the new second ary seat through the hole of the secondary lever 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 ofthe secondary spring Push down compressing the spring until the fulcrum pin can be slid into place Insert screw to hold lever and torque to 4 5 Nm 40 in Ibs Verify the secondary lever height by placing a straight edge over the mating surface rim ofthe 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 meet this specification the EPR cannot be repaired and must be replaced Place the EPR Actuator facing upward and place the new clamp plate seal into the open end of the Actuator Pl
176. e wiring harness re pair section Go to Step 7 Repair circuit as necessary See wiring harness re pair section Go to Step 10 Go to OBD System Check Sec tion Go to Step 3 Intermittent problem Go to Inter mittent section Go to Step 6 Go to Step 6 Repair circuit as necessary See wiring harness re pair section Go to Step 8 e Replace ECM Go to Step 11 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Go to Step Observe the MIL OS 9 Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2123 check for any stored codes Does the engine operate normally with no stored codes Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2123 check for any stored codes Does the engine operate normally with no stored codes
177. ec tor CN1 and engine ground Do you have continuity e Using a DVOM check for continuity on the coil control circuit 104 between ECM connec tor CN1 and ignition module connector CN6 Do you have continuity 451 Value s _ Yes Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 12 Go to Step 6 Go to Step 7 Repair the shorted to ground coil 1 circuit Go to Step 9 Go to OBD System Check Sec tion Intermittent problem See Electrical Section In termittent Electrical Di agnosis Go to Step 4 Repair the open power circuit See wiring har ness repairs Repair the open power circuit See wiring har ness repairs Go To Step 8 Repair the open ignition module cir cuit See wiring har ness repairs Replace the ignition module Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2309 check for any stored codes Does the engine operate normally with no stored Value s _ Yes No Go to Step 10 System OK Go to Step 11 7 e Replace the ECM Go to Step Is the replacement complete
178. eck condition Engine running or cranking Fault condition Adaptive dwell greater than 2 0ms or total dwell greater than 14 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers ignition by providing ground to the ignition circuit 103 This code will set if the ECM low side driver circuit 103 is open or shorted to ground 442 DTC 2306 Primary Loop Open Low Side Short to Ground Action Did you perform the On Board OBD System Check Key ON Engine OFF DST Diagnostic Scan Tool connected in System Data Mode Clear DTC 2306 Crank the engine Does DTC 2306 re set e Remove and check the ignition fuse Is the fuse OK e Replace the ignition fuse Is the replacement complete e Key ON e Using a DVOM check for voltage at the igni tion fuse terminal circuit 927 CHECK THIS BEFORE THE POWER RELAY CIRCUIT SHUTS DOWN Do you have voltage e Key OFF e Disconnect the ignition module connector CN6 e Using a DVOM check for voltage between ignition module connector circuit 812 and engine ground Do you have voltage e Disconnect ECM wire harness connector CN1 e Using a DVOM check for continuity on the coil control circuit 103 between ECM connec tor CN1 and engine ground Do you have continuity e Using a DVOM check for continuity on the coil control circuit 103 between ECM connec tor CN1 and ignition module connector CN6 Do you have continuity 443
179. ector Driver 4 Ignition Fuse and Power Relay Conditions for Setting the DTC e Injector loop open or low side short to ground e Check Condition key on and engine running e Fault Condition System voltage greater than 9 volts and injector low side less than 4 0 volts for 10 injector firings e MIL On for active fault e Adaptive Disabled e 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 258 D TC 270 Injector Driver 4 Open or Low Side Short to Ground Action Did you perform the On Board OBD System Check e Key On Engine Running e DST Diagnostic Scan Tool connected in System Data Mode e Clear System DTC 270 Does DTC 270 reset with the engine idling Key OFF Disconnect the injector interface connector C20 Using a high impedance DVOM measure the resistance between the fuel injector pins at the fuel metering body at an ambient tem perature of 50 to 90 degrees F Does the
180. ed Convert the plot into a snapshot that may be panned zoomed scrolled and saved Close Button Close the DST Plot interface Load Setup Button Load Plot Button Load tags from a previously saved plot plt file to allow for similar plots and logs to be generated Load a previously saved plot from the PC into the DST Plot inter face Variable Selector Menu Selects the active variable for axis scaling Single Shot Acquisition Checkbox Exclusive Serial Use Checkbox When checked this does not allow the plot to scroll past the Time Interval thereby preserving plotted data for post processing When checked this allows exclusive serial communication for the 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 Sample Interval ms Field Define the sample period for recording and display Frequency 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 HE EDIS Plot Figure 7 DST Plot e Click on the Start button to start the DST plot function e Click on the variable selector button to view selected sensors 110 EDIS Plot Figure 8 DST Plot Sna
181. ed codes Does the engine operate normally with no stored codes 456 Value s Yes No System OK Go to Step 7 System OK Go to Step 6 Go to OBD system check Servicing the Fuel System PROTECTION OF ELECTRICAL COMPONENTS N CAUTION To prevent permanent damage to the ECM and or other electrical components follow ing the steps listed below 1 ALWAYS turn ignition to OFF prior to removing the harness and or the negative or positive battery cable ALWAYS disconnect the negative and positive battery cable Remove the negative cable first when welding on a vehicle NEVER use a charger or voltage supply in excess of 16 volts I ENGINE CONTROL MODULE This procedure relates to removal and installation ofthe ECM see Diagnostic Scan Tool for access ing ECM software REMOVAL PROCEDURE 1 Disconnect Negative battery cable 2 Push connector lock back to unlock connector unplug the Wire Harness from ECM and re move 3 Remove four bolts mounting the controller to the mounting bracket ECM and its Four Mounting Bolts INSTALLATION PROCEDURE IMPORTANT The ECM is calibrated for each engine Verify you have the correct controller by noting the P N on the ECM label The calibration number can also be found by connecting the DST and finding the calibra tion number on the Gauge Page 1 Mount controller into mounting bracket with four
182. ed fitting 12 Start the vehicle and leak check the LPG fuel system at each serviced fitting 13 Test drive vehicle to ensure it operates correctly at all throttle ranges Ifa DTC code is found re fer to the Electrical Section for further diagnosis gi 32030 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 e 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 e Rough Idle e Stalling e High idle speed FUNCTIONAL CHECK Any blow by in excess of the system capacity from a badly worn engine sustained heavy load etc is exhausted into the air cleaner and is drawn back into the 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 The PCV is Located Between Two Hoses as Shown Above 1 Locate the PCV connected to hoses as shown above 2 R
183. ed 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 or possibly tubing which is compatible with the LPG fuel and should always be replaced with an OEM supplied part A N CAUTION The bulkhead assembly should never be removed Never run a service line through the sheet metal FUEL FILTER LPG fuel like all other motor fuels is subject to contamination from outside sources Refueling of the equipment tank and removal of the tank from the equipment can inadvertently introduce dirt and other foreign matter into the fuel system It is therefore necessary to filter the fuel prior to enter ing the fuel system components downstream of the tank An inline fuel filter has been installed in the fuel system to remove the dirt and foreign matter from the fuel which is replaceable as a unit only Maintenance of the filter is critical to proper operation of the fuel system and should be replaced according to the maintenance schedule or more frequently under severe operating condi tions i Fuel Flow a Inline Fuel Filter LPG SHU
184. ed to the fuel tank for recirculation The fuel pressure regula tor has no adjustments and is integrated into the fuel block assembly The fuel inlet pipe contains a Schrader valve which is utilized to test the regu lated pressure of the fuel system FUEL INJECTOR Gasoline Fuel Injector The fuel pressure is maintained on the top of the injector by the fuel pressure regulator The injector is fed a pulse signal through the wire harness which causes the injector to open The ECM con trols the opening and duration of the injector During lower RPM operation the injector signals or pulses are shorter than when the engine is oper ating at higher rpms The certified engine has been calibrated to deliver the precise amount of fuel for optimum performance and emission control THROTTLE CONTROL DEVICE DRIVE BY WIRE Drive By Wire Engine speed control is maintained by the amount of pressure applied to the foot pedal located in the engine compartment In a Drive By 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 electro
185. een them Key OFF Disconnect ECM wire harness connector CN1 Using a DVOM check for power between ECM connector circuit 178 and engine ground with the key ON Do you have power e Replace the power relay Go to Step Is the replacement complete 7 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 629 check for any stored codes Does DTC 687 still re set 311 No Go to OBD System Check Sec Value s Yes Go to Step 2 tion Go to Step 3 Go to Step 4 Go to Step 9 Go to Step Go to Step 3 5 Go to Step 6 Go to Step 9 Repair the short to pow er See wiring har ness repair System bat tery voltage Go to Step 8 e Replace the ECM Go to Step 9 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After
186. eference circuit 119 and engine ground Do you have continuity e Inspect ECM and MAP wire harness con nector and terminals for corrosion contamination or mechanical damage Any problems found e Replace ECM Refer to ECM replacement in the Engine Controls Section Is the replacement complete Disconnect ECM connector Check for continuity on the MAP signal circuit 123 between MAP sensor connec tor CN4 and ECM connector CN1 Do you have continuity between them 140 Value s Yes Go to Step 17 Go to Step 9 Go to Step 10 Repair the circuit as necessary Refer to Wir ing Repairs in Engine Electrical Repair the circuit as necessary Refer to Wir ing Repairs in Engine Electrical Go to Step 17 Repair the Go to Step 14 Repair the circuit as necessary Refer to Wir ing Repairs in Engine Electrical Go to Step 13 Repair the circuit as necessary Refer to Wir ing Repairs in Engine Electrical Go to Step 11 Go to Step 16 circuit as necessary Refer to Wir ing Repairs in Engine Electrical Check for continuity between MAP sensor connector CN4 signal circuit 123 and en gine ground Do you have continuity e Inspect ECM connector and wire harness connector terminals for corrosion conta mination or mechanical damage Any problems found e Replace ECM Refer to ECM replacement in the Engine Controls Section Is the replacement complete
187. efore starting this proce dure complete the following tasks to verify that liquid fuel is being delivered to the EPR e Inspect fuel tank to verify it has a sufficient amount of fuel e Verify manual shut off valve on the LPG tank is fully opened e Verify that the excess flow valve has not been activated e Inspect fuel tank to ensure it is properly mounted and rotated to the correct position e Inspect the hoses leading from the tank en suring they are properly connected and do not have any kinks or damage TOOLS REQUIRED e 7 16 Open end wrench for test port plugs e Test port adapter e Straight Blade screw driver e Needle nose pliers DST e Diagnostic Scan Tool DST PRESSURE GAUGES e 0 10 Water Column Gauge e 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 zer Action Value s Were you referred to this procedure by a DTC diagnostic Chart Go to Step 3 eN to Step 2 Connect the Diagnostic Scan Tool DST to the ECM Data Link Connector DLC and check for any DTCs Are any DTCs present in the ECM Go to appli cable DTC Table Go to Step 3 Perform the following visua
188. el injector s Primary Circuit The low voltage or input side of the ignition coil Propane An odorless and colorless gas C3Hg found in natural gas and petroleum Psia pounds per square inch absolute PTV Pressure Trim Valve Reactivity Refers to the tendency of an HC in the presence of NOX and sunlight to cause a smog forming reaction The lighter the HC the lower reactivity tends to be Regulator An assembly used to reduce and con trol the pressure of a liquid or vapor Resistance The opposition to the flow of current in an electrical circuit Measured in ohms Rest Pressure Fuel pressure maintained within the system after engine shutdown Rich Mixture An air to fuel ratio below the stoichi ometric ratio too much fuel SAE Society of Automotive Engineers Secondary Circuit The high voltage output side of the ignition coil SEFI or SFI Sequential Electronic Fuel Injection or Sequential Fuel Injection Sensors Devices that provide the control module with engine information as needed to properly control engine function Spark Line The portion of an oscilloscope pattern that represents the time during which the air fuel mixture is being burned in the combustion cham ber Splice An electrical term for the joining of two or more conductors at a single point Stoichiometric Ratio An ideal fuel air ratio for combustion in which all of the fuel and most of the oxygen will be burned Sulfur Oxides Chemical c
189. el system or personal property A WARNING is an advisement that by per forming a process or procedure listed in this manual improperly may result in serious bodi ly injury death and or serious damage to the vehicle or property Typical Warning Label A N WARNING Failure to heed instructions could re sult in death injury or property damage 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 IMPCO could however result in serious bodily injury and or serious damage to the vehicle or prop erty damage A CAUTION Less severe than WARNING but has the potential to cause injury or damage Also used to notify of situations that could lead to eventual failure injury or damage This caution label may also appear in area of this manual that applies to service and repair procedures which could render the fuel and emissions control system non compliant In addition it may also be used to indicate a fail ure to observe which may influence the terms of the warranty An IMPORTANT statement generally de notes a situation that requires strict adherence to the assembly tightening or service procedure Failure to observe this procedure could result in an unsafe condition or improper performance of the vehicle or a component A NOTE statement appl
190. em Data Mode Does DST display MAP pressure of 16 psia or greater Go to Step 2 3 Go to Step 3 No Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Replace TMAP sensor Is the repair complete Go to Step 4 Der Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2229 check for any stored codes Does the engine operate normally with no stored 425 System OK Go to OBD System Check DTC 2300 Primary Loop Open Low Side Short to Ground Cylinder 1 Cylinder 4 Cylinder 3 Ignition Coil Pack Puse Interface Power Relay Fuse Block CN25 Conditions for Setting the DTC Ignition Control Check Check condition Engine running or cranking Fault condition Adaptive dwell greater than 2 0ms or total dwell greater than 14 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled 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 DTC 2300 Primary Loop Open Low Sid
191. emove the PCV 3 Insert a thin rod into the PCV against the plun ger and gently push 463 Testing the PCV Action If the plunger moves irregularly or fails to move the PCV is clogged and should be cleaned or replaced Connect the PCV to the vacuum hose leaving the opposite end open Start engine Testing the PCV for Vacuum 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 Turn the engine OFF Inspect the PCV orifice in the valve cover for de bris or blockage Clean with carburetor cleaner as necessary Reconnect hose to PCV Start the vehicle and let run until it reaches nor mal operating temperature If a DTC code is found refer to the Electrical Section for further diagnosis MIXER ADAPTER THROTTLE BODY amp RELATED SEALS REMOVAL PROCEDURE Disconnect the negative battery cable 2 Relieve the LPG fuel system pressure Refer to Ill LPG Fuel System Pressure Relief 3 Remove the air intake duct 4 Remove the retaining pin holding the fuel hose fitting and remove fuel hose 5 Remove two hoses attached to the sides of the Mixer 6 Remove the electrical connector to the Throttle Body 7 Remove four screws on Mixer that secure the Mixer Adapter and Throttle Body to the Intake Manifold 8 Lift up Mixer and Adapter noting the place ment of
192. ent problem Go to Intermit tent section Go to Step 4 e Jump TPS 1 signal circuit 147 to the 5 volt reference circuit 119 at connector CN3 Does DST display TPS 1 voltage over 4 900 volts Repair the TPS 1 circuit shorted to voltage as necessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 6 Go to Step 9 Go to Step 8 e Inspect wire terminals at throttle connector for damage corrosion or contamination Any problems found e Replace the electronic Throttle Key OFF Disconnect electronic throttle connector CN3 Key ON 3 Change DST mode to DBW drive by wire test mode Is the voltage for TPS 1 less than 0 1 volts e Key OFF e Disconnect ECM wiring harness connector CN1 e Key ON 4 e Using a DVOM check for voltage between ECM connector TPS 1 signal circuit 148 and engine ground Do you have voltage 5 6 Is the replacement complete 223 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 12 Go to Step 7 Step Action e Key OFF e Disconnect ECM wire harness connector CN1 e Using a DVOM check for continuity between throttle connector CN3 TPS 1 signal circuit 147 and ECM connector CN1 circuit 147 Do you have continuity between them e Using a DVOM check for continuity on the ground circuit 120 between throttle connector CN3 and ECM connector CN1 Do you have continuity between them Go to Step 9
193. ent 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 limiting maximum power 392 DTC 1616 Invalid Interrupt Action Value s Go to OBD Did you perform the On Board OBD System Go to Step System Check 2 Check Sec tion e Key On Engine Running f e DST Diagnostic Scan Tool connected in intermittent System Data Mode Go to Step proniem e Clear system fault code 3 E section Does DTC 1616 reset with the engine idling Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical e Check ECM power and ground circuits Go to Step 4 Did the power and ground circuits check OK e Replace ECM Go to Step 5 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds nn the an and ae the vehicle to Go to OBD ull operating temperature Observe the MIL Sys OK pS Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 1616 check for any stored codes Does the engine operate normally with no stored codes 393 DTC 1628 CAN Address Conflict Circuit Wire Color 114 G R a CAN 1 St CAN Device 115 G Br CAN 1 ECM
194. eplace 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 amp 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 manufacturers 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 A
195. eprogram process may render the ECM non programmable in the field Target Reprogram Progress Reprogramming 243 The status bar shows the update process 115 Pace All memory programmed successfully 198 2 Kbytes programmed in 80 4 seconds 2 5 Kbytes second program rate Target application code checksum 4BB1 Buffer application code checksum 4BB1 Target total memory checksum 19D9 Buffer total memory checksum 19D9 Buffer source file a F2_LPG_2700LPG_7613200B 009 mot 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 eng
196. ept the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 687 check for any stored codes Does DTC 687 still re set 327 No Go to OBD System Check Sec Value s Yes Go to Step 2 tion Go to Step 3 Go to Step 4 Go to Step 9 Go to Step Go to Step 3 5 Go to Step 6 Go to Step 9 Repair the short to pow er See wiring harness re pair System bat tery voltage Go to Step 8 Yes e Replace the ECM Go to Step 9 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 687 check for any stored codes System Does the engine operate normally with no stored codes 328 329 DTC 1111 Fuel Rev Limit Electronic Throttle Circuit Wire ECM Color L TPS 1 Signa
197. ery Voltage EPR lgnition Fuses Conditions for Setting the DTC e Power relay check e Check Condition Key ON e Fault Condition Relay coil shorted to power 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 a short circuit to power 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 326 DTC 687 Relay Coil Short to Power Action Did you perform the On Board OBD System Check DST connected and in the System Data Mode Key OFF Remove the power relay from the fuse block Using a DVOM check the resistance of the relay coil between power relay terminals for circuits 173 and 160B Is the resistance value less than 60 ohms e Replace the power relay Is the replacement complete Using a DVOM check for continuity between relay terminals for circuits 173 and 160B Do you have continuity between them Key OFF Disconnect ECM wire harness connector CN1 Using a DVOM check for power between ECM connector circuit 173 and engine ground with the key ON Do you have power e Replace the power relay Go to Step Is the replacement complete 7 Remove all test equipment exc
198. es 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 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 3 Reinstall Port Fittings on both ends of the hose and secure with retaining pins Make sure hose is correctly positioned and not twisted or kinked Reconnect negative battery cable Open valve on the LPG tank Turn Key to the ON position for several 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 Startthe vehicle and check for leaks Let run until it reaches normal operating temperature 8 Ifa DTC code is found refer to the Electrical Section for further diagnosis Dar XIII LPG FUEL SYSTEM PRESSURE CHECK Turn ignition to OFF Disconnect negative battery cable Remove plug on EPR listed as PRIMARY PRESSURE TEST Install Pressure Gauge Reconnect negative battery cable Start engine and note val
199. essary Ensure all mating surfaces are clean 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 ne cessary the follow the additional steps Oth erwise continue to Reassembly 17 18 19 20 Release coolant pressure Clamp off the two radiator hoses near the point where they connect to the EPR Remove Coolant Hoses Fuel Temperature Sensor and Fuel Vapor Hose by first remov ing Retaining Clips then pulling each out of the EPR ports 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 ing a Safety Solvent N WARNING Use only Safety Solvents for the cleaning of the regulator and its components Sol vents such as carburetor or brake cleaners may damage gaskets seals O rings di aphragms or other non metal components REASSEMBLY OF EPR Inspect all parts to ensure the Repair Kit is complete and all components are free of de terioration cracks tears etc 2 Place the new primary valve pin into the cover plate orifice 3 Holding the valve pin in place turn the body cover plate over Place the valve pin spring 10 11 12 13 14 15 over the valve pin and install C clip or retain ing clip Place a new secondary body gasket ensur ing th
200. et been corrected Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature eS ee System OK Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1178 check for any stored codes Does DTC 1178 still re set e Replace the EPR Go to Step 6 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds re the engine and operate the vehicle to Go to OBD ull operating temperature Observe the MIL System OF me an Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1178 check for any stored codes Does the engine operate normally with no stored codes 383 DTC 1612 RTI 1 Loss Microprocessor Conditions for Setting the DTC 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
201. ete foot pedal sensor assembly must be replaced 404 DTC 2115 FPP 1 Higher Than IVS Limit Value s Action Did you perform the On Board OBD System Check e Key ON Engine OFF e DST Diagnostic Scan Tool connected in System Data Mode Does the DST display FPP 1 voltage greater than 1 00 volts with the foot pedal in the idle po sition e Depress the foot pedal about half way Does IVS voltage drop below 1 0 volt with the foot pedal depressed e Disconnect the System Interface connector CN21 e Check for continuity between circuits 153 and 119 at the system interface connector CN21 Do you have continuity e Disconnect the System Interface connector CN21 e Check for continuity between circuits 154 and 119 at the system interface connector CN21 Do you have continuity e Disconnect the ECM connector CN1 e Check for continuity on the sensor ground circuit 120 between the system interface connector CN21 and the ECM connector CN1 Do you have continuity on the circuit e Inspect the FPP IVS connector the ECM connector CN1 and the system interface connector CN21 for damage corrosion or contamination Any damage found e Replace FPP IVS sensor Is the replacement complete 405 Greater than 1 00 volt Less than 1 00 volt Go to Step 2 Go to Step 4 Go to Step 5 Repair circuit as necessary See wiring harness re pair section Repair circuit as necessary Se
202. etected make repairs Check coolant line connections to ensure no leaks are present 20 Start engine recheck for leaks at the regulator 21 Dispose of any drained material in safe and proper manner AIR FUEL MIXER THROTTLE CONTROL DEVICE MAINTENANCE AND INSPECTION IMPORTANT The Air Fuel Mixer components have been specifically designed and calibrated to meet the fuel system requirements of the emission certified engine The mixer should not be disassembled or rebuilt If the mixer fails to operate or develops a leak the mixer should be replaced with the OEM recommended replacement parts When inspecting the mixer check for the following items e Leaks at the inlet fitting e Fuel inlet hose for cracking splitting or chaff ing replace if any of these condition exist e Ensure the mixer is securely mounted e Inspect air inlet hose connection and clamp Also inspect inlet hose for cracking splitting or chafing Replace if any of these conditions ex ist e Inspect Air cleaner element according to the Recommended Maintenance Schedule found in this section e Check Fuel lines for cracking splitting or chaf ing Replace if any of these conditions exist e Verify Throttle Body return action to ensure throttle shaft is not sticking Repair if neces sary e Check for leaks at the Throttle Body and in take manifold 17 EXHAUST SYSTEM AND CATALYTIC CONVERTER INSPECTION AND MAINTENANCE IMPORTANT The exhaust sys
203. fault will set if the coolant tem 120 0 825 perature reading exceeds 230 degrees F and engine RPM is greater 104 0 1148 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 DTC 116 ECT CHT Higher Than Expected 1 Diagnostic Aid e Thoroughly inspect the entire cooling system and for any signs of coolant leakage including coolant lines and hoses water pump engine block radiator etc e Insure the radiator cap is in good repair and maintaining suitable cooling system pressure e Compare the ECM measured temperature value with an analog temperature measurement IR temperature measurement thermometer etc if possible e f no problems are found continue with DTC 117 ECT low voltage diagnostic 157 DTC 117 ECT CHT Low Voltage Circuit Wire Color System Interface Connector CN21 Conditions for Setting the DTC e Engine Coolant Temperature ECT Sensor e Check Condition Engine Running Resistance Scaling e Fault Condition ECT sensor voltage less than 0 10 Temp deg F Ohms e MIL On during active fault p deg 10 e Adaptive Disabled during active fault 248 0 116 ORNS e 230 0 147 Circuit Description 212 0 188 The ECT Engine Coolant Temperature sensor is a temperature 200 0 220 sensitive resistor located i
204. for Setting the DTC EPR supply voltage Check condition Engine running or cranking MIL On during active fault Fault condition EPR internal supply voltage low 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 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 Action Did you perform the On Board OBD System Check DST connected and in the system data mode Engine running Check the system battery voltage 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 Be sure to ac
205. fuel when the flow exceeds a pre determined rate FTV Fuel Trim Valve FFV Flexible Fuel Vehicle Firing Line The portion of an oscilloscope pattern that represents the total amount of voltage being expended through the secondary circuit FMVSS Federal Motor Vehicle Safety Standards FPP Foot Pedal Position Sensor Fuel Injector a spring loaded electromagnetic valve which delivers fuel into the intake manifold in response to an electrical input from the control module Fuel Lock A solenoid controlled valve located in the fuel line to stop the flow when the engine stops or the ignition switch is off Gasohol 10 percent ethanol 90 percent gasoline Often referred to as E 10 Gasoline A motor vehicle fuel that is a complex blend of hydrocarbons and additives Typical oc tane level is 89 GCP Spectrum Ill 90 pin ECM Greenhouse Effect A scientific theory suggesting that carbon dioxide from the burning of fossil fuels is causing the atmosphere to trap heat and cause global warming HC Hydrocarbon An organic chemical compound HD 10 A fuel of not less than 80 liquid volume propane and not more than 10 liquid volume propylene HD 5 A fuel of not less than 90 liquid volume propane and not more than 5 liquid volume propylene HDV Heavy Duty Vehicle Heavy Ends A term used to describe the buildup of wax like impurities that fall out of LPG when vaporized HEGO Heated Exhaust Gas Oxygen used to de scrib
206. g the splices CONNECTORS AND TERMINALS 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 through the Weather Pack seals with oversized wire probes Use tachometer adapter J 35812 or equivalent which provides an easy hook up of the tach lead The connector test adapter kit 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 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 ona 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 REPAIRING TWISTED SHIELDED CABLE Drain Wire 1 Remove outer jacket 2 Unwrap aluminum Mylar tape Do not re
207. g F System State Foot Pedal Position Throttle Position Run Mode Stopped B Votage 100 100 Power Mode Standby 80 80 Fuel Type Propane 100 200 60 60 Fuel Supply OF 00 30 0 40 40 Fuel Spark inhibit input Inactive Normal 20 20 Fuel Control Mode Open Loop 14 7 volts 0 0 Govemor switch state None 0 0 Oil pressure state OK Active govemor type Min Active govemor mode isochronous ochronous Customer Configuration Information Ht Renders name mucber OHS Software and Hardware Information Cust software name number Jnot_applicablo mot Software model 21050008 Hardware model 1687002A Cust govemor cal name 2007 Govemor Calibration O Iniialcalmodel 2042400A Manufacture date 29 2007 Cust govemor cal date 132007 Initial cal date 132007 Serial number 6936 peinte Bas OT Current cal model 2042400A Hour meter 0 079 hours Es Be III Current cal date 1 3 2007 Cumulative starts 3 starts Displacement 20 L Cyinders 4 Emissions Calibration Checksum F6A20978 Spark system type Coil Per Cylinder Total Calibration Checksum SECFIIFS4 Fang Ore TB TE EA 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 EDIS ECI et Communications File Page Flash Comm Port Plot Log Help Rawyols UM Connected at 19200 bp
208. gine Coolant Temperature sensor or ECT is a variable resistance thermistor that changes resistance as the engine s coolant temperature changes The sensor s output is monitored by the ECM to determine a cold start condition and to regulate various fuel and emission control func tions via a closed loop emission system OIL PRESSURE SENSOR The Engine Oil Pressure Sensor is designed to ensure adequate lubrication throughout the en gine It provides a pressure value for the oil that is monitored by the ECM If the pressure drops a DTC will occur and the engine will shut down Injector Pulse increases or decreases fuel delivery to the engine ECM calculates changes and commands y fuel flow to ye increase PAS or decrease Gasoline Closed Loop Control Schematic 61 Input Heated Exhaust Gas Oxygen Sensor HEGO to ECM 62 Gasoline System Diagnosis GASOLINE SYSTEM DIAGNOSIS MIL GAUGES j Intake Air Air Fuel Mixture 2 Ff A Q E Gasoline Injection Systems FUEL SYSTEM DESCRIPTION The Engine Control Module ECM receives in formation from various engine sensors in order to control the operation of the fuel injectors The electric fuel pump prevents fuel flow unless the engine is cranking or running During Key ON the electric fuel pump receives a short prime cycle from the ECM which allows gasoline to flow from the tank through fuel filter and fuel lines to the
209. gnal 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 13 Start the vehicle and let run until it reaches normal operating temperature Leak check the LPG fuel system at each serviced fitting 14 If a DTC code is found refer to the Electrical Section for further diagnosis 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 Ill Electron other components may damage or cau
210. h fuel injector by 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 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 238 DTC 262 Injector Driver 1 Coil Shorted Value s Action Did you perform the On Board OBD System Check e Key On Engine Running e DST Diagnostic Scan Tool connected in System Data Mode e Clear System DTC 262 Does DTC 262 reset with the engine idling Key OFF Disconnect the injector interface connector CN17 Using a high impedance DVOM measure the resistance between the fuel injector pins at the fuel metering body at an ambient tem perature of 50 to 90 degrees F Does the DVOM display a resistance value of 5 ohms or more e Replace the Fuel Injector Is the replacement complete Disconnect the ECM wire harness connector CN1 Key ON Using a DVOM check for voltage between the ECM connector CN1 injector control cir cuit 164 and engine ground Does the DVOM display voltage e Replace the ECM Is the replacement complete Go to Step 2 Go to Step 3 Greater than Go to Step 5 0 Ohms 5 Go to Step 8 Repair the shorted to voltage injec tor driver circu
211. he relay is at a reasonable temperature between 20 and 100 degrees F 320 DTC 685 Relay Coil Open Step Did you perform the On Board OBD System Check DST connected and in the system data mode Key OFF Remove the power relay from the fuse block Using a DVOM check the resistance of the relay coil between the relay terminals for cir cuits 173 and 160B 1 Is the resistance value less than 100 ohms 3 e Check ECM fuse 4 Is the fuse open e Disconnect ECM connector CN1 e Using a DVOM check for continuity between ECM connector CN1 circuit 173 and power relay circuit 173 Do you have continuity e Remove ECM fuse e Using a DVOM check for continuity on circuit 160B between fuse block cavity for the pow er relay and the ECM fuse Do you have continuity Check all system fuses Check all relay placement positions in fuse block Run complete pin to pin checks on chassis wiring to fuel system harness See complete fuel system schematic for fur ther details Did you find the problem 321 Value s _ Go to OBD System Check Sec Yes Go to Step 2 tion Go to Step Go to Step 4 3 e Replace the power relay Go to Step FE Is the replacement complete 9 Replace ECM Go to Step fuse 5 Repair the open circuit Go to Step Go to Step 7 as required Go to Step 9 See wiring harness re pairs Repair the open circuit as required See wiring harness re pairs Go to Step
212. he secondary valve An increase in vacuum in the secondary chamber increases the downward action on the secondary lever causing it to open wider and permitting more fuel flow to the mixer Electronic Pressure Regulator N CAUTION The EPR is an emission control device and should only be serviced by qualified technicians AIR FUEL MIXER The air valve mixer is a completely self contained 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 The mixer is mounted in the air stream ahead of the throttle control device When the engine begins to crank it draws in air with the air valve covering the inlet and negative pres sure begins to build This negative pressure signal is communicated to the top of the air valve chamber through 4 vacuum ports in the air valve assembly A pressure force imbalance begins to build across the air valve diaphragm between the air valve va cuum chamber and the atmospheric pressure below the diaphragm The air valve vacuum spring is calibrated to generate from 101 6 mm 4 0 inch es of water column at start to as high as 355 60 mm 14 0 inches of water column at full throttle The vacuum being created is referred to as Air Valve Vacuum AVV As the air valve vacuum reaches 101 6mm 4 0 inches of water column the air valve begins to lift against the air valve spring The amount
213. he vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 113 check for any stored codes Does the engine operate normally with no stored codes 154 Yes Go to Step 11 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical System OK Go to Step 5 Go to Step 8 Go to OBD System Check 155 DTC 116 ECT CHT Higher Than Expected 1 Circuit Wire Color System Interface Connector CN21 Conditions for Setting the DTC ECT Sensor e Engine Coolant Temperature Resistance Scaling e Check Condition Engine Running Ohms e Fault Condition ECT greater than 230 F Temp degF 109 e MIL On during active fault 248 0 416 e 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 engine airflow calculation gasoline cold enrichment and to enable wen gt 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
214. ic 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 Onl Step 1 Did you perform the On Board OBD System Check DST connected and in the System Data Mode Key OFF Remove the fuel pump relay from the fuse block Using a DVOM check the resistance of the relay coil between the relay terminals for cir cuits 144B and 178 Is the resistance value less than 100 ohms Value s _ Yes Go to Step 2 Go to Step 4 e Replace the relay Go to Step Is the replacement complete 9 e Check VSW fuse Is the fuse open e Disconnect ECM connector CN1 e Using a DVOM check for continuity between ECM connector CN1 circuit 178 and fuel pump relay circuit 178 Do you have continuity e Remove ECM fuse e Using a DVOM check for continuity on circuit 144B between fuse block cavity for the fuel pump relay and the VSW fuse Do you have continuity Check all system fuses Check all relay placement positions in fuse block Run complete pin to pin checks on chassis wiring to fuel system harness See complete fuel system schematic for fur ther details Did you find the problem 305 Replace ECM fuse Go to Step 6 Go to Step 7 Go to Step 9 Go to OBD System Check Sec tion Go to Step 3 Go to Step 5 Re
215. ical 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 Preliminary Checks Do not use the DTC tables If a fault is an intermittent the use of the DTC 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 Terminal tension is not adequate 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 Faulty Electrical Con nections or Wiring 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
216. idling apply a load with the hydraulic system for at least 10 seconds and observe the Adaptive 1 value Did the Adaptive 1 fuel correction remain within the specified values 15 to 15 Go to Step 22 Go to Step 24 22 Raise the engine rpms to 75 90 of maximum full governed speed with no load for at least 10 seconds and observe the Adaptive 1 fuel correction Did the Adaptive 1 fuel correction remain within the specified values 15 to 15 Go to Step 23 Go to Step 24 23 e With the engine still running at 75 90 of full governed speed apply a moderate load with the hydraulic system e Observe the Adaptive 1 fuel correction Did the Adaptive 1 fuel correction remain within the specified values 15 to 15 Go to Step 29 Go to Step 24 24 Was the Adaptive 1 fuel correction less than 15 Go to Step 26 Go to Step 25 35 Step 25 Action Was the Adaptive 1 fuel correction more than 15 Values Yes Go to Step 27 No NA 26 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 e Ignition system See Step 7 e Air cleaner and intake system including vehicle intake duct ing for airflow obstructions e Exhaust system for flow obstructions e HEGO 1 for correct switching characteristics Are all actions complete
217. ies to a specific item or procedure that is to be followed during the servicing of the vehicle or its components PROPER USE OF THIS SERVICE MANUAL TOOLS AND EQUIPMENT To reduce the potential for injury to the tech nician or others and to reduce damage to the vehicle during service repairs the technician should observe the following steps e 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 GENERAL INFORMATION e The installed IMPCO fuel system has been certified with the Environmental Pro 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 should follow all the recommended ser vice and repair procedures to insure the fuel and emissions system is operating as designed and certified Purposely or kno wingly defeating or disabling any part or the fuel and emission system may be in violation of the anti tampering provision of the EPA s Clean Air Act e Tools identified in this manual with the prefix J or BT can be procured through SPX in Warren Michigan e Tools identified in this manual with a prefix ITK can be acquired through OEM Parts Distrib
218. ine 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 ign
219. ing a DVOM check for voltage between ECM connector CN1 TPS 1 signal circuit 147 and engine ground Do you have voltage e Jump TPS 1 signal circuit 147 to the 5 volt reference circuit 119 at connector CN3 Does DST display TPS 1 voltage over 4 90 volts Repair the TPS 1 circuit shorted to voltage as necessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 6 Go to Step 9 Go to Step 8 e Inspect wire terminals at throttle connector for damage corrosion or contamination Any problems found e Replace the electronic throttle assembly Is the replacement complete 167 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 12 Go to Step 7 e Key OFF e Disconnect ECM wire harness connector CN1 e Using a DVOM check for continuity on the TPS 1 circuit 147 between throttle connector CN3 and ECM connector CN1 Do you have continuity between them e Using a DVOM check for continuity on sen sor ground circuit 120 between throttle connector CN3 and ECM connector CN1 Do you have continuity between them Go to Step 9 Go to Step 10 Repair the open circuit as necessary Refer to Wir ing Repairs in Engine Elec trical Repair the open circuit as necessary Refer to Wir ing Repairs in Engine Elec trical e Inspect ECM connector terminals for damage corrosion or contamination Any problems found e
220. ing 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 RQ EDIS ECI Target Communications es File Page Flash Comm Port Plot Log Help Faults ve SPECTRUM Sj Mm at 19200 bps I Toggle Page F9 pad FaultAccess a MIL Closed Loop Control System States Monitored Drivers Diagnostic Modes Engine Speed drm gor 0 652 volts Run Mode Stopped Injector Injector on Injector ff Spark kill Nomai v Manifold Pressure 024 psa Ciosedioop 1 00 Power Mode Standby ee ae sie Inectorki Nomal Y Barometric Pressu pS nic re 8 30 psia Adaptive 1 00 Fuel Type Propane o eee D _oft vl Coolant Temperature 40 0 F EGO2 0 702 volts Fuel Supply FE 7 A a pomo Cylinder Head Temp 190 0 F ClosedJoop 2 00 FueVSpark inhibi input Nomai 3 Mw 50
221. intained properly to ensure proper performance and longevity A N WARNING Do not remove the cooling system pressure cap radiator cap when the engine is hot Allow the engine to cool and then remove the cap slowly to allow pressure to vent Hot coolant under pressure may discharge vio lently Note that the LPG vaporizer is connected to the cooling system and the fuel system may be ad versely affected by low coolant levels and restricted or plugged radiator cores Therefore the cooling system must be maintained according to the recommend maintenance schedule in this section and also include e The regular removal of dust dirt and debris from the radiator core and fan shroud e Inspection of coolant hoses and components for leaks especially at the radiator hose con nections Tighten hose clamps if necessary e 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 e Inspect the radiator cap to ensure proper seal ing COOLANT Check coolant level in coolant recovery tank and add coolant as required Add 50 50 mixture of ethylene glycol antifreeze and distilled water or coolant per engine manufacturer s instructions Do not add plain water Replace coolant per the recommended schedule IMPORTANT The manufacturers of the engine and fuel system do not recommend the
222. ion 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 Gas Fuel System Diagnosis Check the in line fuel filter for restrictions Fuel System Checks Check for the proper ignition output voltage using the spark tester J26792 or the equivalent Verify that the spark plugs are the correct type and properly gapped Remove the plugs and inspect them for the following conditions Wet plugs Cracks Wear Improper gap Burned electrodes Heavy deposits Check the Crankshaft Position CKP sensor Ignition System Checks Check the ECM grounds for being clean tight and in their proper loca tions Additional Check Check the generator output voltage Check the vacuum hoses for kinks or leaks Check Transmission 83 84 Electrical Section 86 Diagnostic Scan Tool 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 comm
223. ion or contamination Did you find a problem 164 Go to Step 9 Go to Step 10 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 14 Go to Step 13 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 12 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 11 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 11 Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature Observe the MIL O Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 118 check for any stored codes System Does the engine operate normally with no stored codes 165 DTC 121 TPS 1 Lower Than TPS 2 Electronic Throttle Circuit Wire ECM Color L TPS 1 Signal Sensor Ground TPS 2 Signal 5 Volts Conditions for Setting the DTC 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
224. ipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1176 check for any stored codes Does the engine operate normally with no stored codes 379 Value s Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 6 System OK Go to OBD System Check Sec tion Go to Step 6 System OK Go to OBD System Check DTC 1177 EPR internal Circuitry Fault Circuit Wire Color 115 G Br Ground Ground To Power Relay Fuse Block CN25 Conditions for Setting the DTC EPR internal circuitry test Check condition Engine running or cranking MIL On during active fault Fault condition 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 if the ECM detects an internal circuitry fault in the EPR In the event of multiple code sets always start the di
225. ir 2 cccccceseeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeneeeeeeeaeeaeeeseaeaeeneas 125 Repairing a wire harness on the vehicle Diagnostic Trouble Codes DTCs ccccccccccccccncnoninnnnonannnnnnncnonncnnnnnnnnnnnnnnnnnannas 129 Application schematic and DTC specific code information O SPECTRUM by IMPCO Servicing the Fuel System uuuun2ue 457 Step by step instructions on how repair and or replace fuel related components Definitions pata ee 475 Definitions of phrases and acronyms used throughout this Service Manual Tool Kit amp Accessories ae 481 Definitions of phrases and acronyms used throughout this Service Manual ABPPENARE en ee 483 Altitude vs Barometric Pressure amp Ignition System Specifications General Information IMPCO INTRODUCTION This service manual supplement has been developed to provide the service technician with the basic understanding of the IMPCO certified fuel and emission systems for the 2 0L engine This manual should be used in conjunction with the base engine manual and the OEM service manual when diagnosing fuel or electrical problems HOW TO IDENTIFY THE ENGINE YEAR The 2 0L engine blocks have been stamped with a serial number The number can be found on the left side of the top edge of the engine block near the exhaust manifold ENGINE IDENTIFICATION NUMBER The engine identification number consists of 11 digits L 4 G C X 10 0 0 O 0 1
226. ircuit 120 between CKP connector CN9 and ECM connector CN1 Do you have continuity between them e Inspect the CKP connector CN9 terminals for damage corrosion or contamination Did you find a problem e Inspect the ECM connector CN1 terminals for damage corrosion or contamination Did you find a problem 267 5 0 volts Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 Go to Step 6 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check Sec tion Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 7 Go to Step 8 Value s Yes e Replace CKP sensor Go to Step 10 Is the replacement complete 10 e Replace ECM Go to Step 11 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 opera
227. ircuits 120 and 137 for damage corrosion or contamination Did you find a problem 163 Go to Step 2 Go to Step 3 0 10 volts or less Go to Step 4 See resis tance chart vs tempera ture in the DTC 118 circuit de scription Go to Step 6 Go to Step 14 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 8 Go to Step 5 Go to Step 7 Intermittent problem Go to Inter mittent section Jump the ECT connector CN5 signal circuit 137 at the ECT connector to engine ground Does DST display ECT voltage of 0 10 or less e Key OFF e Disconnect ECM wire harness connector e Using a DVOM check for continuity on ground circuit 120 between ECT connector CN5 and ECM connector CN1 Do you have continuity between them e Inspect ECM connector CN1 circuits 120 and 137 for damage corrosion or contamination Did you find a problem e Replace ECM Is the replacement complete e Key OFF e Disconnect ECM wire harness connector CN1 e Using a DVOM check for continuity on ECT signal circuit 137 between ECT connector CN5 and ECM connector CN1 Do you have continuity between them e Inspect ECM connector CN1 circuit 120 and 137 for damage corros
228. it 119 49 Lt 5 Volts Wire Color RAW ECM Conditions for Setting the DTC External 5 volt reference Check Condition Engine cranking or running Fault Condition 5 volt reference higher than 5 40 volts MIL On during active fault Adaptive Disabled during active fault 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 Value s Action Did you perform the On Board OBD System Check e Key ON Engine running e DST Diagnostic Scan Tool connected in System Data Mode Does DST display DTC 643 e Check all ECM ground connections e Refer to Engine electrical power and ground distribution Are the ground connections OK Key OFF Disconnect ECM connector CN1 Key ON Using DVOM check for Voltage between ECM connector CN1 circuit 119 and engine ground Do you have voltage e Replace ECM Is the replacement complete Remove all test equipment except the DST Connect any disconnected compone
229. it as ne cessary Refer to Wir Engine Elec trical Go to Step 7 ing Repairs in Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 4 Go to Step 6 239 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature System OK Go to OBD Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC262 check for any stored codes system check Does the engine operate normally with no stored codes 240 241 D TC 264 Injector Driver 2 Open or Low Side Short to Ground Circuit Wire Color 164 Injector Driver 1 Injector Driver 2 Injector Driver 3 Injector Driver 4 Ignition Fuse and Power Relay Conditions for Setting the DTC e Injector loop open or low side short to ground e Check Condition key on and engine running e Fault Condition System voltage greater than 9 volts and injector low side less than 4 0 volts for 10 injector firings e MIL On for active fault e Adaptive Disabled e Closed Loop Disabled Circuit Description System battery voltage is supplied to each fuel injector The ECM controls each fue
230. ition 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 v
231. ity After operating the engine within the test pa rameters of DTC 183 check for any stored codes Does the engine operate normally with no stored codes 207 Go to Step 13 Repair the cir cuit as necessary Refer to Wiring Repairs in En gine Electrical System OK Repair the cir cuit as necessary Refer to Wiring Repairs in En gine Electrical Go to Step 11 Go to OBD System Check DTC 187 LP Temp Voltage Low Circuit Wire Color ECT CHT Signal Sensor Ground Conditions for Setting the DTC LP Temperature Check Condition Engine Running Fault Condition FT sensor voltage less than 0 050 volts MIL On Adaptive Disabled Circuit Description The LP Temp Fuel Temperature sensor is a temperature sensi Mu RUSS tive resistor located near the fuel outlet of the electronic pressure regulator It is used to help determine fuel charge density for accu Temperature in Ohms 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 Value s Action Did you perform the On Board OB
232. ixture is ignited by something other than the spark plug such as a hot spot in the combustion chamber Also caused by a fuel with an octane rating that is too low and or incorrect ignition tim ing Also called detonation or ping Lambda Sensor A feedback device usually lo cated in the exhaust manifold which detects the amount of oxygen present in exhaust gases in re lation to the surrounding atmosphere See HEGO LDV Light Duty Vehicle Lean Mixture An air to fuel ratio above the stoi chiometric ratio too much air LEV Low Emission Vehicle Limp in or Limp Home A mode where the ECM or a component has failed but the vehicle re mains operational although the engine may operate minimally This term may also describe the drivability characteristics of a failed computer system Liquid Petroleum Gas LPG A fuel commonly known as propane consisting mostly of propane CHa derived from the liquid components of natural gas stripped out before the gas enters the pipeline and the lightest hydrocarbons produced during petroleum refining Octane level of LPG is 107 LPG Liquified Petroleum Gas M85 A blend of gasoline and methanol consisting of 85 methanol and 15 gasoline MSV Abbreviated MSV Refers to the manually operated valve on the LPG tank Measurements of Pressure 1 PSI 2 06 Hg mercury 27 72 H20 water column At sea level atmospheric pressure is 29 92 Hg Methanol Known as wood alcohol CH
233. jector connector control circuit Value s 20 ohms or less Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 8 Repair the shorted to ground injec Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent electrical sec tion Go to Step 4 5 Ohms or tor control Go to Step 5 165 and engine ground legs circuit 6 See wire har Does the DVOM display a resistance of 5 Ohms ne or less ach e Using a DVOM check for continuity between ee the CN19 connector injector control pin and GotoStep control circuit 6 the ECM injector driver pin Do you have continuity between them 7 See wire har ness repair section 251 Value s Yes e Replace the ECM Go to Step 8 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 267 check for any stored codes Does the engine operate normally with no stored codes 252 253 DTC 268 Injector Driver 3 Coil Shorted Circuit Wire Color 164 L Injector Driver 1 Injector Driver 2
234. k Key On DST connected in the System Data Mode e Clear DTC 686 e Start the engine Does DTC 686 re set e Disconnect ECM connector CN1 e Using a DVOM check the resistance value between ECM connector CN1 circuit 173 and engine ground Is the resistance less than 60 ohms Remove the power relay from the fuse block Using a DVOM check the resistance value again between ECM connector circuit 173 and engine ground Is the resistance less than 60 ohms Value s Yes Go to Step 2 mittent Go to Step 3 section Go to Step Go to Step 4 6 Repair the Go to Step 5 Go to OBD System Check Sec tion Intermittent problem Go to Inter shorted to ground relay control circuit as necessary See wiring harness re pairs a E Is the replacement complete 7 e Replace ECM Go to Step a ee l Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 686 check for any stored codes Does the engine operate normally with no stored codes 325 Go to OBD System Check System OK DTC 687 Relay Coil Short to Power Power Relay Relay Control VSW fuse Batt
235. k the electronic throttle connector ter minals for damage corrosion or contamination Did you find a problem e Replace throttle Is the replacement complete Key OFF Disconnect ECM wire harness connector CN1 Using a DVOM check for continuity on the TPS 1 signal circuit between throttle connec tor CN3 and ECM connector CN1 Do you have continuity between them 401 Value s Go to Step 3 Go oa Go to Step 8 Goto Step Goto Step 6 5 Go to Step 11 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 11 Go to Step 9 Go to System Check Section Intermittent problem Go to Intermit tent section Go to Step 7 Repair the circuit as ne cessary Refer to Wiring Re pairs in Engine Elec trical e Using a DVOM check for continuity between throttle connector TPS 1 signal circuit 147 and engine ground Do you have continuity between them e Replace ECM Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2112 check for any stored codes Does the engine operate normally
236. kBroi60327 6 ignition Female p Kum PB625 06027 8 nt Switch Female 1p amp 1723202 RubberCover 9 pom Crank Femalesp amp 85205 3 Gold Pin Manifold Assy Female 4 KUM PUA65 02127 12 13 E 14 Female 2P 12162195 15 Female 8P 16 P 17 j 18 KUM PU465 02127 KUM PU465 02127 KUM PU465 02127 a Systeminterf Female16P amp 368047 1 22 Startersolenoid 10 20A_ Deco 95225 38050 23 24 26 Maxifuse 6oa litte Des FuseBox Fuses 15A Pacific MiniFuse Des FuseBox Fuse ioa Pacific MiniFuse Des FuseBox Fuses 15a Pacific MiniFuse Des FuseBox Fuse6 15a Pacific MiniFuse Des FuseBox 27 Startersolenoid Femailap amp 1723202 28 Ground Toms 2 FuelPump ammRing FuelPump Smmeing J E 31 Alternators 8mmRing _ J 3a Beten 8mmRing Battey a2 123 124 Engine Wire Harness Repair 125 ON VEHICLE SERVICE 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 er part number harnesses When wires are spliced into a harness use wire with high tem perature insulation only 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 solderin
237. l Sensor Ground TPS 2 Signal 5 Volts Conditions for Setting the DTC Fuel Rev Limit Check Condition Engine Running Fault Condition Engine rpm greater than 4 000 MIL On during active fault 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 Action Value s Yes Go to OBD Go to Step System 2 Check Sec Did you perform the On Board OBD System Check tion Go to Step Go to Step 3 4 Go to Step 4 e Key ON Engine OFF e DST in Active Fault Mode Are any other DTC codes present with DTC 1111 e Diagnose and repair any other DTC codes before proceeding with this chart Have any other DTC codes been diagnosed and repaired e Replace ECM with the correct service part number Go to Step 9 Go to Step Go to Step 8 7 Go to Step 9 Is the replacement complete e Check the mechanical operation of the throttle Is the mechanical operation of the throttle OK e Correct mechanical operation of the Throttle Body Has the mechanical operation of the throttle bee
238. l and physical preliminary checks e Check all ECM system fuses and circuit breakers refer to Engine Wiring Schematic e Check the ECM grounds for being clean tight and in their proper locations refer to Engine Wiring Schematic e Check the vacuum hoses for damage splits kinks and prop er connections e Check the fuel system for any type of leak or restriction from the supply tank to the mixer e Check for air leaks at all mounting areas of the intake mani fold sealing surfaces e Check for proper installation of the mixer assembly e Check for air leaks at the mixer assembly and all intake duct ing between intake manifold and air cleaner e Check air cleaner and all vehicle intake ducting for restric tions e Check exhaust system for flow obstructions or leaks Check the ignition wires for the following conditions e Cracking or hardening e Proper routing e Bare or shorted wires e Carbon tracking Check the wiring harness for the following conditions e Proper connections e Pinches e Cuts or abrasions Were any faulty conditions found in the preliminary checks Correct the faulty condi tion and Go to Step 20 Go to Step 4 Does the vehicle start and run Go to Step 9 Go to Step 5 Check the fuel system for the following conditions e Verify the LPG fuel tank is at least full e Verify the manual fuel shut off valve is open and operating correctly e Verify the high flow valve ha
239. l injector by providing a ground signal to pulse the injector ON This fault will set ifthe 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 242 D TC 264 Injector Driver 2 Open or Low Side Short to Ground Action Did you perform the On Board OBD System Check Key On Engine Running DST Diagnostic Scan Tool connected in system data mode Clear System DTC 264 Does DTC 264 reset with the engine idling Key OFF Disconnect the injector interface connector CN18 Using a high impedance DVOM measure the resistance between the fuel injector pins at the fuel metering body at an ambient tem perature of 50 to 90 degrees F Does the DVOM display a resistance value of 20 ohms or less e Replace the Fuel Injector Is the replacement complete Disconnect the injector interface connector CN18 Disconnect the ECM connector CN1 Using a DVOM measure the resistance be tween the injector control circuit 167 at the injector connector CN18 and engine ground Does the DVOM display a resistance of 5 Ohms or less e Using a DVOM check for continuity on the injector control circuit between the CN18 connector and the ECM connector CN1
240. l 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 Action Did you perform the On Board OBD System Check Key ON Engine OFF DST Diagnostic Scan Tool connected in data stream mode Depress Foot Pedal until the Throttle Com mand is between 63 68 Is the TPS 1 voltage greater than 2 0 volts Key OFF Disconnect electronic throttle connector CN3 Probe TPS 1 signal circuit 147 with a test light connected to battery voltage Key ON Does DST display TPS 1 voltage less than 0 2 volts Key OFF Disconnect ECM wire harness connector CN1 Key ON Using a DVOM check for voltage between throttle connector TPS 1 signal circuit 147 and engine ground Do you have voltage e Replace ECM Is the replacement complete e Back probe sensor ground circuit 120 at ECM connector CN1 with a test light con nected to battery voltage Does the test light come on Value s Go to Step 3 Go Go to Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go m En System Check Section Intermittent problem Go to Intermit tent section Go to Step 5 Go to Step 7 Go to Step 13 Go to Step 9 Key OFF Disconnect ECM wire harness connector CN1 Using a DVOM check for continuity between throttle connector signal ground cir
241. le control command Check the ECM grounds for being clean tight and in their proper loca 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 ROUGH UNSTABLE OR INCORRECT IDLE STALLING Checks Action Check the engine for Broken motor mounts Improper valve timing Engine Mechanical Low compression Check Improper valve clearance Worn rocker arms Broken or weak valve springs Worn camshaft lobes 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 Preliminary Checks None 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 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 Fuel System Checks Check for the proper ignition output voltage using the spark tester J26792 or the equivalent Verify that the spark plugs are the correct type and properly gapped Remove
242. ly installed in the system e Verify that the MIL charging and oil pressure lights illuminate momentarily during engine start 13 ENGINE CRANKCASE OIL OIL RECOMMENDATION Select an engine oil that will best match the pre vailing daytime temperature Applied temperature range until replacement Recommended SAE viscosity number 15w 10W 40 30 1 5W 20 engine oil is recommended for everywhere If 5W 20 is not applicable proper engine oil will be possible according to temperature ranges Motor oils meeting this spec receive the API American Petroleum Institute starburst symbol The recommended API classification Above SG The oil capacity for the 2 0L engine including a new filter is 1 1 gallons 4 0L IMPORTANT Oils recommended by the engine manufacturer already contain a balanced additive treatment Oils containing solid additives non detergent oils or low quality oils are not recommended by the engine manufacturer The supplemental addi tives added to the engine oil are not necessary and may be harmful The engine and fuel system supplier do not review approve or recommend such products SYNTHETIC OILS Synthetic oils have been available for use in in dustrial engines for a relatively long period of time and may offer advantages in cold and hot temperatures However it is not known if syn thetic oils provide operational or economic benefits over conventional pet
243. 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 manifold INSTALLATION PROCEDURE 1 Place exhaust manifold against engine block Align holes and thread eight screws into the block Torque to 31 1 39 8ft Ibs 42 2Nm 53 9 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 Ifthe back pressure at either speed exceeds specification a restricted exhaust system is indicated 6 Inspect the entire exhaust system for a col lapsed pipe heat distress or possible internal catalytic converter failure 7 If there are no obvious reasons for the ex cessive back pressure the catalytic converter is likely damaged and should be replaced 8 Check for MIL and clear using the DST Back Pressure Gauge
244. ment that converts voltage and frequency readings into traces on a cathode ray tube also see Cathode Ray Tube Oxides of Nitrogen Chemical compounds of ni trogen bonded to various amounts of oxygen NOX A chief smog forming agent Oxygen Sensor An automotive fuel system that produces a signal in accordance with the oxygen 478 content of the exhaust gas See Lambda Sen sor Oxygenate Oxygenates such as MTBE ethanol and methanol added to gasoline to increase the oxygen content and therefore reduce exhaust emissions Ozone A radical oxygen module Oz that is found in the upper atmosphere and filters out ultraviolet radiation from the sun Ground level ozone is formed by NOX during the formation of photo chemical smog Particulates Microscopic pieces of solid or liquid substances such as lead and carbon that are dis charged into the atmosphere by internal combustion engines Positive Crankcase Ventilation PCV An auto motive emission control system designed to reduce hydrocarbon emissions by routing crank case fumes into the intake manifold rather than to the atmosphere Power Derate A mode of reduced engine power output for the purposes of protecting engine com ponents during a failure or malfunction Pressure Differential The differential between atmospheric pressure and intake manifold re ferred to as vacuum pressure Pressure Regulator A device to control the pres sure of fuel delivered to the fu
245. move Mylar RAE 3 Untwist conductors strip insulation as ne cessary Drain Wire 4 Splice wire using splice clips and rosin core solder Wrap each splice to insulate 5 Wrap with Mylar and drain wire uninsu lated wire EA 3 6 Tape over entire juncture and secure 126 REPAIRING TWISTED LEADS SEE SCS Locate Damaged Wire 2 Remove insulation as required EEES 3 Splice two wires together suing splice clips and rosin core solder Esa 7 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 placement of a Micro Pack terminal Micropack Connector Cable Terminal Locking Tang Tool J33095 BT8234 A SI 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 into the connector to seat it in place Metri Pack Series 150 Terminal Removal 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
246. ms before running this setup program Click Cancel to quit the setup program then close any programs you have running Click Next to continue the installation WARNING This program is protected by copyright law and international treaties Unauthorized reproduction or distribution of this program or any portion of it may result in severe civil and criminal penalties and will be prosecuted to the maximum extent possible under law e Click Next to continue 90 Destination Folder Select a folder where the application will be installed The installation wizard will install the files for Impco GCP Display in the following folder To install into a different folder click the Browse button and select another folder You can choose not to install Impco GCP Display by clicking Cancel to exit the installation wizard Destination Folder CAlmpcoGCP_Disk N_ e Click Next to continue Ready to Install the Application Click Next to begin installation Click the Back button to reenter the installation information or click Cancel to exit the wizard N e Click Next to continue 91 13 Impco GCP Display Setup tos Impco GCP Display has been YA successfully installed 2 Click the Finish button to exit this installation e Click the Finish box to complete the installation i Installer Information to Impco GCP Display to
247. n Engine Elec trical Go to Step 11 Go to OBD System Check DTC 217 ECT CHT Higher Than Expected 2 Circuit Wire Color System Interface Connector CN21 Conditions for Setting the DTC ECT Sensor Resistance e Engine Coolant Temperature Scaling e Check Condition Engine Running 3 e Fault Condition ECT greater than 248 F Tempided F Ohms 210 e MIL On during active fault 248 0 116 e Engine shutdown 230 0 147 e 212 0 188 oa o 200 0 220 Circuit Description 185 0 275 The ECT Engine Coolant Temperature sensor is a temperature 176 0 322 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 y 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 DTC 217 ECT CHT Higher Than Expected 2 Diagnostic Aid Thoroughly inspect the entire cooling system and for any signs of coolant leakage including coolant lines and hoses water pump engine block radi
248. n corrected e Check engine for large manifold vacuum leaks Refer to Fuel Systems symptom diag nostics Go to OBD Go to Step System 9 Check Sec tion e Check the service part number on the ECM to ensure correct calibration is in use Go o7 Go to Step 5 Is the service part number correct Did you find and correct the vacuum leak 331 Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD operating temperature Observe the MIL SYPIE OR oe Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 1111 check for any stored codes Does the engine operate normally with no stored codes 332 333 DTC 1112 Spark Rev Limit Electronic Throttle Circuit Wire ECM Color L TPS 1 Signal Sensor Ground TPS 2 Signal 5 Volts Conditions for Setting the DTC Spark Rev Limit Check Condition Engine running Fault Condition Engine RPM greater than 4200 MIL On during active fault Engine Shut Down 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
249. n an ap proved container when the procedure is completed Follow any additional user rec ommendations in the manufacturer instructions for the fuel pressure gauge in use N CAUTION 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 4 Clean any spillage of gas with a shop towel and dispose of properly 5 Reconnect negative battery cable 6 Turn ON the ignition with the engine OFF for 2 seconds Inspect for leaks Turn ON ignition 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 by use ofthe DST tool See section DIAGNOSTIC SCAN TOOL XVI LPG FUEL SYSTEM LEAK TEST 1 Use a commercially available liquid leak detector or an electronic leak detector and follow the manufacturer s instructions IMPORTANT When using both methods use the electronic leak detector first to avoid contamination by the liquid leak detector XVII ELECTRONIC PRESSURE REGULATOR 10 11 EPR REMOVAL PROCEDURE Disconnect the negative battery cable Relieve the LPG fuel system pressure Refer to lll LPG Fuel System Pressure Relief Disconnect the LPG fuel inlet line from the Shut Off Valve fitting Disconnect the EPR electrical connector Disconnect the Shut Off Valve electrical connec tor Clamp both coolant lines ne
250. n and servicing The owner and or service agent should review the operating conditions of the equipment to deter mine the inspection and maintenance intervals N WARNING When performing maintenance on the engine turn the ignition OFF and disconnect the bat tery negative cable to avoid injury or damage to the engine The engine installed in this equipment uses a ser pentine drive belt configuration that drives the water pump alternator and additional pumps or devices It is important to note that the drive belt is an integral part ofthe cooling and charging sys tem and should be inspected according to the maintenance schedule in this section When in specting the belts check for Cracks Chunking of the belt Splits Material hanging loose from the belt Glazing hardening If any of these conditions exist the belt should be replaced with the recommended OEM replace ment belt N WARNING Alcohol or Methanol based anti freeze or plain water are not recommended for use in the cooling system at anytime 12 SERPENTINE BELT SYSTEM Serpentine belts utilize a spring loaded tensioner to keep the belt properly adjusted Serpentine belts should be checked according to the main tenance schedule in this section IMPORTANT The use of belt dressing or anti slipping agents on belts is not recommended COOLING SYSTEM It is important that the cooling system of the en gine be ma
251. n 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 reads higher voltage and lower when warm This fault will set if the 100 at 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 Value s Action Did you perform the On Board OBD System Check e Key On e DST Diagnostic Scan Tool connected in System Data Mode Does DST display ECT voltage of 0 10 or less e Key Off e Disconnect the ECT wire harness connector CN5 e Key ON Does the DST display ECT voltage of 4 90 volts or greater Replace ECT sensor Is the replacement complete e Key OFF e Disconnect ECM wire harness connector CN1 e Check for continuity between ECT sensor connector CN5 signal circuit 137 and sensor ground circuit 120 Do you have continuity between them e Check for continuity between ECT sensor connector CN5 signal circuit 137 and engine ground Do you have continuity 159 Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 8 Repair the circuit as ne ce
252. n 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 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 converter The HEGO sensors are used to measure the amount of oxygen present in the ex 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 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
253. n the test pa rameters of DTC 1151 check for any stored codes Does the engine operate normally with no stored codes 340 Repair the shorted circuit as necessary Refer to Wir ing Repairs in Engine Elec trical Go to Step ave 8 heater ground Go to Step 9 Go to OBD System OK System Check Go to Step 7 341 DTC 1152 Closed Loop Multiplier Low LPG Circuit Wire Color G B EGO 1 Signal Signal Ground EGO 1 Heater Ground Power Relay Fuse Block CN25 T Ignition Fuse Conditions for Setting the DTC e Heated Oxygen Sensor e Functional Fault Closed Loop multiplier out of range at limit of 35 e MIL Disabled 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 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
254. nd 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 S Enter Password Password 5 Clear Password Past Password Single Serial Number Access Serial Number Save password and S N Quit Figure 1 Populated Password Dialog Box 98 PASSWORD DIALOG BOX FUNCTIONS e Clear Password Button Erases the current password from the password field e Paste Password Button Allows the user to copy a 16 character string from any word processor and paste the string in the password field e Single Serial Number Access Checkbox Tells the software that the password is applicable for sin gle serial number access e 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 e 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 f
255. ne cessary Refer to Wir ing Repairs in Engine Elec trical Step Action 11 Disconnect ECM connector C001 Check for continuity on sensor ground circuit 120 between MAP sensor connector CN4 and ECM connector CN1 Do you have continuity between them e Replace ECM Refer to ECM replacement in the Engine Controls Section Is the replacement complete e Correct MAP mechanical connection Has the MAP mechanical connection problem been corrected e Remove all test equipment except the DST e Connect any disconnected components fus es etc e Using the DST clear DTC information from the ECM e Turn the ignition OFF and wait 30 seconds e Start the engine and operate the vehicle to full operating temperature e Observe the MIL e Observe engine performance and driveability e After operating the engine within the test pa rameters of DTC 108 check for any stored codes Does the engine operate normally with no stored codes Go to Step 9 Go to Step 11 Go to Step 11 System OK Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check 144 145 DTC 111 IAT Higher Than Expected 1 Wire Color ECM Conditions for Setting the DTC e Intake Air Temperature e Check Condition Engine Running e Fault Condition Intake Air Temperature greater than 200 degrees F with engine rpm great er than 1000 e MIL
256. nec 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 128 Diagnostic Trouble Codes DTCs 129 DTC 16 Never Crank Synced at Start ECM Circuit Wire Color 5 volt reference Crank Sensor Sensor Ground Crank 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 Value s Action Did you perform the On Board OBD System Check e Check that the ECM ground terminal CN28 is clean tight and in the proper location Are the ground terminals clean and tight e Key On Engine OFF e Disconnect the CKP Crankshaft position Sensor conne
257. nected components fus es 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 temperature System OK Go to OBD Observe the MIL System Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 223 check for any stored codes Does the engine operate normally with no stored codes 232 233 D TC 261 Injector Driver 1 Open or Low Side Short to Ground Circuit Wire Color 164 Injector Driver 1 Injector Driver 2 Injector Driver 3 Injector Driver 4 Ignition Fuse and Power Relay Conditions for Setting the DTC e Injector loop open or low side short to ground e Check Condition key on and engine running e Fault Condition System voltage greater than 9 volts and injector low side less than 4 0 volts for 10 injector firings e MIL On for active fault e Adaptive Disabled e 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 ifthe 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
258. ng Ignition wires for arcing and proper routing Cross firing Insulation cracks Primary ignition coil wires for cracks or carbon tracking Check for manifold vacuum or air induction system leaks 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 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 Check the connection at primary ignition coil wire Check for deteriorated spark plug wire insulation Ignition System Checks COREK lie Spano plug Remove the plugs and inspect them for the following conditions Wet plugs Cracks Wear Improper gap Burned electrodes Heavy deposits Check the engine for the following Improper valve timing Engine compression 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 Gas Fuel System Diagnosis Engine Mechanical Check 79 LACK OF POWER SLUGGISHNESS OR SPONGINESS Checks Action DEFINITION The engine delivers less than expected power There is little or no incre
259. ng e DST Diagnostic Scan Tool connected in System Data Mode e Run engine greater than 1000 rpm Does DST display system voltage greater than 16 volts Value s Yes Go to Step 2 Go To Step 3 Go to OBD System Check Sec tion Intermittent problem Go to Engine Electrical In termittent section e Check voltage at battery terminals with DVOM with engine speed greater than 1000 rpm Is it greater than 16 volts e Repair the charging system Has the charging system been repaired e Replace ECM Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 563 check for any stored codes Does the engine operate normally with no stored codes 297 Go to Step 4 Go to Step 6 Go to Step 6 System OK Go to Step 5 Go to OBD System Check DTC 601 Flash Checksum Invalid Microprocessor Conditions for Setting the DTC 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 EC
260. ng f e DST Diagnostic Scan Tool connected in intermittent System Data Mode Go to Step proniem e Clear system fault code 3 E section Does DTC 1615 reset with the engine idling Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical e Check ECM power and ground circuits Go to Step 4 Did the power and ground circuits check OK e Replace ECM Go to Step 5 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds nn the an and ae the vehicle to Go to OBD ull operating temperature Observe the MIL Sys OK pS Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 1615 check for any stored codes Does the engine operate normally with no stored codes 391 DTC 1616 Invalid Interrupt Microprocessor Conditions for Setting the DTC 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 ev
261. ng 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 Preliminary Checks Fuel System Checks Sensor Checks Exhaust System Checks Engine Mechanical Check Additional Check 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 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 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
262. nic throttle control device utilizes an electric motor connected to the throttle shaft In addition a Foot Pedal Position sensor FPP is lo cated in the operator s compartment When the engine is running electrical signals are sent from the foot pedal position sensor to the en gine ECM when the operator depresses or release the foot pedal The ECM then sends an electrical signal to the motor on the electronic throttle control to increase or decrease the angle of the throttle blade thus increasing or decreasing the air fuel charge to the engine The electronic throttle control 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 The Catalytic Converter is a component of the emissions system which is designed and calibrated to meet the emission standards in effect for 2007 2009 The exhaust gases pass through the honeycomb catalyst which is coated with a mixture of metals such as platinum palladium and rhodium to oxid ize and reduce CO HC and NOX emission gases 58 L Three Way Catalytic Converter ENGINE CONTROL MODULE To obtain maximum effect from the catalyst and accurate control of the air fuel ratio the emission certified engine is equipped with an onboard computer or Engine Control M
263. nnector CN1 Do you have continuity between them e Check for continuity on the sensor ground circuit 120 between TMAP sensor connector CN4 and ECM connector CN1 Do you have continuity between them 181 Value s Go to Step 2 Go to Step 3 Go to Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 6 Go to Step 7 Go to Step 17 Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 8 Go to Step 5 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Probe TMAP connector signal circuit 123 with a test light connected to battery voltage Does the DST display BP pressure of 16 00 psia or greater e Key OFF e Disconnect ECM connector CN1 e Check for continuity on the 5 volt supply cir cuit 119 between TMAP sensor connector CN4 and ECM connector CN1 Do you have continuity between them e Check for continuity between TMAP sensor connector 5 volt reference circuit 119 and engine ground Do you have continuity e Inspect TMAP and ECM connector pins for corrosion contamination or mechanical damage Any problems found e Replace ECM Refer to ECM
264. no crankshaft signal is present for 6 cam pulses this fault will set 270 DTC 337 Crank Loss Action Value s Yes Go to OBD Did you perform the On Board OBD System Go to Step System 2 Check Check Sec tion Repair the e Check thatthe ECM ground terminal CN28 is a clean tight and in the proper location Go Ta E i 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 ground 5 0 volts Go a Refer to Wir ing Repairs CHECK THIS BEFORE THE POWER RELAY in Engine SHUTS OFF Electrical Do you have voltage e Key OFF Repair the e Disconnect ECM connector CN1 circuit as necessary So E Refer to Wir 5 ing Repairs in Engine Do you have continuity between them Electrical Repair the e Using a DVOM check for continuity on the circuit as sensor ground circuit 120 between CKP con Go to Ste necessary nector CN9 and ECM connector CN1 6 P Refer to Wir ing Repairs Do you have continuity between them in Engine Electrical e Using a DVOM check for continuity on crank signal circuit 125 between CKP connector and ECM connector Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical e Inspect the CKP connector CN9 terminals for damage corrosion or contamination Go to Step
265. nstall ECOM e1793000C on your computer lt is recommended that you close all other applications before Click Next to continue or Cancel to exit Setup e Click Next to continue 96 Installation Options Select which files to install lt is recommended that you install both drivers and software if you plan to use your device for development purposes Only the hardware drivers are required if you plan to use your device exclusively for EControls display software Install ECOM Drivers and Supporting Software 9 Install ECOM Drivers Only ly 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 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 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 a
266. nsuring the seals properly seat and are not twisted or pushed down 4 Place Mixer on top of the Adapter 5 Place gasket on top of Intake Manifold 6 Align the holes of the Mixer Adapter Throttle Body Gasket and Intake Manifold and secure with four screws Torque to 106 in Ibs 12 Nm 7 Attach the two hoses to Mixer 8 Attach the air intake duct from the Mixer 9 Reconnect negative battery cable 10 Open LPG tank valve 11 Start the vehicle and let run until it reaches nor mal operating temperature 12 If a DTC code is found refer to the Electrical Section for further diagnosis XII FUEL VAPOR HOSE EPR TO FUEL MIXER REMOVAL PROCEDURE 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 464 INSTALLATION PROCEDURE Lightly lubricate Port Fitting O rings with Vase line or petroleum jelly prior to installation Insert Port Fittings into each end of the hose and secure with hose clamps N WARNING 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 hos
267. nt 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 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 DTC 122 TPS 1 Signal cn Low Action Did you perform the On Board OBD System Check e Key ON Engine OFF e DST Diagnostic Scan Tool connected in DBW Drive by Wire throttle test mode Does the DST display TPS 1 voltage of 0 200 volts or less with the throttle closed e Slowly depress Foot Pedal while observing TPS 1 voltage Does TPS 1 voltage ever fall below 0 200 volts Key OFF Disconnect the electronic throttle connector CN3 Jump the 5 volt reference circuit 119 and TPS 1 signal circuit 147 together at the throt tle connector CN3 Key ON Does DST display TPS 1 voltage of 4 0 volts or greater Key OFF Disconnect ECM wire harness connector CN1 Using a DVOM check continuity on the TPS 1 circuit 147 between the electronic throttle connector CN3 and ECM connector CN1 Do have continuity between them e Replace ECM Is the replacement complete VENTO Go gt GEB System Check Go ps A Section Intermittent Go Ds ne problem Go to Intermit tent section Repair the circuit as ne cessary Refer
268. ntermittent problem Go to Inter mittent section Go to Step 5 Repair the open oil pres sure switch circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 289 Inspect the oil pressure switch connector terminal and ECM connector for damage cor rosion or contamination Repair the circuit as ne cessary Refer to Wir Go to Step 8 Did you find a problem e Replace ECM Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 524 check for any stored codes Does the engine operate normally with no stored codes 290 ing Repairs in Engine Elec trical Go to Step 9 System OK Go to OBD System Check 291 DTC 562 System Voltage Low Circuit Wire Color ECM GROUND 181 B 181 160 is 160 179 R VBAT 179 Conditions for Setting the DTC 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 MIL On for active fault Adaptive Disabled Circuit Description The battery
269. nterpreted 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 Onl No Yes fo Go to Step Go to Step 3 2 Go to Step Go to Step 6 4 Action Value s Perform the On Board OBD System Check Are any other DTCs present Visually and physically check the following items The air intake duct collapsed or restricted The air filter for being plugged The EGO sensor installed securely and the wire leads not damaged or contacting the secondary ignition wires ECM grounds for being clean and tight Run the fuel system diagnostic checks Was a repair made Key OFF Disconnect EGO sensor wire harness connec tor CN11 Disconnect ECM wire harness connector CN1 Key ON Using a DVOM check for voltage at the EGO connector C11 signal circuit 121 and engine ground
270. nts fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 643 check for any stored codes Does the vehicle engine normally with no stored codes 319 Go to Step 2 Go to Step 3 Go to Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 6 System OK Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 5 Go to OBD System Check DTC 685 Relay Coil Open Power Relay Relay Control VSW fuse Battery Voltage EPR lgnition Fuses Conditions for Setting the DTC e Power relay check e Check Condition Key ON e 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 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 t
271. o to OBD System Check Sec tion Intermittent problem Go to Inter mittent electrical sec tion Go to Step 4 Go to Step 6 Repair the open injector control circuit See wire har ness repair section Value s Yes e Replace the ECM Go to Step 8 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 261 check for any stored codes Does the engine operate normally with no stored codes 236 237 DTC 262 Injector Driver 1 Coil Shorted Circuit Wire Color 164 L Injector Driver 1 Injector Driver 2 Injector Driver 3 Injector Driver 4 Ignition Fuse and Power Relay Conditions for Setting the DTC Injector coil shorted Check Condition key on and engine running 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 Adaptive Disabled Closed Loop Disabled Circuit Description System battery voltage is supplied to each fuel injector The ECM controls eac
272. odule ECM The ECM receives input data from sensors mounted to the engine and fuel system and then outputs various signals to control engine operation Inputs Outputs Cam Crank Signals TPS_____ gt CAN Line _ gt LPG Shut Off Speed Control Gauges pu OO aal gt A ENGINE CONTROL MODULE 02 Senso s n TMAP Speed Motor Control e Shut Off Valve Engine Control Module ECM Inputs amp Outputs One specific function of the controller is to main tain a closed loop fuel control which is accomplished by use of the Heated Exhaust Gas Oxygen sensor HEGO mounted in the exhaust system The HEGO sensor sends a voltage sig nal to the controller which then outputs signals to change the amount of fuel being delivered from the regulator or mixer to the engine 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 code and by using the diagnostic charts in this manual to determine the cau
273. oggle Test Cell F10 VE Base MIL MAP psia oo 35 45 so 70f sof o 120 130 140 135 150 150 150 150 150 CylinderHead Temperature Estimate 30 0 500 soo 500 520 520 sof seo 620 mof mo mof mof mo mof m0 Wietimiesm co 6 300 soo soo sool saof seo 630 630 700 sof sof s10 810 810 810 810 EBEN 00 degF 500 30 0 00 450 540 540 560 630 680 715 770 sof sof 810 810 810 810 CHT tau 5 008 seconds 600 300 400 450 520 555 590 650 700 730 770 81 0 81 0 81 0 81 0 810 810 CHT offset start tau 10 027 seconds 200 300 400 sool 610 625 650 nof 740 755 790 815 815 815 815 815 815 1000 300 500 560 635 660 eso 740 760 770 805 825 825 825 825 S25 825 Cylinder Wall Temperature Estimate 1300 300 580 620 675 700 720 765 790 eos 820 845 845 e45 845 845 845 VECWTC 250 o s fuel speed 1600 300 600 650 60 710 730 770 200 elo 830 eso 850 850 850 850 850 VECWTtauide 2 000 seconds fem 2000 f 200 cool esf 710 7aof 745 rao sro s20 ess eso 860 esof 860 eso 860 ve cwt mide 600 mm 2500 300 620 ssf 710 735 750 795 825 sof 855 sof eso 8so 860 860 860 ve cwr octe P oo 3000 350 eso 725 735 760 780 835 eso 860 eso 880 eso 88 0 es0 880 880 vECWTmaximk I seo f sso eof 7151 xof roof ssf erol ssf ssf sos sol mol ol sol ol 0 vecwTmnimt a 4000 300 650 730 785 815 830 eso 900 905 910 320 920 920 920
274. olts 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 e Jump pins A and D at the DLC connector e Turn the ignition key to the on position e 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 e 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 e f no DTC codes are found the ECM will continue to flash 1654 only This means no stored DT
275. om the intake manifold in order to isolate the leaking fuel injector Did you complete the replacement e Repair the restricted fuel return pipe between the chassis fuel pipe and the fuel tank Did you complete the repair e Inspect for a missing or damaged O ring seal before replacing the fuel pressure regulator If the O ring seal is not missing or damaged replace the fuel pressure regulator Did you complete the replacement e Replace the fuel sender assembly or external fuel pump if so equipped Did you complete the replacement Yes Go to Step 21 Go to Step 23 Go to Step 23 Go to Step 23 Go to Step 23 No Go to Step 19 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and drivability Does the engine operate normally with no stored codes 69 System OK Go to OBD System Check 70 Gasoline Symptom Diagnostics Checks Before Using This Section Fuel System Check Visual Checks GAS SYMPTOM DIAGNOSTICS Action Before using this section you should have performed On Board Diagnostic Check and determined that 1 The ECM and MIL are operating correctly 2 There are no Diagnostic Trouble Codes DTCs stored or
276. ompounds where sulfur is bonded to oxygen produced by the combustion of gasoline or any other fuel that contains sulfur As sulfur oxides combine with water in the at mosphere to form sulfuric acid System Pressure The fuel pressure maintained in the system during normal engine operation Tap An electrical term for a type of splice where the original circuit is not interrupted TBI Throttle Body Injection Any of several injec tion systems that have the fuel injector s mounted in a centrally located throttle body Throttle Body Controls engine RPM by adjusting the engine manifold vacuum to the mixer Con sists of a housing shaft throttle liner and butterfly valve TLEV Transitional Low Emission Vehicle TMAP Combined Air Inlet and Manifold Pressure Sensor Toluene A liquid aromatic hydrocarbon C7Hs TPS Throttle Position Sensor 479 TSB Technical Service Bulletin ULEV Ultra Low Emission Vehicle USB Universal Serial Bus A plug or interface sup plied on most personal computers Vaporization A process in which liquid changes states into gas Venturi Air Valve Vacuum VAVV An amplified air valve vacuum signal coming from the venturi area of the mixer directly exposed to airflow be fore the addition of vaporized LPG Volt ohmmeter VOM A combination meter used to measure voltage and resistance in an electrical circuit Available in both analog and digital types May also referred to as AVOM and DVOM
277. on 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 e Windows Vista 32 Bit e Windows XP 32 Bit e Windows 2000 Minimum processor speed e Pentium II 450 MHz e Pentium lll 1 0 GHz for Windows Vista Minimum RAM requirement e Windows Vista 512 MB e Windows XP 256 MB e Windows 2000 128 MB At least one available RS232 serial or USB port ECOM cable supports USB port only 88 Computer DVD RW Drive D 070413 0948 Favorite Links E Documents E Pictures E Music More Folders BZ Desktop B Top Tech Public ME Computer amp Local Disk C DVD RW Drive D 070413 0948 KINGSTON E Y Network Control Panel Recycle Bin Name Size Type Files Currently on the Disc 1 DST_Series II 1 item e Open the DST_Series III folder Favorite Links E Documents E Pictures IE Music More Folders EE Desktop BE Top Tech de Public Computer amp Local Disk C DVD RW Drive D 070413_0948 Ji DST_Series I ECOM_Driver Je Latest_GCP_Display USB Driver KINGSTON E Y Network Control Panel E Recycle Bin Ww Name Size Files Currently on the Disc 3 ECOM_Driver i File Folder J USB Driver
278. ondary chamber of the Electronic Pressure Regulator EPR These oil and heavy ends may be a result of poor fuel quality contamination of the fuel or regional variation of the fuel make up A signifi cant build up of oil can affect the performance of the secondary diaphragm response The Rec ommended Maintenance Schedule found in this section recommends that the oil be drained pe riodically This is the minimum requirement to maintain the emission warranty More frequent draining of the EPR is recommended for special situation where substandard fuel may be a prob lem IMPCO recommends the EPR be drained at every engine oil change if contaminated or subs tandard fuel is suspected or known to have been used or in use with the emission complaint fuel system This is known as special maintenance 16 and failure to follow this recommendation may be used to deny a warranty claim IMPORTANT Draining the regulator when the engine is warm will help the oils to flow freely from the regulator To drain the EPR follow the steps below 1 Move the equipment to a well ventilated area and ensure no external ignition sources are present 2 Start the engine 3 With the engine running close the LPG tank valve 4 When the engine runs out of fuel turn OFF the key when the engine stops and disconnect the negative battery cable IMPORTANT A small amount of fuel may still be present in the fuel line use gloves to prevent burns wear
279. onnect any disconnected components fus es 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 temperature Go to Step Observe the MIL emer 10 Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2112 check for any stored codes Does the engine operate normally with no stored codes e Replace ECM Go to Step 11 Is the replacement complete Su Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Go to OBD Observe the MIL System OK System Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2112 check for any stored codes Does the engine operate normally with no stored codes 418 419 DTC 2139 FPP 1 Lower Than IVS Limit Circuit Wire Color FPP IVS Sensor Interface CN25 Check OEM chassis wiring diagram for specific pin numbers and wire colors Conditions for Setting the DTC Foot Pedal Position Check Condition Key On Fault Condition FPP 1 voltage less than 0 850 volts and IVS off idle MIL On during active Power derate Circuit Description The Foot Pedal Position
280. oolant temperature reading is more than 10 de Sensor Checks grees greater or less than the ambient air temperature on a cold engine 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 Check for fuel pump electrical circuit Verify proper fuel pump pressure Fuel System Checks Verify proper fuel rail pressure Check the in line fuel filter for restrictions Refer to the Gasoline Fuel System Diagnosis 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 Check the spark plugs for the following conditions Wet plugs Cracks Wear Burned electrodes Heavy deposits Check for bare or shorted ignition wires Check for moisture in the distributor cap Check for loose primary ignition coil wire connections Ignition System Checks 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 Check for the following Vacuum leaks Improper valve timing Low compression Worn rocker arms Broken or weak valve springs Worn camshaft lobes Check the intake and exhaust manifolds for casting flash Engine Mechanical Checks 75 HARD START Checks Action Check the exhaust system for a
281. 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 Circuit Wire Color G Br Ground Ground To Power Relay Fuse Block CN25 Conditions for Setting the DTC EPR delivery pressure Check condition Engine running or cranking MIL On during active fault 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
282. or 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 Password Error x Password is invalid Exiting 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 The serial number of the connected module does not agree with the serial number for which you enterred a password on program start Hit the exit key below to quit the program or connect to the correct module to continue Password Verified S N lo Connected Module S N bpo o Exit Program 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 EDIS ECI Serial Communications E lol x File Page Flash CommPort Plot Log Help Tal Not authorized to connect to this target Gaug OS Not authorized to connect to this target Not Connected 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
283. ow 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 Wire Color 120 Gr Circuit ECM Conditions for Setting the DTC Intake Air Temperature Check Condition Engine Cranking or Running Fault Condition IAT Sensor Voltage less than 0 050 MIL On during active fault Adaptive Disabled during active fault 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 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 Value s Action Did you perform the On Board OBD System Check e Key On e DST Diagnostic Scan Tool connected in System Data Mode Does DST display IAT voltage of 0 050 or less e Key Off e Disconnect the TMAP sensor connector CN4 e Key ON Does the DST di
284. pair open EGO 2 signal ground Go to OBD System Check 191 DTC 171 Adaptive Learn High Bi Fuel Gasoline Onl Circuit Wire Color G B EGO 1 Signal Signal Ground EGO 1 Heater Ground Power Relay Fuse Block CN25 7 Ignition Fuse Conditions for Setting the DTC Heated Oxygen Sensor Check Condition Engine Running Fault Condition Adaptive multiplier out of range greater than 30 MIL On 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 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
285. pair the open circuit as required See wiring harness re pairs Repair the open circuit as required See wiring harness re pairs Go to Step 8 e Replace the ECM Go to Step 9 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 627 check for any stored codes Does the engine operate normally with no stored codes 306 307 DTC 628 Relay Control Ground Short Bi Fuel Gasoline Onl Fuel Pump Relay Relay Control VSW fuse Battery Voltage F Pump Fuse Conditions for Setting the DTC e Fuel pump relay ground control e Check Condition Key ON e Fault Condition Relay control shorted to ground 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 a short to ground 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 i
286. perly gapped Check for faulty spark plug wires Check for fouled spark plugs Check for manifold vacuum or air induction system leaks AOS 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 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 Ifthe meter reads over 30 000 ohms replace the wires Check the connection at primary ignition coil wire Check for deteriorated spark plug wire insulation Ignition System Checks Remove the plugs and inspect them for the following conditions Wet plugs Cracks Wear Improper gap Burned electrodes 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 Improper valve timing 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 casti
287. pment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature Observe the MIL O Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2122 check for any stored codes System Does the engine operate normally with no stored codes 410 411 DTC 2123 FPP 1 Low Voltage Circuit Wire Color FPP IVS Sensor Interface CN25 Check OEM chassis wiring diagram for specific pin numbers and wire colors Conditions for Setting the DTC Foot Pedal Position Check Condition Key On Fault Condition FPP sensor voltage less than 0 300 MIL On during active Low rev limit Force idle 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 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 FPP sensors are OEM specific and vary in configuration The exact wire color and pin num bers for the FPP connection
288. possible restriction e Inspect the exhaust system for damaged or collapsed pipes e Inspect the muffler for signs of heat distress or for possible internal failure e Check for possible plugged catalytic converter Refer to Restricted Ex haust System Diagnosis Exhaust System Checks 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 Preliminary Checks None 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 e Insulation cracks Ignition System Checks Wear Improper gap Burned electrodes Heavy deposits Visually Physically inspect the secondary ignition for the following e Ignition wires for arcing and proper routing e Cross firing e Primary ignition coil wires for cracks or carbon tracking e Perform a cylinder compression check Check the engine for the following Engine Mechanical e Improper valve timing Checks Worn rocker arms Worn camshaft lobes Broken or weak valve springs Check the intake and exhaust manifold pas
289. pplicable in the state of California 18 LPG Fuel System UA Tank Pressure MM Regulated Pressure Intake Air Air Fuel Mixture MN Exhaust Gas LPG FUEL SYSTEM OPERATION Speed control motor Fuel Cylinder A Fuel Filter Shut Off Valve TMAP Cam Signal Crank Signal ENGINE ECT IAT Catalytic Muffler Engine Control Module 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 vice electric Shut Off Valve Engine Control Module ECM Oxygen Sensor and a Catalytic Converter The system operates at pressures which range from 355 60mm 14 0 inches of water col umn up to 21 5 BAR 312 psi LPG FUEL TANK LPG is stored in the fuel tank as a liquid The ap proximate pressure of the fuel in the tank is 8 8 bar 130 psi when the tank is full at an ambient tem perature of 27 C 81 F The boiling point temperature at which the liquid fuel becomes va por is approximately 40 C 40 F When the fuel changes from liquid to vapor the fuel expands and creates pressure inside the tank When the tank service valve is opened the pressure inside the tank forces the liquid fuel out though the pickup tube located near the bottom of the fuel cylinder
290. pressure regulator before it reaches the fuel injector With the Ignition ON engine OFF and fuel pump running the pressure should be TBD TBD kPa TBD TBD psi At idle manifold pressure is much lower than at mospheric pressure which creates a high vacuum This vacuum will offset the pressure regulator diaphragm resulting in a lower fuel pressure Fuel pressure at idle will vary some what depending on barometric pressure but should be approximately 69 kPa 10 psi less than the ignition ON engine OFF pressure Un 64 used fuel is returned to the fuel tank by a sepa rate return fuel line The fuel pump pressure test port is located on the fuel rail DIAGNOSTIC AIDS This procedure is intended to diagnose a ve hicle operating on Gasoline If the vehicle will not continue to run on Gasoline refer to Hard Start section for preliminary checks Before starting this procedure verify that the vehicle has a sufficient quantity of fuel TOOLS REQUIRED e J34730 1 or equivalent e J37287 or equivalent DIAGNOSTIC SCAN TOOL e Diagnostic Scan Tool Software DST TEST DESCRIPTION The numbers below refer to step numbers in the diagnostic table 4 11 14 15 Connect fuel pressure gage Refer to the Fuel Injection Pressure Tester Owner s Ma nual supplied in the IMPCO Test Kit for instructions on relieving gasoline fuel pres sure for fuel systems without a Schrader valve or test port Wrap a shop towel around th
291. prop er eye protection If liquid fuels continues to flow from the connections when loosened check to make sure the manual valve is fully closed 5 Slowly loosen the inlet fitting and disconnect 6 Loosen the hose clamp at the outlet hose fitting and remove the hose 7 Remove the Retaining Pin in the LPG Tem perature Sensor and remove from the EPR 8 Remove the EPR mounting bolts 9 Place a small receptacle in the engine com partment 10 Rotate the EPR to 90 so that the outlet fitting is pointing down into the receptacle and drain the EPR 11 Inspect the secondary chamber for any large dried particles and remove 12 Remove the receptacle and reinstall the EPR with the two retaining bolts and tighten to specifications 13 Reinstall the outlet fitting and secure with the previously removed Retaining pin 14 Reconnect the electrical connector push in until it clicks and securely locks then pull on the connector to ensure it is locked 15 Connect the vacuum line 16 Reconnect the outlet hose and secure the hose clamp 17 Reinstall the fuel inlet line and tighten connec tion to specification 18 Slowly open the LPG tank valve IMPORTANT The fuel cylinder manual valve contains an Excess Flow Check Valve Open the manual valve slowly to prevent activating the Excess Flow Check Valve 19 Check for leaks at the inlet and outlet fittings using a soapy solution or an electronic leak detector Ifleaks are d
292. pshot e 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 I X yo Er 4 C de Accessories AS ADSTech Instant DVD Internet Wirele B AOL Explorer Ly Autodesk Volo View e CyberLink PowerDVD gt p dJi Extras and Upgrades gt Xx iw Jo Games gt n Impco GCP Display AOL 9 0 Maintenance e Default Programs Jo McAfee New Office Document gt Windows Media Player gt Windows Meeting Space El Windows Movie Maker gt a Windows Photo Gallery Computer ie edis_saplot XJ Impco GCPlsisplay gt gt d Microsoft Office Tools gt Le National Instruments Le PSI Display e ScreenShot 2000 2 gt de Startup gt BB Adobe Reader 8 8 eDrawings 2007 Internet Explorer Microsoft Excel r Microsoft PowerPoint Microsoft Word E Windows Calendar Windows Contacts did Windows Defender fo Windows DVD Maker iE Windows Fax and Scan amp amp Windows Live Messenger Download Windows Mail Windows Media Center Open Office Document er Windows Update Programs RI Documents 2 Settings Search Help and Support un Shut Down Windows Vista Er gt 11 11 AM e 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
293. r external leaks before proceeding with this diag nostic e Turn ON the ignition with the engine OFF e Command the fuel pump ON with the DST or fuel pump test circuit Does the fuel pump operate 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 manded ON a few times in order to obtain the highest possible fuel pressure 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 should stabilize and remain constant Monitor the fuel pressure gage for 1 minute Does the fuel pressure decrease by more than the specified value Relieve the fuel pressure to the first specified value Monitor the fuel pressure gage for 5 minutes Does the fuel pressure decrease by more than the second specified value Turn ON the ignition with the engine OFF e Monitor the fuel pressure gauge e Start the engine Does the fuel pressure decrease by the specified value when the engine is started 66 TBD TBD kPa TBD TBD psi TBD TBD kPa TBD
294. r Ground TPS 2 Signal 5 Volts Conditions for Setting the DTC Engine shutdown Circuit Description Throttle Position Sensor 2 Check Condition Cranking or Running Fault Condition TPS 2 sensor exceeds 4 800 volts MIL On during active fault Dual throttle Position Sensors are used within the throttle that use variable resistors to deter 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 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 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 2 voltage is greater than 4 800 volts The MIL command is ON and the engine will shutdown 230 DTC 223 TPS 2 Signal Voltage Action Value s Did you perform the On Board OBD System Go to Check ae System Check Section Key ON Engine OFF e DST Diagnostic Scan Tool connected in DBW Drive by Wire throttle test mode Go a Go to Step 3 Does the DST display TPS 2 voltage of 4 800 volts or greater with the throttle closed e Slowly depress Foot Pedal while observing Intermittent TPS 2 voltage Go to S
295. r secondary ignition system voltages for the equivalent gasoline operating conditions e Check for the proper ignition voltage output with J 26792 or the equiva lent e Verify that the spark plugs are the correct type and properly gapped Check the spark plugs for the following conditions Wet plugs Cracks Wear Burned electrodes Heavy deposits Check for bare or shorted ignition wires Check for moisture in the distributor cap Check for loose primary ignition coil wire connections 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 Checks Engine Mechanical Checks Exhaust System Checks HARD START Action Important The LPG Fuel system is more sensitive to intake manifold lea kage than the gasoline fuel supply system Check for the following Vacuum leaks Improper valve timing Low compression Improper valve clearance Worn rocker arms Broken or weak valve springs Worn camshaft lobes Check the intake and exhaust manifolds for casting flash Check the exhaust system for a possible restriction e Inspect the exhaust system for damaged or collapsed pipes e 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
296. r 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 Action Did you perform the On Board OBD System Check Disconnect the LPG shut off solenoid con nector CN13 Using a DVOM check for power across ter minals circuits 177 and 821 while cranking the engine then turn the key to the OFF posi tion Did the voltage immediately turn OFF with the Key cycle Unplug the LPG Shut off valve electrical con nector Start the engine and let it idle until the engine stops THIS MAY TAKE SEVERAL MINUTES Did the engine ever stop e Replace the LPG shut off valve Is the replacement complete Key OFF Disconnect the ECM wire harness connector CN1 Using a DVOM check for continuity between circuit 177 and engine ground Do you have continuity e Inspect the ECM wire harness and connector for damage corrosion or contamination Did you find a problem Replace the ECM Is the replacement complete 283 Value s _ System Vol tage Yes Go to Step 2 Go to Step 3 Intermittent problem See intermittent problems in
297. 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 Value s _ Action Did you perform the On Board OBD System Check e Key ON e DST Diagnostic Scan Tool open in System Data Mode Does DST display FRP Fuel Pressure voltage greater than 4 80 volts Key OFF Disconnect the FRP sensor connector CN16 and jump circuits 120 and 113 Key ON Does the DST display FRT voltage less than 0 10 volts e Check wire harness and FRP sensor con nector for damage corrosion or contamination Any problems found e Replace FRP sensor Is the replacement complete e Key OFF e Jump FRP sensor connector CN16 signal circuit 113 to engine ground e Key ON Does the DST display FRP voltage less than 0 10 volts Key OFF Disconnect the ECM wire harness connector CN1 Check for continuity on FRP signal circuit 113 between FRP sensor connector CN16 and ECM connector CN1 Do you have continuity between them 13
298. 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 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 IMPCO Gasoline IMPCO recommends the use of name brand high detergent gasoline Gasoline is a mixture of many different hydrocarbons including ole fins which are heavy waxy compounds Over time these deposits can build up and clog the fuel injectors The formation of these deposits is a normal consequence of engine operation 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 cleaning procedure requires special equip ment that may not be practical in the industrial lift truck market Speak with your f
299. re of the incoming air The ECM uses the resistance value to monitor incoming air tem 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 COOLANT TEMPERATURE SENSOR 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 CY Oil pressure 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 OUTPUT EPR increases or decreases fuel to the engine a ENGINE ECM calculates changes and commands EPR to increase Ordecrease fuel flow LPG Closed Loop Schematic 27 Input Heated Exhaust Gas Oxygen Sensor HEGO to ECM 28 LPG System Diagnosis LPG FUEL SYSTEM DIAGNOSIS The Electronic Pressure
300. res 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 The fuel filter The fuel feed pipe Did you find and correct the condition Inspect the wiring harness connectors and ground circuits of the fuel pump for poor connections Refer to system wiring sche matic Did you find and correct the condition 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 for poor connections The fuel strainer or external filter for a restric tion The fuel tank for contaminants Did you find and correct the condition 68 TBD kPa Go to Step TBD psi 21 Go to Step 23 Go to Step 23 Go to Step 23 Go to Step 15 Go to Step 16 Go to Step 17 Go to Step 22 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 Turn ON the ignition with the engine OFF Inspect for a fuel leak from the fuel pressure regulator Is the fuel pressure regulator leaking fuel e Remove the fuel injectors fr
301. roleum based oils in industrial engines Use of synthetic oils does not permit the extension of oil change intervals CHECKING FILLING ENGINE OIL LEVEL IMPORTANT Care must be taken when checking engine oil lev el Oil level must be maintained between the ADD mark and the FULL mark on the dipstick To ensure that you are not getting a false reading make sure the following steps are taken before checking the oil level 1 Stop engine 2 Allow approximately five minutes for the oil to drain back into the oil pan 3 Remove the dipstick Wipe with a clean cloth or paper towel and reinstall Push the dipstick all the way into the dipstick tube 4 Remove the dipstick and note the amount of oil on the dipstick The oil level must be be tween the FULL and ADD marks MIN MAX Figure 2 Engine Oil Dip tick Typical 5 If the oil level is below the ADD mark reinstall the dipstick into the dipstick tube and proceed to Step 6 6 Remove the oil filler cap from the valve cover 7 Add the required amount of oil to bring the level up to but not over the FULL mark on the dipstick Reinstall the oil filler cap to the valve rocker arm cover and wipe any excess oil clean CHANGING THE ENGINE OIL IMPORTANT When changing the oil always change the oil filter 1 Start the engine and run until it reaches nor mal operating temperature A N CAUTION An overfilled crankcase oil
302. rve the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 604 check for any stored codes Does the engine operate normally with no stored codes 301 Value s Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 5 System OK Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check DTC 606 COP Failure Microprocessor Conditions for Setting the DTC Engine Control Module Check Condition Key on Fault Condition Internal microprocessor error MIL On Adaptive Disabled 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 output 302 DTC 606 COP Failure Action Did you perform the On Board OBD System Check e Key On Engine Running e DST Diagnostic Scan Tool connected in System Data Mode e Clear system fault code Does DTC 606 reset with the engine idling e Check ECM power and
303. s Toggle Page F9 rh by RPCO SHI 2 Raw Voltage Inputs miL age pus TPS rm 0 005 vots EGO Law 2356 vots GOVitaw 0 474 vols ung gl TPS2 raw 0 000 vots EGO2 raw 2590 volts GOV2 DIG4_raw 0 474 vols Manifold Pressure 1 00 psa EGO3 raw 0 000 volts AUX_DIG1_raw 0 479 volts Coolant Te FPP1_rew 0 015 volts y lant Temperature 190 0 degF EGO4 raw 0 000 vots AUX_DIG2_rew 0 479 volts Cylinder Head Temp 1300 deg F HES BED aT AUX_DIG3 row 0484 vots Ve 2615 volts AA E E ae 0000 wis py 250 vote AUK PWM LS ow 0000 vots Intake Air Temperature 7100 degF TIP yw 5000 vots a er ER T vols BE Tan VESa_FB_raw 4550 volts AUX_PWM2_LS_raw 0 000 ve mm ves FB raw 4291 vots AUX_PWM3_LS raw 0 000 vots Vbat 147 volts WGP_raw 0 000 volts AUX PWM4 LS raw 0 000 volts Vew 128 vots FRP raw 0010 vots AUXPUiraw 500 vots AUX wus LS ew 0000 vots Gov1 voltage 20 volts FTP_raw 5 000 volts AUX_PU2_raw 5 000 vols u Gov2 voltage 20 vots Em hoot AUX_PU3 raw 5 000 volts EGO1H_LS_raw 0 000 volts Oil pressure voltage 50 vots or vay EGO2H_LS_rew 0 000 volts 5 000 volts AUX_PD1_raw 0 000 volts EGO3H LS raw 000 vots Injector Injectoron Injector off 5 000 volts AUX_PD2_raw 5 000 volts EGO4H_LS raw 0 000 volts low side low side 5 000 volts AUX_PD3_raw 5 000 volts firing order voltage voltage 500 vots WG_PWM_LS_raw 0 000 volts 1 00 383 AUX_PUD1_raw 0 010 vols LOCKOFF_LS_raw 0000 volts 2 oof as 5 000 volts AUX_PUD2 raw 5 000 volts en 0000 ve 3 oof ms
304. s e Rapid acceleration e 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 e Check the EPR fuel pressure Refer to LPG Fuel System Diagnosis Fuel System Checks e Check the fuel system for leakage Sensor Checks e Check the TMAP sensor Verify that the spark plugs are the correct type and properly gapped Remove the plugs and inspect them for the following conditions e Wet plugs Cracks Wear Improper gap Ignition System Checks Burned electrodes Heavy deposits Preliminary Checks Check the ignition wires for the following items e Cracking e Hardness Proper connections Cooling System Checks nn the engine thermostat to see if it is stuck open or for the wrong heat e Check the transmission shift pattern Additional Check e Refer to the OEM Transmission Controls section the Service Manual e Check for dragging brakes 50 ROUGH UNSTABLE OR INCORRECT IDLE STALLING Checks 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 Preliminary Check None Check the Heated Exhaust Gas Oxygen Sensors HEGO performance e 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
305. s at a reasonable temperature between 20 and 100 degrees F 308 DTC 628 Relay Control Ground Short Bi Fuel Gasoline Onl Action Did you perform the On Board OBD System Check Key On DST connected in the System Data Mode e Clear DTC 628 e Start the engine Does DTC 628 re set e Disconnect ECM connector CN1 e Using a DVOM check the resistance value between ECM connector CN1 circuit 178 and engine ground Is the resistance less than 60 ohms Remove the power relay from the fuse block Using aDVOM check the resistance value again between ECM connector circuit 178 and engine ground Is the resistance less than 60 ohms e Replace the power relay Is the replacement complete Replace ECM Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 628 check for any stored codes Does the engine operate normally with no stored codes 309 No Go to OBD System Check Sec tion Value s Yes Go to Step 2 Go to Step 3 Go to Step Go to Step 4 6 Repair the Go to Step 5 shorted to Intermittent problem Go to Inter mittent section
306. s ITPS_pet N_P_act avg FPP_pct MJ_P_cmd BP EU DTC 1637 PWM4 open ground short ea Jfuel_state Feet SnapShot Custom Definitions EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY 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 Connected at 19200 bps Toggle Page F9 4 _T
307. s 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 Action Value s Yes a 2 Perform the On Board OBD System Check Go to Step Go to Step 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 The EGO sensor is installed securely and the Go to Step Go to Step 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 e Diagnose any other DTC codes before pro ceeding with this chart Go to Step Go to Step 6 4 Have any other DTC codes been detected diag 6 4 nosed and repaired Key OFF Disconnect EGO sensor wire harness connec tor CN11 Disconnect ECM wire harness connector C
308. s not tripped e Verify the quick disconnect is fully engaged and there are no kinks or obstructions in the high pressure LPG supply hose e Verify the LPG fuel filter is clean and unobstructed Were any faulty conditions found in the fuel supply system Correct the faulty condi tion and Go to Step 20 Go to Step 6 32 Step Action Value s Yes No If NO pressure e Connect a calibrated 0 5 PSI pressure gauge to the pri ieee no mary pressure test port ofthe EPR nage A e Make sure the manual shut off valve is open and turn the 59_49 re 6 ignition to ON PSI Goto Step 7 if LOW i or e 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 e Correct plug type for LPG application faulty condi 7 e Wet electrodes oil fouling tomaid 000 e Cracks Go to Step Step 8 e Wear 20 e Improper gap e Burned electrodes e Heavy deposits Were any faulty conditions found in the ignition system check Repair the 8 Perform a leak down test on the engine lt 10 Go to Step ee Are all cylinder leak down test results within specification le
309. sages 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 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 Additional Check 77 Checks enough HESITATION SAG STUMBLE 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 Fuel System Checks Ignition System Checks Additional Check Check for fuel pump electrical circuit Verify proper fuel pump pressure Verify proper fuel rail pressure Check the in line fuel filter for restrictions Refer to the Gasoline Fuel System Diagnosis Check electrical connections of fuel injectors Check for the proper ignition voltage output with J 26792 or the equiva lent Remove Spark Plugs Verify that the spark plugs are the correct type and properly gapped Check for fouled spark plugs Wear Improper gap Burned electrodes Heavy deposits Visually Physically inspect the secondary ignition for the followi
310. screws Torque to 7 5 Nm 5 5 ft Ibs Plug connector into controller Push lock into place Reconnect the negative battery cable Install Diagnostic Service Tool Start the vehicle and let run until it reaches nor mal operating temperature If a DTC code is found refer to the Electrical Section for further diagnosis Aankhon N ENGINE WIRE HARNESS REPLACEMENT 1 Disconnect negative battery cable Lay out the new wire harness noting the loca tion type of connectors and identifying markings Take special note of identical or simi lar connectors such as the coils or HEGO Sensors to avoid crossing connections during installation Note the routing of the existing wire harness in and around the engine and the ve hicle Refer to the Electrical Schematic N CAUTION 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 8 Reconnect negative battery cable 458 9
311. se Wire RAV 5 volts Dist Cam Sensor Conditions for Setting the DTC Camshaft position sensor Check Condition Cranking or Running 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 Value s Action Did you perform the On Board OBD System Check e Check that the ECM ground terminal CN28 is clean tight and in the proper location Are the ground terminals clean and tight e Key OFF e Disconnect the CMP Camshaft position Sensor connector CN2 e Using A DVOM check for voltage at the CMP sensor connector CN2 circuit 119 and engine ground Do you have voltage e Key OFF e Disconnect ECM connector CN1 e Using a DVOM check for continuity on the CMP signal circuit 127 between CMP con nector CN2 and ECM connector CN1 Do you have continuity between them e Using a DVOM check for continuity on the sensor ground circuit 120 between CMP connector CN2 and ECM connector CN1 Do you have continuity between them e Inspect the CMP connector terminals for damage corrosion or contamination Did you find a problem e Inspect the ECM connector CN1 for damage corrosion or contamination
312. se 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 converter The HEGO sensors are used to measure the amount of oxygen present in the ex haust stream to determine whether the fuel air ratio is to rich or to lean Itthen communicates this measurement to the ECM Ifthe 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 Ifthe 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 By monitoring output from the sensor upstream and the sensor downstream of the catalytic con verter the ECM can determine the performance of the converter The Heat Exhaust Gas Oxygen HEGO Sensor 59 HEGO1 volts HEGO 2 volts 50 51 52 53 54 55 56 57 58 59 60 Time sec HEGO1 upstream or before the catalytic con verter and HEG
313. se the EPR to ic Pressure Regulator EPR malfunction and void warranty coverage 1 Seal Clamp Plate 2 Seat Secondary N WARNING 3 Gasket Body Secondary a Ein Primary The Repair Kit consists of the only serviceable gt an Primary components for the Spectrum lll EPR Do not 7 a dej use any other components or regulator repair a Maly kits to service the Spectrum III EPR The Kit is 8 O ring specifically designed for the Spectrum lll EPR 9 O ring and is not compatible with other regulators Repair Kit Includes 1 9 8 9 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 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 Be sure to identify the type of screw and its loca tion during each stage of disassembly to ensure proper placement during reassembly 7 Gently pull the Regulator away from the Ac tuator If necessary tap around the edge of the face plate with the handle of a plastic scre
314. sec Key cycles since fault was active Jo 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 electric
315. sets always start the diagnostic repair with the lowest numerical value DTC first 372 DTC 1174 EPR Voltage Supply High Action Did you perform the On Board OBD System Check DST connected and in the System Data Mode Engine running Check the system battery voltage Is the charging voltage within specifications e Using a DVOM compare the system battery voltage to the DST display Is the voltage reading within 1 volt between the two of them e Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1174 check for any stored codes Does the engine operate normally with no stored codes Step 373 Value s e Replace the EPR Is the replacement complete e Replace the ECM Is the replacement complete Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 6 Go to Step 6 System OK Go to OBD System Check Sec tion Repair the charging sys tem Go to Step 5 Go to OBD System Check DTC 1175 EPR Supply Voltage Low Circuit Wire Color 115 G Br Ground Ground To Power Relay Fuse Block CN25 Conditions
316. sition Sensor Check Condition Cranking or Running Fault Condition Actual throttle position is 20 less than the throttle command MIL On during active fault 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 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 TPS Action Did you perform the On Board OBD System Key ON Engine OFF DST Diagnostic Scan Tool connected in DBW data stream mode Depress foot pedal until the throttle com mand is 63 68 Is the TPS voltage less than 2 0 volts Key OFF Disconnect electronic throttle connector CN3 Probe TPS 1 signal circuit 147 with test light connected to battery voltage Key ON Is TPS voltage 4 0 volts or greater e Check throttle bore for foreign object Did you find a problem e Remove the foreign object Has the object been removed e Chec
317. splay IAT voltage of 4 90 volts or greater e Replace TMAP sensor Is the replacement complete e Key OFF e Disconnect ECM wire harness connector CN1 e Check for continuity between TMAP sensor connector CN4 circuit 120 and TMAP sensor connector CN4 IAT circuit 136 Do you have continuity between them e Check for continuity between TMAP sensor connector CN4 IAT circuit 136 and engine ground Do you have continuity 149 Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 9 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 5 Go to Step 6 Go to Step 7 Value s Yes e Replace ECM Refer to ECM replacement in the Engine Controls Section Go to Step 8 Is the replacement complete e Remove all test equipment except the DST e Connect any disconnected components fus es etc e Using the DST clear DTC information from the ECM e Turn the ignition OFF and wait 30 seconds e ee the vehicle to a Go to OBD Observe the MIL Clock e Observe engine performance and driveability e After operating the engine within the test pa rameters of DTC 112 check for any stored codes Does the engine operate normally with no stored codes
318. ss e Replace TMAP sensor Is the replacement complete e Key OFF e Disconnect the ECM wire harness connector C001 e Check for continuity between TMAP sensor connector CN4 signal circuit 136 and ECM connector CN1 IAT circuit 136 Do you have continuity between them e Check for continuity between TMAP sensor connector CN4 ground circuit 120 and ECM connector CN1 ground circuit 120 Do you have continuity between them Value s Go to OBD System Check Sec tion Go to Step 3 0 10 volts or less Yes Go to Step 2 Intermittent problem Go to Inter mittent section Go to Step 9 Go to Step 4 0 10 volts or less Go to Step 7 Go to Step 11 Go to Step 10 Go to Step 10 Go to Step 6 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 153 Replace the ECM Is the replacement complete Re check wire harness and TMAP sensor connector for damage corrosion or contami nation Any problems found e Re check wire harness and TMAP sensor connectors for damage corrosion or conta mination Any problems found Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate t
319. ss connector CN1 e Using a DVOM check for continuity between EGO 1 connector circuit 121 and ECM con nector circuit 121 Do you have continuity e Using a DVOM check for continuity on the sensor ground circuit 120 between EGO 1 connector CN5 and ECM connector CN1 Do you have continuity e Replace EGO 1 sensor Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 134 check for any stored codes Does the engine operate normally with no stored codes 186 Value s Correct the problem as required see Electrical Section wire harness re pair Go to Step 11 Go to Step 9 Go to Step 10 Go to Step 11 System OK Go to Step 7 Repair open EGO 1 circuit Repair open EGO 1 signal ground Go to OBD System Check 187 DTC 154 EGO 2 Open Inactive Circuit Wire Color G B EGO 2 Signal Signal Ground EGO 2 Heater Ground Power Relay Fuse Block CN25 T Ignition Fuse Conditions for Setting the DTC Heated Oxygen Sensor Check condition Engine running Fault condition EGO 2 post catalyst sensor col
320. ssary Refer to Wir ing Repairs in Engine Elec trical Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 5 Go to Step 6 Go to Step 7 Value s Yes e Replace ECM Refer to ECM replacement in the Engine Controls Section Go to Step 8 Is the replacement complete e Remove all test equipment except the DST e Connect any disconnected components fus es etc e Using the DST clear DTC information from the ECM e Turn the ignition OFF and wait 30 seconds e ee the vehicle to a Go to OBD Observe the MIL Clock e Observe engine performance and driveability e After operating the engine within the test pa rameters of DTC 117 check for any stored codes Does the engine operate normally with no stored codes 160 161 DTC 118 ECT CHT High Voltage Circuit Wire Color 137 Vi Sensor Ground System Interface Connector CN21 Conditions for Setting the DTC ECT Sensor e Engine Coolant Temperature Resistance Scaling e Check Condition Engine Running Ohms e Fault Condition ECT sensor voltage exceeds 4 90 volts Temp degF 4 490 e MIL On during active fault ABD 446 e Adaptive Disabled 230 0 147 Circuit Description 212 0 188 200 0 220 The ECT Engine
321. t any disconnected components fus es 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 Go to OBD operating temperature Observe the MIL SYPIE OR oe Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 1112 check for any stored codes Does the engine operate normally with no stored codes 336 337 DTC 1151 Closed Loop Multiplier High LPG Circuit Wire Color G B EGO 1 Signal Signal Ground EGO 1 Heater Ground Power Relay Fuse Block CN25 7 Ignition Fuse Conditions for Setting the DTC Heated Oxygen Sensor 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 Oxygen Sensor Wire Heated Oxygen sensor wires may be mis routed and contacting the ex haust manifold Vacuum Leaks Large vacuum leaks and crankcase leaks can cause a lean exhaust condition at
322. t 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 be
323. t 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 Wire Color ECM Conditions for Setting the DTC Barometric Pressure Check Condition Key On Fault Condition BP less than 8 30 psia MIL On for active fault Adaptive Disabled 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 Action Did you perform the On Board OBD System Check e Key On e DST Diagnostic Scan Tool connected in System Data Mode Does DST display BP pressure of 8 30 psia or less Key OFF Disconnect the TMAP sensor connector CN4 Jump the 5 volt reference circuit 119 and MAP signal circuit 123 together Key ON Does the DST display BP pressure of 16 00 psia or greater e Inspect TMAP connector and wire harness connector terminals for corrosion contamina tion or mechanical damage Any problems found e Key OFF e Disconnect ECM connector CN1 e Check for continuity between TMAP sensor connector CN4 circuit 123 and ECM connec tor CN1 circuit 123 Do you have continuity between them e Check for continuity on the 5 volt supply cir cuit 119 between TMAP sensor connector CN4 and ECM co
324. t the negative battery cable 3 Start the vehicle and let run until it reaches normal operating temperature 4 Ifa DTC code is found refer to the Electrical Section for further diagnosis VII ENGINE COOLANT TEMPERATURE SENSOR ECT REMOVAL PROCEDURE 1 Disconnect the negative battery cable 2 Locate the Engine Coolant Temperature Sen sor on the back of the engine opposite end of the fan Water Temperature Sensor Location of the Water Temperature Sensor 3 Remove electrical connector 4 Drain the cooling system N DO w N Remove the sensor INSTALLATION PROCEDURE 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 Install Engine Coolant Temperature Sensor Torque to 10 8 14 5 ft lbs 14 7 19 6 Nm Refill the cooling system Reconnect electrical connector Reconnect the negative battery cable Start the vehicle and let run until it reaches nor mal operating temperature If a DTC code is found refer to the Electrical Section for further diagnosis Vill HEATED EXHAUST GAS OXYGEN SENSOR 4 HEGO REPLACEMENT Disconnect Negative battery cable Locate the affected Oxygen Sensor on the three way catalytic converter muffler assembly There are two sensors one between the engine and catalytic brick upstream and one between the catalytic brick and tail pipe
325. t voltage with the spark tester J 26792 or the equivalent Check electrical connections of fuel injectors Check the ECM grounds for being clean tight and in their proper loca 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 e Visually and physically inspect all electrical connections within the sus pected circuit and or systems e 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 e Check the air cleaner element filter for dirt or being plugged e Visually check the vacuum hoses for splits kinks and proper connec tions e Check for properly inflated tires Check the operators driving habits for the following e Excessive idling or stop and go driving e Carrying of very heavy loads e Rapid acceleration e 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 e Refer to Gas Fuel System Diagnosis Remove the plugs and inspect them for the following conditions Verify that the spark plugs are the correct type and properly gapped Wet plugs Cracks Wear Improper gap
326. tandards follow the recommended maintenance schedule contained in this section INSPECTION AND MAINTENANCE OF THE FUEL STORAGE CYLINDER The fuel storage cylinder should be inspected daily or at the beginning of each operational shift for any leaks external damage adequate fuel supply and to ensure the manual service valve is open Fuel storage cylinders should always be securely mounted inspect the securing straps or retaining devices for damage ensure that all lock ing devices are closed and locked Check to ensure that the fuel storage cylinder is positioned with the locating pin in the tank collar on all hori zontally mounted cylinders this will ensure the proper function of the cylinder relief valve When refueling or exchanging the fuel cylinder check the quick fill valve for thread damage Also verify O ring is in place and inspect for cracks chunking or separation If damage to the o ring is found replace prior to filling Check the ser vice line quick coupler for any thread damage IMPORTANT When refueling the fuel cylinder wipe both the female and male connection with a clean rag prior to filling to prevent dust dirt and debris from being introduced to the fuel cylinder INSPECTION AND REPLACEMENT OF THE LPG FUEL FILTER The LPG system on this emission certified engine utilizes an in line replaceable fuel filter element This element should be replaced at the intervals specified in the recommended maintenance
327. te the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2306 check for any stored codes Does the engine operate normally with no stored codes 444 Go to OBD system check System OK 445 DTC 2307 Primary Coil Shorted to Voltage Cylinder 1 Cylinder 4 Cylinder 3 Ignition Coil Pack Fuse gt Interface Power Relay Fuse Block CN25 Conditions for Setting the DTC Ignition Control Check Check condition Engine running or cranking Fault condition Adaptive dwell less than 2 0ms or total dwell less than 4 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers the ignition coil 1 ignition by providing ground to the ignition connector circuit 103 This code will set if the ECM low side driver circuit 103 remains high or is shorted to vol tage 446 DTC 2307 Primay Coil Shorted to Voltage Action Did you perform the On Board OBD System Check Key ON Engine OFF DST Diagnostic Scan Tool connected in System Data Mode Clear DTC 2307 Crank the engine Does DTC 2307 re set Key OFF Disconnect ECM connector CN1 Disconnect ignition module connector CN6 Using a DVOM check for voltage between ignition module connector CN6 circuit 103 and engine ground Do you have voltage e Replace the ignition module 4 Is
328. tem on this emission certified en gine contains a Heated Exhaust Gas Oxygen Sensor HEGO which provides feed back to the ECM on the amount of oxygen present in the ex haust stream after combustion The measurement of oxygen in the exhaust stream is measured in voltage and sent to the ECM The ECM then makes corrections to the fuel air ratio to ensure the proper fuel charge and optimum catalytic performance Therefore it is important that the exhaust connections remain secured and air tight IMPORTANT The HEGO sensor is sensitive to silicone based products Do not use silicone sprays or hoses which are assembled using silicone lubricants Silicone contamination can cause severe damage to the HEGO When inspecting the Exhaust system check the following e Exhaust manifold at the cylinder head for leaks and that all retaining bolts and shields if used are in place e Manifold to exhaust pipe fasteners to ensure they are tight and that there are no exhaust leaks repair if necessary e HEGO electrical connector to ensure connec tor is seated and locked check wires to ensure there is no cracking splits chafing or burn through Repair if necessary e Exhaust pipe extension connector for leaks tighten if necessary e Visually inspect converter to ensure muffler is securely mounted and tail pipe is properly aimed e Check for any leaks at the inlet and outlet of the converter LPG amp BI FUEL CERTIFIED ENGINE MAINTE
329. tep problem 4 Go to Intermit Does TPS 2 voltage ever exceed 4 800 volts tent section e Key OFF e Disconnect electronic throttle connector CN3 e Key ON Go ao Go to Step 5 Does DST display TPS 2 voltage less than 0 2 volts Key OFF Disconnect ECM wire harness connector Repair the CN1 circuit as ne Key ON cessary Using a DVOM check for voltage between Refer to Wir Go to Step 6 electronic throttle connector TPS 2 signal cir Ing Repairs in cuit 148 and engine ground Engine Elec trical Do you have voltage e Replace ECM Go to Step 11 Is the replacement complete 1 e Probe sensor ground circuit at the ECM side of the wire harness circuit 120 with a test Go to Ste Go to Ste light connected to battery voltage 8 p 10 p Does the test light come on e Inspect the electronic throttle wire harness Repair the connector and terminals for damage corro circuit as ne sion or contamination cessary Refer to Wir Go to Step 9 Did you find a problem ing Repairs in Engine Elec trical e Replace electronic throttle Go to Step 11 Is the replacement complete 231 Key OFF Repair the Disconnect ECM connector CN1 circuit as ne Using aDVOM check for continuity on the Go to Step cessary Refer sensor ground circuit 120 between throttle 6 to Wiring Re connector CN3 and ECM connector CN 1 pairs in Engine Elec have continuity between them trical Remove all test equipment except the DST Connect any discon
330. ter mittent section e Jump the fuel temperature sensor connector signal circuit 138 to engine ground Does DST display FT voltage of 0 05 or less e Key OFF e Disconnect ECM wire harness connector CN1 e Using a DVOM check for continuity on the sensor ground circuit 120 between fuel tem perature sensor and ECM connector Do you have continuity between them e Inspect ECM connector pins for damage corrosion or contamination Did you find a problem 206 Go to Step 9 Go to Step 10 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 12 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 11 e Replace ECM Is the replacement complete Go to Step 14 e Key OFF e Disconnect ECM wire harness connector CN1 e Using a DVOM check for continuity between the fuel temperature connector CN16 signal circuit 138 and ECM connector circuit 138 Do you have continuity between them e Inspect ECM connector pins for damage cor rosion or contamination Did you find a problem Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveabil
331. the DTC 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 limiting maximum power 386 DTC 1613 RTI 2 Loss Action Value s Go to OBD Did you perform the On Board OBD System Go to Step System Check 2 Check Sec tion e Key On Engine Running f e DST Diagnostic Scan Tool connected in intermittent System Data Mode Go to Step proniem e Clear system fault code 3 E section Does DTC 1613 reset with the engine idling Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical e Check ECM power and ground circuits Go to Step 4 Did the power and ground circuits check OK e Replace ECM Go to Step 5 Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds nn the an and ae the vehicle to Go to
332. the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1173 check for any stored codes Does the engine operate normally with no stored codes 371 DTC 1174 EPR Supply Voltage High Circuit Wire Color 115 G Br Ground Ground To Power Relay Fuse Block CN25 Conditions for Setting the DTC EPR supply voltage Check condition Engine running or cranking MIL On during active fault Fault condition internal EPR supply voltage too high Adaptive disabled Closed loop 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 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
333. the electrical section of this manual Go to Step 8 Repair the LPG solenoid control short to ground Correct the problem as required See wire harness repair Go to Step 8 No Go to Step 5 Go to Step 4 Go to Step 6 Go to Step 7 Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK Observe the MIL Check Observe engine performance and drivability After operating the engine within the test pa rameters of DTC 359 check for any stored codes System Does the engine operate normally with no stored codes 284 285 DTC 420 Catalyst Monitor Test Bi Fuel Gasoline Onl Circuit Wire Color G B EGO 1 Signal Signal Ground EGO 1 Heater Ground Power Relay Fuse Block CN25 T Ignition Fuse Conditions for Setting the DTC Heated Oxygen Sensor Check condition Engine running Fault condition Catalyst monitor test failed MIL On during active fault 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
334. the plugs and inspect them for the following conditions Wet plugs Ignition System Checks Cracks Wear Improper gap Burned electrodes Heavy deposits Check the Crankshaft Position CKP Sensor Check the ECM grounds for being clean tight and in their proper loca tions Additional Check Check the generator output voltage Check the vacuum hoses for kinks or leaks Check Transmission 53 54 Gasoline Fuel System GAS FUEL SYSTEM OPERATION FUEL MIXTURE FRESH AIR EXHAUST GASES MI GASoLine RETURN E cASoLINE FUEL PRESSURE Gasoline z Fuel Pump Fuel Filter MIL Light Gauges 2 GASOLINE FUEL PUMP PRESSURE Engine Control Module FPP ECT Sr Air Cleaner TPS control motor TMAP Catalytic Muffler 56 GASOLINE MULTIPORT FUEL INJECTION SYSTEM MFI The primary components of the Gasoline Multiport Fuel Injection MFI fuel system are the gasoline fuel tank electric fuel pump fuel filter fuel rails fuel pressure regulator fuel injectors O2 sensors engine control module and a catalytic converter GASOLINE FUEL STORAGE TANK The gasoline fuel storage tank location may vary on equipment applications The fuel tank may be inte grated into the chassis frame or may be a standalone vessel mounted on the equipment For precise location for the equipment application refer to the OEMs vehicle manual GASOLINE FUEL
335. the replacement complete 447 Value s _ Yes Go to Step 2 Go to Step 3 Repair the shorted to voltage coil 1 circuit Go to Step 6 Go to OBD System Check Sec tion Intermittent problem See Intermittent problems in the electrical section Go to Step 4 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2307 check for any stored codes Does the engine operate normally with no stored codes e Replace the ECM Is the replacement complete e Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 2307 check for any stored codes Does the engine operate normally with no stored codes 448 Value s Yes No System OK Go to Step 7 System OK Go to Step 6 Go to OBD system check 449 DTC 2309 Primary Loop
336. the temperature of the injector increases Injector driv ers at the ECM are numbered in sequence order and injectors by cylinder number 234 D TC 261 Injector Driver 1 Open or Low Side Short to Ground Action Did you perform the On Board OBD System Check e Key On Engine Running e DST Diagnostic Scan Tool connected in System Data Mode e Clear System DTC 261 Does DTC 261 reset with the engine idling Key OFF Disconnect the injector interface connector CN17 Using a high impedance DVOM measure the resistance between the fuel injector pins at the fuel metering body at an ambient tem perature of 50 to 90 degrees F Does the DVOM display a resistance value of 20 ohms or less e Replace the Fuel Injector Is the replacement complete Disconnect the injector interface connector CN17 Disconnect the ECM connector CN1 Using a DVOM measure the resistance at connector CN17 between the injector control circuit 164 and engine ground Does the DVOM display a resistance of 5 Ohms or less e Using a DVOM check for continuity on the injector control circuit 164 between the injec tor connector CN17 and the ECM connector CN1 Do you have continuity between them 235 Value s 20 ohms or less 5 Ohms or less Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 8 Repair the shorted to ground injec tor control circuit See wire har ness repair section Go to Step 7 G
337. the throttle shaft Speed and load control are de termined 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 located in the operator s compartment When the engine is running electrical signals are sent from the foot pedal position sensor to the engine ECM when the operator depresses or re lease the foot pedal The ECM then sends an electrical signal to the motor on the electronic throttle control to increase or decrease the angle of the throttle blade thus increasing or decreasing the air fuel charge to the engine The electronic throttle control 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 emission CATALYTIC CONVERTER The Catalytic Converter is a component of the emissions system which is designed and cali brated to meet the emission standards in effect for 2007 2009 model year The exhaust gases pass through the honeycomb catalyst which is coate
338. the top menu bar as shown below in figure 6 EDIS ECI Serial Communications File Page Flash Comm Port Plot Log Help Clear Tags Link error attempting reconnect JE Connected at 19200 bps Load Yot Setup Fau Log T gs Ctrl L Fault Access o MIL Closed Loop Contro System Siates Monitored Drivers Run Mode Running Fuel Type Propane Fuel Control Mode cl inactive Govemor switch state None Injector Injector on Injector off Driver low side low side firing order voltage voltage 1 0 Engine Speed 1pm EG01 0 305 volts Closed loop 1 Manifold Pressure 0 24 psia Adaptive 1 5 0 0 0 0 Barometric Pr 7 830 psi arometric Pressure psia E602 az 0 0 0 0 muaa o Coolant Temperature 400 F Closed loop 2 Active governor type Min CylinderHead Temp 1900 F Adaptive 2 Active governor made Isochronous if E Brake it level Ground Manifold Temperature 1475 F EGO3 032 input fi Intake Air Temperature I Dan F Dil pressure state I OK Post cat CL offset 0 000 9 Altemate Fuel Spark Advance I 22 0 BTDC an ade Foo Pulse width I 0 0 ms Gaseous pressure target I 1 02 H20 DBW Variables CH precsune a IVS state ddd ddl o JM un Coil Driver Spark Coil iri dwell Gaseous pressure actual 0 00 y2q TPS command 30 4 Gov1 voltage 2 0 volts TE R gt 1
339. ting temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 336 check for any stored codes Go to Step System OK 9 Does the engine operate normally with no stored codes Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 336 check for any stored codes Does the engine operate normally with no stored codes 268 269 DTC 337 Crank Loss ECM Circuit Wire Color 5 volt reference Crank Sensor Sensor Ground Crank Conditions for setting the DTC Crankshaft position sensor Check Condition Engine cranking Fault Condition 6 cam pulse signals without crankshaft activity 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 The ECM must see a valid Crankshaft posi tion signal while cranking If
340. tion Go to Step 10 Go to OBD System Check 137 DTC 107 TMAP Low Voltage Wire Color 120 Gr Circuit ECM Conditions for Setting the DTC 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 Action Did you perform the On Board OBD System Check e Key On Engine running e DSC Diagnostic Scan Tool connected in System Data Mode Does DST display MAP voltage of 0 050 or less with the engine running with TPS above 5 0 Key OFF Disconnect the MAP sensor connector CN4 Jump the 5 volt reference circuit 119 and MAP signal circuit 123 together Key ON Does the DST display MAP voltage of 4 50 volts or greater e Inspect MAP connector and pins for cor rosion contamination or
341. tion Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to OBD System Check DTC 604 RAM Failure Microprocessor Conditions for Setting the DTC 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 output 300 DTC 604 RAM Failure Action Did you perform the On Board OBD System Check e Key On Engine Running e DST Diagnostic Scan Tool connected in System Data Mode e Clear system fault code Does DTC 604 reset with the engine idling e Check ECM power and ground circuits Did the power and ground circuits check OK e Replace ECM Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Obse
342. tion Sensors are used within the throttle that use variable resistors to deter 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 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 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 2 voltage is less than 0 200 volts The MIL command is ON and the engine will shut down 226 DTC 222 TPS 2 Signal Low Action Did you perform the On Board OBD System Check e Key ON Engine OFF e DST Diagnostic Scan Tool connected in DBW Drive by Wire throttle test mode Does the DST display TPS 2 voltage of 0 200 volts or less with the throttle closed e Slowly depress Foot Pedal while observing TPS 2 voltage Does TPS 2 voltage ever fall below 0 200 volts Key OFF Disconnect electronic throttle connector CN3 Jumper the 5 volt reference circuit 119 and TPS 2 signal circuit 148 together at the throt tle connector CN3 Key ON Does DST display TPS 2 voltage of 4 0 volts or greater Key OFF Disconnect ECM wire harness connector CN1 Using aDVOM check continuity on the TPS 2 signal circ
343. tivate relay control ON using the DST function or check before ECM relay control times out e 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 e Inspect the EPR connector and fuses for damage corrosion or contamination Did you find a problem e Check the power relay circuit Check the power relay connections for damage corro sion or contamination Did you find a problem 375 Value s Go to Step 2 Go to Step 3 Go to Step 6 Correct the problem as necessary See wiring harness re pair in the electrical sec tion of this manual Correct the problem as necessary See wiring harness schematic in the electrical section of this manual Go to OBD System Check Sec tion Repair the charging sys tem Go to Step 4 Go to Step 5 10 Disconnect the ECM connector CN 1 Using a DVOM check continuity between the EPR ground circuit 181 at EPR connector CN15 and ECM connector CN1 circuits 181 and 169 Do not forget to subtract any resistance val ue that may be present in you test cables Is the resistance reading less than 0 5 ohms e Replace the EPR Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF
344. tor 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 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 Note LPG being a gaseous fuel requires higher secondary ignition system 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 Ignition System Checks Check for the proper ignition voltage output with J 26792 or the equiva lent Verify that the spark plugs are the correct type and pro
345. ue on gauge Turn engine OFF Relieve the LPG fuel system pressure Refer to lll LPG Fuel System Pressure Relief 9 Disconnect negative battery cable 10 Remove Gauge eN gt oONDTR 11 Replace Plug 12 Reconnect negative battery cable 13 Turn ignition to ON for approximately 30 seconds then OFF 14 Check for leaks XIV GASOLINE FUEL PRESSURE CHECK ITK 3 or ITK 4 test kit gauge or J 34730 1A fuel pressure gauge or equivalent Fuel Pressure Gauge Turn ignition to OFF Disconnect the negative battery cable Refer to the Fuel Injection Pressure Tester Owner s Manual supplied in the IMPCO Test Kit for instructions on relieving gasoline fuel pres sure for fuel systems without a Schrader valve or test port ON gt NM WARNING Systems without test ports require that fuel lines be removed or disconnected Be aware that these lines may be UNDER PRESSURE and when remove could cause fuel to spray and or leakage onto hot engine parts 465 NM CAUTION Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system to reduce the risk of personal injury After you relieve the fuel system pressure a small amount of fuel may still be released when servicing the fuel lines the fuel injec tion pump or the connections Always cover the fuel system components with a shop to wel before disconnecting to absorb any fuel that may leak out Dispose of towel i
346. uel supplier to verify that the fuel you are supplied con tains the necessary fuel additives to keep your fuel system clean IMPCO may deny emissions related warranty claims due to the use of low quality low detergent gasoline FUEL SYSTEM CAUTIONS A CAUTION Do not smoke carry lighted tobacco or use a lighted flame of any type when working on or near any fuel related component Highly flammable air fuel mixtures may be present and can be ignited causing personal injury A CAUTION Do not allow LPG to contact the skin LPG is stored in the fuel tank as a liq uid When LPG contacts the atmosphere it immediately expands into a gas resulting in a refrigeration effect that can cause severe burns to the skin GENERAL INFORMATION A CAUTION Do not allow LPG to accumulate in areas below ground level such as in a service pit or underground ventilation systems LPG is heavier than air and can displace oxygen creating a dan gerous condition A CAUTION Do not make repairs to the LPG fuel system if you are not familiar with or trained to service LPG fuel system Contact the dealer who sold you the vehicle to locate a repair facility with trained technicians to repair your fuel system WARNINGS CAUTIONS AND NOTES 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 fu
347. uickly 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 Onl Action Value s Perform the On Board OBD System Check No Yes fo Go to Step Go to Step 3 2 Go to Step Go to Step 6 4 Was a repair made e Diagnose any other DTC codes before pro ceeding with this chart Go to Step Go to Step 6 4 Have any other DTC codes been detected diag 18 a nosed and repaired 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 The EGO sensor is installed securely and the wire leads not damaged or contacting the secondary ignition wires ECM grounds for being clean and tight Fuel system diagnostic checks Key OFF Disconnect EGO sensor wire harness connec tor CN11 Disconnect ECM wire harness connector CN1 Key ON Using a DVOM check for voltage at EGO 1 connector CN11 signal circuit 121 and engine ground Repair the circuit as ne cessary Refer to Wir es eee ing Repairs in 5 Engine Elec trical Do you have voltage e
348. uipment except the DST Connect any disconnected components fus es 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 temperature Go to OBD System OK System Observe the MIL Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 182 check for any stored codes Does the engine operate normally with no stored codes 202 203 DTC 183 FRT Voltage High Gasoline Bi Fuel Onl Wire Color ECM Conditions for Setting the DTC Fuel Rail Temperature Check Condition Engine Running Fault Condition FT sensor voltage exceeds 4 90 MIL On Adaptive Disabled during active fault Circuit Description The FRT Fuel Rail Temperature sensor is a temperature sensitive resistor located in the gasoline supply line It is used to help determine fuel charge density for accurate fuel mixture control The ECM provides a voltage divider circuit so that when the sensor is cool the signal reads a higher voltage and lower when warm This fault will set if the signal voltage is greater than 4 90 volts anytime the engine is running 204 Rail Sensor Temp Resistance in Ohms Degrees Degrees 6 40 40 48153 20 4 15614 0 32 5887 20 68 2510 40 104 2000 60 140 612 70 158 446 80 176 330 100 212 186 120 248 110 130
349. uit e Disconnect ECM connector CN1 e Using a DVOM check for continuity EGO heater 2 circuit 161 between EGO 2 connec tor CN12 and ECM connector CN1 Do you have continuity e Inspect EGO 2 connector and ECM pins for damage corrosion or contamination Did You find a problem 189 Go to Step 6 Correct the problem as required see Electrical Section wire harness re pair Repair open heater ground circuit Go to Step 7 Replace ECM Is the replacement complete Go to Step 11 7 8 e Key OFF Disconnect ECM wire harness connector CN1 Using a DVOM check for continuity on circuit 122 between EGO 2 connector CN12 and ECM connector CN1 Do you have continuity Using a DVOM check for continuity on the sensor ground circuit 120 between EGO 2 and ECM connector Do you have continuity Is the replacement complete Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 154 check for any stored codes Does the engine operate normally with no stored codes 190 Go to Step 9 Go to Step 10 Go to Step 11 System OK Repair open EGO 2 circuit Re
350. uit 148 between TPS 2 connector CN3 and ECM connector CN1 Do have continuity between them e Replace ECM Is the replacement complete e Inspect the electronic throttle wire harness connector terminals for damage corrosion or contamination Did you find a problem e Replace the electronic throttle Is the replacement complete 227 Go to Step 6 Value s System Check Intermittent Go to Step 4 tent section circuit as ne pairs in Go de ae en 2080 Section Go to Step Go to Step 3 4 problem Go to Intermit Go to Step Goto Step 5 7 Repair the cessary Refer to Wiring Re Engine Elec trical Go to Step Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 8 Go to Step 9 Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature System OK Go to OBD Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 222 check for any stored codes System Check Does the engine operate normally with no stored codes 228 229 DTC 223 TPS 2 Signal Voltage High Electronic Throttle Circuit Wire ECM Color L TPS 1 Signal Senso
351. unning 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 Action Did you perform the On Board OBD System Check e Verify that the engine has oil pressure using a mechanical oil pressure gauge before pro ceeding 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 temperature is above 160 degrees F and has been running for at least 20 seconds or more Increase engine speed above 600 RPM 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 Start engine let idle for at least one minute with ECT over 160 degrees F Increase engine speed above 600 RPM Does DTC 524 reset e Replace oil pressure switch Is the replacement complete e Key OFF e Disconnect ECM harness connector CN1 e Leave the oil pressure switch connector grounded to a good engine ground e Using a DVOM check for continuity between oil pressure switch connector CN1 and en gine ground Do you have continuity between them Value s _ Yes Go to Step 2 Go to Step 3 Go to Step 4 Go to Step 6 Go to Step 9 Go to Step 7 Go to OBD System Check Sec tion Repair faulty Oiling System I
352. uorescent screen and pro duce a luminous spot Circuit A path of conductors through which elec tricity flows Closed Loop Operation Applies to systems utiliz ing an oxygen sensor In this mode of operation the system uses oxygen sensor information to de termine air fuel ratio Adjustments are made accordingly and checked by comparing the new oxygen sensor to previous signals No stored in formation is used 476 CNG Compressed Natural Gas CKP Crankshaft Position Sensor CMP Camshaft Position Sensor Conductor A material normally metallic that permits easy passage of electricity Contaminants Impurities or foreign material present in fuel Control Module One of several informal names for a solid state microcomputer which monitors engine conditions and controls certain engine functions i e air fuel ratio injection and ignition time etc The formal name and the one used throughout this manual is ECM or Engine Control Module Converter A LPG fuel system component contain ing varying stages of fuel pressure regulation combined with a vaporizer Cryogen A refrigerant used to obtain very low temperatures Current The volume or flow of electrons through a conductor Measured in amperes or amps DBW Drive By Wire Dedicated Fuel System A motor fuel system de signed to operate on only one fuel type Diaphragm A thin flexible membrane that sepa rates two chambers When the pressure in one chamber is lower
353. 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 e Check Positive and Negative cables for corro sion rubbing chafing burning and to ensure tight connections at both ends e Check battery for cracks or damage to the case and replace if necessary e Inspect engine wire harness for rubbing chaf ing pinching burning and cracks or breaks in the wiring e Verify that engine harness connectors are cor rectly locked in by pushing in and then pulling the connector halves outward e Inspect primary ignition coil wires for harden ing cracking arcing chafing burning separation split boot covers e Check spark plug wires for hardening crack ing chafing arcing or burning separation and split boot covers e Replace spark plugs at the required intervals per the recommended maintenance schedule e Verify that all electrical components are se curely mounted to the engine or chassis e Verify that any additional electrical services installed by the owner are proper
354. uses 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 Preliminary Checks Do not use the DTC tables If a fault is an intermittent the use of the DTC ry 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 Terminal tension is insufficient 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 Faulty Electrical Con nections or Wiring If a visual and physical check does not locate the cause of the problem op Operational Test erate the vehicle with the
355. ution IMPORTANT It is important to remember that there may be a combination of Metric and Imperial fasten ers used in the installation of the IMPCO fuel system Check to insure proper fit when using a socket or wrench on any fastener to prevent damage to the component being removed or injury from slipping off the fastener The IMPCO fuels system utilizes fuel lines hoses with swivel connections which attach to fixed mating connectors You should always use a wrench of the proper size on both the swivel and fixed fitting to prevent turning of the fixed fitting Turning of the fixed fitting may cause a twisting or kinking of the hose and may result in a restriction of the fuel line or a leak IMPCO EA BE GENERAL INFORMATION A N WARNING 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 10 Maintenance MAINTENANCE The maintenance of an engine and related com ponents are critical to its operating performance and lifespan Industrial engines operate in envi ronments that often include hot and cold temperatures and extreme dust The recom mended maintenance schedule is listed in this section however environmental operating condi tions and additional installed equipment may require more frequent inspectio
356. ve battery cable 5 Using the DST clear DTC information from the ECM 6 Turn the ignition OFF and wait 30 seconds 7 Start the vehicle and let run until it reaches normal operating temperature 8 Ifa DTC code is found refer to the Electrical Section for further diagnosis V OIL PRESSURE SWITCH REMOVAL PROCEDURE Disconnect the negative battery cable 2 Locate the Oil Pressure Switch on the side of the engine OV Pu V RONDS 460 A A er Oil pressure switch Location of the Oil Pressure Switch Remove electrical connection from Oil Pressure Switch Unscrew and remove INSTALLATION PROCEDURE Apply Loctite 567 or equivalent high temp thread locker sealer to the threads on the Oil Pressure Switch Install Oil Pressure Sender Torque to 9 4 10 8 ft Ibs 12 7 14 7 Nm Plug in electrical connector Reconnect negative battery cable Start the vehicle and check for leaks Let run until it reaches normal operating temperature If a DTC code is found refer to the Electrical Section for further diagnosis TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR TMAP REMOVAL PROCEDURE Disconnect the negative battery cable Locate the TMAP Sensor on the intake manifold Remove the retaining screw Remove TMAP Sensor by pulling straight up with a slight rocking motion TMAP Sensor INSTALLATION PROCEDURE 1 Install the TMAP and torque the retaining screw to 19 in lbs 2 1 Nm 2 Reconnec
357. ve 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 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 Ignition System Checks 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 Improper valve timing Low compression Improper valve clearance Worn rocker arms Broken or weak valve springs Worn camshaft lobes Engine Mechanical Checks Check the exhaust system for a possible restriction Inspect the exhaust system for damaged or collapsed pipes Inspect the muffler for signs of heat distress or for possible internal fail
358. 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 Value s _ Action Did you perform the On Board OBD System Check e Key On Engine Running e DST Diagnostic Scan Tool connected in System Data Mode Does DST display system voltage greater than 9 0 volts e Check battery condition Is it OK e Check charging system Is it OK Yes Go to Step 2 Intermittent problem Go to Engine Electrical In termittent section Go to Step 4 Go to Step 5 Go to OBD System Check Sec tion Go to Step 3 Replace Bat tery Repair charg ing System Key OFF Disconnect the ECM connector CN1 Using a DVOM check the voltage between ECM connector CN1 circuits 160 and 179 and engine ground Is the voltage greater than for each pin 9 0 volts e Using a DVOM check voltage between bat tery positive and ECM connector CN1 circuits 169 and 181 Is the voltage greater than 9 0 volts e Replace ECM Is the replacement complete 293 Repair ECM Ground cir cuit Go to Power and Ground sec tion in engine Electrical Repair ECM power circuit Go to Power and Ground section in en gine Electrical Go to Step
359. w Gasoline Bi Fuel Gasoline Onl Circuit Wire Color G B EGO 1 Signal Signal Ground EGO 1 Heater Ground Power Relay Fuse Block CN25 7 Ignition Fuse Conditions for Setting the DTC Heated Oxygen Sensor Check Condition Engine Running Fault Condition Adaptive multiplier out of range greater than 30 MIL On 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 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 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 q
360. wdriver to break the regulator free Note that the lever from the primary valve slides into a slot of the secondary diaphragm re quiring the Regulator to be moved sideways to free the tab from the diaphragm Remove and discard Clamp Plate Seal EPR Actuator Not Serviceable EPR LPG Regulator Serviceble 4 The two major components of the EPR As sembly Regulator and the Actuator A N WARNING Care must be used when removing regula tor from the actuator to prevent damage to the lever and diaphragm Neither part is serviceable and if damaged the entire EPR assembly must be replaced 8 Place Regulator face down and remove the retaining screw holding the secondary lever 9 Remove secondary lever fulcrum pin and spring 10 Inspect lever and fulcrum pin for excessive wear Ifthe pin diameter is reduced at any point or if the holes in the lever are irregular oblong the EPR assembly is not repairable and must be replaced 469 11 12 13 14 15 16 Turn the Regulator over and remove the seven screws from the face of the Regulator Remove cover Remove the primary diaphragm Remove the body cover plate and C clip from the primary valve pin Turn the plate over and remove pin and spring Discard pin and keep the spring Remove the secondary body gasket Inspect the Regulator body and cover plates for debris deposits or heavy ends and re move using a Safety Solvent as nec
361. ween 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 Electronic Throttle Gasoline Sensor LPG temperature sensor FPP TPS 1 TPS 2 Crankshaft Sensor Camshaft Sensor While disconnecting each sensor one at a time did you lose continuity e Replace the last disconnected sensor Is the replacement complete 315 Value s Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 7 Go to Step 6 Go to Step 7 Go to OBD System Check Sec tion Intermittent problem Go to Inter mittent section Go to Step 4 Repair short ed wire harness Remove all test equipment except the DST Connect any disconnected components fus es 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 Go to OBD full operating temperature Observe the MIL O Check Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 642 check for any stored codes System Does the engine operate normally with no stored codes 316 317 DTC 643 External 5 Volt Reference High Circu
362. with no prob lems found Run the EPR pressure test in the fuel system diagnostic section Did the EPR pass the fuel pressure test specifi cations Inspect the EPR electrical connector CN15 for damage corrosion or contamination Remove all test equipment except the DST Connect any disconnected components fus es 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 temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1172 check for any stored codes Does the engine operate normally with no stored codes 367 Go to Step 2 Go to Step 4 Go to Step 4 Repair the circuit as ne cessary Refer to wire harness re pair section Go to Step 6 System OK Go to OBD System Check Sec tion Go to Step 3 Follow the EPR service recommenda tions from the fuel pressure test chart Go to Step 5 Go to OBD System Check DTC1173 EPR Communication Lost Circuit Wire Color 115 G Br Ground Ground To Power Relay Fuse Block CN25 Conditions for Setting the DTC EPR CAN communication Check condition Engine running or cranking MIL On during active fault Fault condition No packets received within 500 ms Adaptive disabled Circuit Description The EPR Electronic
363. with no stored codes 402 Repair the shorted to ground circuit as necessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 11 System OK Go to Step 10 Go to OBD System Check 403 DTC 2115 FPP1 Higher Than IVS Limit Circuit Wire Color Pull up Resistor 5 volts FPP IVS Sensor Interface CN25 Check OEM chassis wiring diagram for specific pin numbers and wire colors Conditions for Setting the DTC Foot Pedal Position Check Condition Key On 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 compl
364. wnloaded from the OEM service network To update the ECM calibration follow the instructions listed on the next three pages 113 EDIS ECI Target Communications File Page Flash Comm Port Plot Log Help Save Calibration to Disk g at 19200 bps Load Calibration from Disk NX v SIT Clear Cal Tags Toggle Page F9 El Coolant Temperature Intake Air Temperature System Variables 250 Engine Speed 200 150 100 50 o 50 40 degF 22 degF System State Foot Pedal Postion Throttle Position Hon Mode 100 Power Mode 80 Fuel Type 60 Fuel Supply Customer Configuration Information Cust hardware name number e529143 Cust software name number not_applicable mot Software model 21050004 Fring Order 1 3 Ja 2 x x X X 40 Fuel Spark inhibit input 20 Fuel Control Mode Open Loop 0 Govemor switch state LE me a Oil pressure state Active govemor type m Active govemor mode tsochronous Software and Hardware Information Hardware model 1687002A Cust govemor cal name 2007 Govemor Calibration Initial cal model 20424004 Manufacture date 2 9 2007 Cust govemor cal date 1 3 2007 Initial cal date 1 3 2007 Serial number 6936 e E Ba SSCS Current cal model 2042400A Hour meter 0 079 hours Es 6399399999 Curent cal date 1 3 2007 Cumulative starts 3 stats Displacement 20 L Cylinders 4 Emissions Calibration Checksum F6A20978 Spark system type Coil Per Gyinder Total Calibration Checksum
365. y providing ground to the ignition circuit 102 This code will set if the ECM low side driver circuit 102 is open or shorted to ground 434 DTC 2303 Prima Loop Open Low Side Short to Ground Action Did you perform the On Board OBD System Check Key ON Engine OFF DST Diagnostic Scan Tool connected in System Data Mode Clear DTC 2303 Crank the engine Does DTC 2303 re set Value s _ Yes Go to Step 2 Go to Step 3 Go to OBD System Check Sec tion Intermittent problem See Electrical Section In termittent Electrical Di agnosis e Remove and check the ignition fuse Go to Step Goto Step Is the fuse OK 5 4 e Replace the ignition fuse Go to Step FF Is the replacement complete 12 Key ON Using aDVOM check for voltage at the igni tion fuse terminal circuit 927 Step Oo Oo 2 CHECK THIS BEFORE THE POWER RELAY CIRCUIT SHUTS DOWN Do you have voltage e Key OFF e Disconnect the ignition module connector CN6 e Using a DVOM check for voltage between ignition module connector circuit 812 and engine ground Do you have voltage e Disconnect ECM wire harness connector CN1 e Using a DVOM check for continuity on the coil control circuit 102 between ECM connec tor CN1 and engine ground Do you have continuity e Using a DVOM check for continuity on the coil control circuit 102 between ECM connec tor CN1 and ignition module connector CN6 Do you have continuity Go to

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