Beruflich Dokumente
Kultur Dokumente
Wire Schematic...................................................................................................81
Engine wiring schematics
Engine Wire Harness Repair .............................................................................85
Repairing a wire harness on the vehicle
Diagnostic Trouble Codes (DTCs) ....................................................................89
Application, schematic and DTC specific code information
Servicing the Fuel System .................................................................................... 237
Step by step instructions on how repair and/or replace fuel related Components
LPG Parts Diagram ................................................................................................ 255
Illustrations and part views
Labor Time Guide .................................................................................................. 299
The labor reimbursed by IMPCO for warrantable service and repairs
Definitions .............................................................................................................. 317
Definitions of phrases and acronyms used throughout this Service Manual
Appendix ............................................................................................................... . 323
Supplemental charts and tables
General Information
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 3.0L GM engine.
This manual should be used in conjunction with
the base engine manual and the OEM service
manual when diagnosing fuel or electrical problems.
Do not use Teflon tape to seal any fuel fittings. Fragments of the tape may enter into
the fuel system, causing damage or malfunction of critical fuel system components.
WASHING
Caution should be used when pressure washing
near or on an engines electrical system. Avoid
direct pressure spray on the system electrical
connectors. The electrical connectors are splash
resistant, but if high pressure water or steam is
sprayed directly at the connectors, moisture can
become trapped behind the connector seal and
cause serious system problems, many of them
showing up as intermittent.
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 damage.
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 necessary procedures
to safely remove and replace a failed component.
Tools identified in this manual with the prefix
J or BT can be procured through SPX in
Warren, Michigan.
IMPCO tools identified in this manual with a
prefix ITK can be acquired through OEM
Parts Distribution.
IMPORTANT
It is important to remember that there may be a
combination of Metric and Imperial fasteners 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 fuel system utilizes fuel lines and hoses with
high pressure connectors. Always use a wrench
of the proper size and torque to the correct value.
For hoses with swivel fittings, be sure not to turn
the fixed fitting which may cause a twisting or
kinking of the hose, possibly resulting in fuel line
restriction and/or leak.
Maintenance
MAINTENANCE
SERPENTINE BELT SYSTEM
The maintenance of an engine and related components are critical to its operating performance
and lifespan. Industrial engines operate in environments that often include hot and cold
temperatures and extreme dust. The recommended maintenance schedule is listed in this
section, however, environmental operating conditions and additional installed equipment may
require more frequent inspection and servicing.
The owner and/or service agent should review the
operating conditions of the equipment to determine the inspection and maintenance intervals.
ENGINE BELTS
The engine installed in this equipment uses a serpentine 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 of the cooling and charging system and should be inspected according to the
maintenance schedule in this section. When inspecting the belts check for:
Cracks
Chunking of the belt
Splits
Material hanging loose from the belt
Glazing, hardening
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 violently.
NOTE that the LPG vaporizer is connected to the
cooling system and the fuel system may be adversely 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:
10
COOLANT
Check coolant level in coolant recovery tank and
add coolant as required. Add 50/50 mixture of
GM Dexcool antifreeze and water or coolant per
engine manufacturers instructions. Do not add
plain water. Replace coolant per the recommended schedule.
OIL RECOMMENDATION
Select an engine oil viscosity that will best match
the prevailing daytime temperature:
IMPORTANT:
The manufacturers of the engine and fuel system
do not recommend the use of stop leak additives
to repair leaks in the cooling system. If leaks are
present the radiator should be removed and repaired or replaced.
ENGINE ELECTRICAL SYSTEM MAINTNANCE
The engines electrical system incorporates computers to control various related components. The
electrical system connections and ground circuits
require good connections. Follow the recommended maintenance schedule in this section to
maintain optimum performance. When inspecting
the electrical system check the following:
Check Positive and Negative cables for corrosion, rubbing, chafing, burning and to ensure
tight connections at both ends.
Check battery for cracks or damage to the
case and replace if necessary.
Inspect engine wire harness for rubbing, chafing, pinching, burning, and cracks or breaks in
the wiring.
Verify that engine harness connectors are correctly locked in by pushing in and then pulling
the connector halves outward.
Inspect ignition coil wire for hardening, cracking, arcing, chafing, burning, separation, split
boot covers.
Check spark plug wires for hardening, cracking, chafing, arcing or burning, separation, and
split boot covers.
Replace spark plugs at the required intervals
per the recommended maintenance schedule.
Verify that all electrical components are securely mounted to the engine or chassis.
The oil must meet GM specification 9986231. Motor oils meeting this spec receive the API
(American Petroleum Institute) starburst symbol:
11
12
13
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 sensor safe RTV sealant for repair
procedures. Silicon contamination will cause
a high but false HEGO signal voltage (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 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.
IMPORTANT:
The Pressure Regulator components have been
specifically designed and calibrated to meet the
fuel system requirements of the emission certified
engine.
If the Regulator fails to operate or develops a
leak, it should be repaired or replaced with the
OEM recommended replacement parts. When
inspecting the regulator check for the following
items:
14
15
16
17
--
Tank Pressure
Regulated Pressure
Injected Gas
Intake Air
Exhaust Gas
Engine Control
Module
Air Cleaner
FPP
Catalytic Muffler
18
SERVICE LINE
LPG flows from the fuel tank to the Regulator via
the service line connected to the tank utilizing a
quick coupler. The other end of the service line is
connected to a bulkhead connector, allowing for a
safe means of passing through the sheet metal
and into the engine compartment. 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.
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 fuel
transport components. A safety valve is built into
the tank. Normally set at 25.8 bar (375 psi), it will
release pressure to prevent tank rupture due to
over-pressurization of the cylinder
19
REGULATOR
The Regulator is a combination vaporizer and pressure regulating device with a built-in LPG shut-off
solenoid valve. The fuel shutoff is a normally
closed valve on the vaporizer, controlled by the
ECM. The valve is opened is opened momentarily
when the ignition is first turned on to allow the system to pressurize and when the engine is running.
When open, LPG passes into the regulator and any
liquid LPG is vaporized by heat provided by the engine coolant. The fuel vapor pressure is then
reduced to approximately 88 kPa (12.6 psi) and
delivered to the fuel rail and fuel injectors. The outlet fuel pressure is referenced to the manifold
pressure for a more stable idle.
Speed control is maintained by the amount of pressure applied to the foot pedal located in the engine
compartment, however, in this Drive By Wire
(DBW) application, the foot pedal has an electronic
20
One specific function of the controller is to maintain a closed loop fuel control which is
accomplished by use of the Heated Exhaust Gas
Oxygen Sensors (HEGOs) mounted in the exhaust system. The HEGO sensors send a
voltage signal to the ECM which then changes
the amount of fuel being delivered from the injectors to the engine.
21
TMAP SENSOR
The Air Temperature/Manifold Absolute Pressure
or TMAP sensor is a combination of two sensors:
1) A variable resistor used to monitor the difference 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) and may alter the fuel mixture
to improve performance and emissions.
HEGO voltage output.
2) The Manifold Air Temperature (MAT or IAT)
sensor is a variable resistance thermistor located in the air intake passage which measures
the temperature of the incoming air. The ECM
uses the resistance value to monitor incoming
air temperature and calculate the en- gines
airflow requirement. The ECM provides a
voltage divider 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.
22
IGNITION SYSTEM
TMAP Sensor
COOLANT TEMPERATURE SENSOR
The Engine Coolant Temperature sensor or ECT is
a variable resistance thermistor that changes resistance as the engine's coolant temperature
changes. The sensor's resistance 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.
CRANK SENSOR
The Engine Oil Pressure Sender is designed to ensure adequate lubrication throughout the engine. It
is monitored by the ECM. If the pressure drops, a
MIL will occur.
Crank Sensor
The crank position sensor is a Hall effect sensor
that is triggered by a reluctor wheel on the crankshaft. Two missing teeth are used to determine
23
stage, pilot actuated principal. When the coil is actuated it pulls the primary seal off the primary orifice
against the force of the flat return spring. This allows gas to flow out of the upper chamber of the
injector. Because the orifice supplying the upper
chamber is smaller than the primary orifice which is
now allowing fuel to flow out of the upper chamber,
the pressure drops in this chamber and the now
higher pressure in the lower chamber pushes the
main secondary seal off the secondary orifice and
allows full flow of the injector (this occurs in about 1
to 2 ms). When the coil is de-energized the primary
seal is returned to cover the primary orifice by the
force of the flat spring and pressure builds in the
upper chamber forcing the secondary seal down to
seal the secondary orifice and shutting off all flow of
gas.
24
25
26
27
Regulator Assembly
FUEL SYSTEM DESCRIPTION
LPG is stored in the tank as a liquid and delivered under pressure up to 21.5 BAR (312
psi). At Key ON the Regulator allows LPG to
flow from the tank through the fuel filter and
inside, where fuel is vaporized and reduced in
pressure.
TOOLS REQUIRED:
DIAGNOSTIC AIDS
This procedure is intended to diagnose a vehicle operating on LPG. If the vehicle will not
continue to run refer to Hard Start for preliminary checks. Before starting this procedure,
complete the following tasks to verify that liquid fuel is being delivered to the EPR:
PRESSURE GAUGES
DST
28
29
Action
Value(s)
Yes
No
Go to Step
(3)
Go to
Step (2)
Go to applicable DTC
Table
Go to
Step (3)
Correct
the faulty
condition
and Go to
Step 20
Go to
Step (4)
Go to Step
(9)
Go to
Step (5)
Correct
the faulty
condition
and Go to
Step 20
Go to
Step (6)
30
Step
Action
Value(s)
Yes
Connect a calibrated 0-5 PSI pressure gauge to the primary pressure test port of the Regulator.
Make sure the manual shut-off valve is open and turn the
ignition to ON.
Crank the engine and observe the pressure gauge.
6
No
If NO
pressure
was indicated, Go
to Step
(14)
2.04.0
PSI
Go to Step
If LOW or
(7)
HIGH
pressure
was indicated,
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.
Correct
the faulty
condition
and
Go to Step
(20)
Go to
Step (8)
Go to Step
(12)
Repair
the engine as
necessary and
Go to
Step
(20)
Go to Step
(16)
Go to
Step
(10)
Are there any deposits built-up in the low-pressure fuel supply hose?
31
Step
Action
10
11
12
13
14
15
Values
Yes
No
Remove the FAP sensor from the Fuel Rail and insert the
Pressure Test Adapter and connect to 103 kPa (15 PSI)
pressure gauge.
Connect the DST to the vehicle DLC connector and open the
DST software.
Turn the manual shut-off valve ON. Start the engine and
allow it to reach operating temperature.
+/-15 kPa
(2.2 PSI)
Is the gauge secondary pressure within the specified percentage of the actual pressure indicated on the DST?
Turn OFF the manual shut-off valve and let the engine run
until it dies.
Turn the ignition OFF.
Go to Step Go to
19
Step (11)
Go to Step Go to
(14)
Step (13)
32
Above
1.0 PSI
Go to Step
17
Go to
Step 18
Go to Step
20
NA
Step
Action
Values
Yes
No
Go to Step
20
NA
Go to Step
20
NA
Go to Step
20
NA
Go to Step
20
NA
-15% to
+15%
Go to Step
21
Go to
Step 24
-15% to
+15%
Go to Step
22
Go to
Step 24
-15% to
+15%
Go to Step
23
Go to
Step 24
-15% to
+15%
Go to Step
29
Go to
Step 24
Pressure Regulator. Inspect, clean and/or repair as necessary (refer to Regulator Repair Instructions).
Are all actions complete?
Replace the ECM.
17
Is the action complete?
Replace the Shut Off Valve.
18
19
20
21
22
23
33
Step
Action
Values
Yes
No
24
Go to Step Go to
(26)
Step (25)
25
Go to Step
(27)
NA
Go to Step
(28)
NA
Go to Step
(28)
NA
NA
NA
NA
NA
26
Engine is running RICH (system is trying to compensate by decreasing the amount of fuel). Check the following for any
condition which may cause the engine to run RICH:
Ignition system (See Step 7).
Air cleaner and intake system (including vehicle intake
ducting) for airflow obstructions.
Exhaust system for flow obstructions.
HEGO for correct switching characteristics.
Are all actions complete?
Engine is running LEAN (system is trying to compensate by
increasing the amount of fuel). Check the following for any
condition which may cause the engine to run LEAN:
Intake manifold for leaks.
All throttle body gaskets or o-rings for leaks.
All vacuum hoses and fittings for leaks.
Exhaust system for leaks
27
29
34
35
Action
Before using this section, you should have performed On Board Diagnostic
(OBD) Check and determined that:
Cracking
Hardening
Proper routing
Carbon tracking
Check the wiring for the following items: proper connections, pinches or
cuts.
The following symptom tables contain groups of possible causes for each
symptom. The order of these procedures is not important. If the DST readings do not indicate a problem, then proceed in a logical order, easiest to
check or most likely to cause the problem.
36
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 table if a fault is an intermittent, the use of the DTC 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:
Operational Test
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 order to ensure the proper contact tension.
If necessary, replace all the connector terminals in the problem circuit in
order to ensure the proper contact tension (except those noted as Not
Serviceable). See section Wiring Schematics.
Checking for poor terminal to wire connections requires removing the
terminal from the connector body.
If a visual and physical check does not locate the cause of the problem, operate the engine with the DST connected. When the problem occurs, an
abnormal voltage or scan reading indicates a problem circuit.
The following components can cause intermittent MIL and no DTC(s):
Intermittent MIL
Illumination
A defective relay.
Switch that can cause electrical system interference. Normally, the problem will occur when the faulty component is operating.
The improper installation of add on electrical devices, such as lights, 2way 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.
37
NO START
Checks
Action
ECM Checks
Sensor Checks
Check for air intake system leakage around the Regulator and throttle
body.
Check the fuel system pressures.
Refer to the Fuel System Diagnosis.
NOTE: Natural Gas and Propane require higher secondary ignition system
voltages for the equivalent gasoline operating conditions.
1. Check for the proper ignition voltage output with J 26792 or the equivalent.
2. Verify that the spark plugs are correct.
Check the spark plugs for the following conditions:
Ignition System Checks
38
Checks
Action
Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel system.
Check for the following:
Engine Mechanical
Checks
39
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 engines operator is using the correct starting procedure.
Sensor Checks
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/crank
sensors.
Check the Throttle Position (TPS) and Foot Pedal Position (FPP) sensor
connections.
Important: A closed LPG manual fuel shut off valve will create a no start
condition.
NOTE: LPG requires higher secondary ignition system voltages for the
equivalent gasoline operating conditions.
Check for the proper ignition voltage output with J 26792 tool or the
equivalent.
Verify that the spark plugs are the correct type and properly gapped.
Important:
1. If the engine starts but then immediately stalls, check the cam/crank sensor.
2. Check for improper gap, debris or faulty connections.
40
Checks
Action
Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel supply system.
Check for the following:
Engine Mechanical
Checks
41
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 low speed, or hard
acceleration for the fuel starvation that can cause the engine to cut-out.
Preliminary Checks
None
1.
2.
3.
4.
Remove the spark plugs and check for the following conditions:
Insulation cracks.
Wear.
Improper gap.
Burned electrodes.
Heavy deposits.
Perform a cylinder compression check. Check the engine for the following:
Engine Mechanical
Checks
Additional Check
Check for Electromagnetic Interference (EMI), which may cause a misfire condition. Using the DST, monitor the engine rpm and note sudden increases in
rpm 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 secondary wires and the ground circuit.
42
Action
DEFINITION: The engine has a momentary lack of response when accelerating the engine. The condition can occur at any engine speed. The condition may cause the engine to stall if its severe enough.
Preliminary Checks
None.
NOTE: Natural Gas and Propane require higher secondary ignition system
voltages for the equivalent gasoline operating conditions.
Ignition System Checks
Additional Check
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 for faulty spark plug wires.
Check for oil fouled spark plugs.
43
BACKFIRE
Checks
Action
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping
noise.
Preliminary Check
None.
NOTE: LPG requires higher secondary ignition system voltages for the
equivalent gasoline operating conditions.
Check for the proper ignition coil 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 ignition coil.
Check for deteriorated spark plug wire insulation.
Remove the plugs and inspect them for the following conditions:
44
Action
DEFINITION: The engine delivers less than expected power. There is little or no increase in speed
when throttling the engine.
Refer to the Fuel system OBD System Check.
Compare the customers engine with a similar unit to verify customer has
an actual problem. Do not compare the power output of the engine operating on Natural Gas and Propane to one operating on gasoline as the
Preliminary Checks
fuels do have different performance 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 pressure. Refer to LPG Fuel System Diagnosis.
Check for the proper ignition output voltage with the spark tester J 26792
or the equivalent.
Check the Regulator and Throttle body for proper installation and leakFuel System Checks
age. Check all air inlet ducts for condition and proper installation.
Check all air inlet ducts for condition and proper installation.
Check for fuel leaks in supply lines.
Verify that the Fuel Supply Valve on the supply line is open.
Verify that liquid fuel (not vapor) is being delivered to the Regulator.
Sensor Checks
Check the Heated Exhaust Gas Oxygen Sensor (HEGO) for contamination and performance. Check for proper operation of the TMAP sensor.
Check for proper operation of the TPS and FPP sensors.
Additional Check
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 locations.
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 suspected circuit and/or systems.
Check the DST data.
45
Action
DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected.
Also, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by
refueling records.
Preliminary Checks
Ignition System
Checks
Check the air cleaner element (filter) for dirt or being plugged.
Visually check the vacuum hoses for splits, kinks, and proper connections.
Properly inflated tires.
Cooling System
Checks
Cracking.
Hardness.
Proper connections.
Check the engine thermostat to see if it is stuck open or for the wrong heat
range.
46
Action
DEFINITION: The engine runs unevenly at under no load. If severe enough, the engine may shake.
The engine speed may vary in rpm. Either condition may be severe enough to stall the engine.
Preliminary Check
None.
Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance:
Sensor Checks
Remove the plugs and inspect them for the following conditions:
Ignition System
Checks
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 leakage
than the gasoline fuel supply system.
Additional Checks
Check for vacuum leaks. Vacuum leaks can cause poor engine performance.
Check the ECM grounds for being clean, tight, and in their proper locations.
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 engine performance.
47
Checks
Action
Check the engine for:
48
SURGES/CHUGGLES
Checks
Action
DEFINITION: The engine has a power variation under a steady throttle. The engine feels as if it speeds
up and slows down with no change to the throttle.
Preliminary Checks
Sensor Checks
None.
Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance.
Remove the plugs and inspect them for the following conditions:
Ignition System
Checks
Additional Check
Check the ECM grounds for being clean, tight, and in their proper locations.
Check the alternator output voltage.
Check the vacuum hoses for kinks or leaks.
Check Transmission
49
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 system depends on a sealed engine. If irregular oil flow or dilution is
noted and the crankcase ventilation 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:
Remove the PCV hose (positive side) from the rocker arm cover.
Operate the engine at idle.
Place your thumb over the end of the hose in order to check for vacuum. If there is no vacuum at the hose end,
inspect for the following items:
Plugged hoses
The manifold vacuum port
50
Electrical Section
51
52
53
Windows 7
Windows Vista
Windows XP
(32 bit)
(32 bit)
(32 bit)
Windows 7
Windows Vista
Windows XP
1 GB
512 MB
256 MB
Additional:
Display capable of at least 1024 x 768 screen resolution and one available USB port.
Examples and snapshots used in this manual are based off of the initial DST tool release as of August, 2011 using the Windows 7 operating system. This tool is used for multiple fuel systems and is
frequently updated. Snapshot illustrations may vary depending on the installed operating system and
changes included in any updated DST display Interface. This software has the ability to automatically detect functions that may or may not be used in any one particular fuel system. In this
instance unused or irrelevant values and graphic displays will be shaded in gray on the DST display
screens. Terms, names and descriptions of systems and other servicing procedures may be updated periodically with new DST installation software.
54
Insert the Ifak CD included with your USB to CAN adapter and open the file folder.
For users with restricted rights using Windows 7 or Windows Vista, select Run as administrator as shown above.
For all others, select the Setup file. You may receive a Windows message asking you to confirm the installation
request by an unknown publisher. You must select Yes to continue the installation.
55
Enter your company name or organization and click the Next box. Follow the next steps using the recommended
defaults.
56
Click the Finish box to complete the installation. It is now recommended you re-boot your computer.
Connect the Ifak adapter to an available USB port. You may see a message confirming you wish to make changes
to the computer from an unknown publisher. If so, you must select the Yes box to continue the installation. Windows will now install the Ifak driver to your computer. You should see a message confirming the driver was
successfully installed as shown above.
57
Open the Start menu. You should see the is CAN Configuration utility confirming the utility installation. Select the
is CAN Configurator.
58
59
When the Ifak device serial number is shown, click the Select box, then click the OK box. The Ifak driver and utility
installation is now complete. If you had problems during this installation please see the additional information and
test instructions for your Ifak adapter included with your service test kit.
60
Insert the CD, USB flash drive, other storage media or find the location where the DST software has been saved on
your computer.
61
For users with restricted rights using Windows 7 or Windows Vista, it may be necessary to select the Run as
administrator box similar to the Ifak USB driver installation. For all others, click the Spectrum Engine Monitor.msi file. You may receive a Windows message asking you to confirm the installation request by an unknown
publisher. If so, you must select the Yes box to continue the installation.
62
Follow the on screen prompts that will guide you through the installation.
The Spectrum 4 logo shortcut is placed on the desktop confirming the installation is complete. It is now recommended that you re-boot your computer.
63
Connect the Diagnostic Link Connector or DLC to the Ifak adapters connector. Connect the other end of the DLC
connector to the engine harness (3 pin connector).
Click on the Spectrum 4 shortcut to open the DST software program. Turn the engine ignition power ON.
64
Click on the S3000 tab at the lower left of the Spectrum Engine Monitor page.
On the S3000 data stream page, pull down the Settings menu and click on Connection Settings
65
The Select CAN Device & Channel dialog box will appear. Select the Ifak device, and then click the OK box.
66
When connected, the live data stream appears in the Value column.
67
68
Under the Tools drop down menu, select Reprogram S3000 Engine Control Unit. Turn ignition power ON.
The S3000 Flash Upgrade Wizard dialog box will appear. Select the Next box.
69
Use the Browse box to navigate to the location of the calibration file.
Enter the password that was supplied with the calibration file.
70
71
Please wait until you receive a message confirming the update is complete.
Turn the ignition power OFF. Wait 10 seconds and select Finish.
Turn the ignition ON. Verify the calibration updated with the new file number in the ECM Part Number data stream
shown above. The reprogramming process is now complete.
72
Shown as the monitor page in the DST, the above page is the default entry page that opens with the DST program. It provides a graphical interface for important engine parameters. Graphics shown in gray are not available
for the specific application the DST may be connected to as shown above. This function is controlled by the ECM
calibration file and cannot be changed by the service technician.
73
DTC codes can be read by clicking on the Diagnostics tab at the bottom of the monitor page. The source of
the DTC stream can be set manually for the MEFI ECM or the S3000 ECM, or left in the default All position for auto
detection of the DTC codes from either MEFI or the S3000 ECM. Codes that can be viewed are set in two categories, active and historic. Active codes are codes that are set and the fault that is causing the code to set is
constant. Historic codes are codes that have set in the past, but the fault that caused them has been corrected
such as with an intermittent problem. This function is selectable by choosing the Active or Historic, as shown in
the above image. Codes can be cleared by clicking the Clear box. The DTC set code list may also be saved by
clicking the Save box shown above. The file will be saved in a convenient HTML file compatible with Windows Internet Explorer and will provide a browse function to save the file to a location of choice for the service technician.
74
Data Stream:
The fuel and emissions service manual will refer to the DST and asked that it be connected in the data stream
mode. This simply means it is first connected and that data is shown on the S3000 data stream page as shown
above. The data stream page can be accessed by selecting the S3000 tab shown at the lower left above.
Plot Data:
Data stream information may also be selected for a trace plot. This page is available by clicking the Plot tab at the
lower page center as shown above.
75
The custom parameters of the plot can be selected by clicking on the plot icon just below the Settings menu item
at the top left of the page shown above. To save the custom settings select OK.
76
Check to be sure the ECM is programmed with the latest calibration file
Check general engine tune up items such as spark plugs, distributor cap and rotor, spark plug wires,
air, and fuel filters if equipped with such.
Check block heaters, battery heaters, battery terminals and fuel supply systems for proper operation.
77
78
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 mixture 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 oc- cur
at idle. Electrical problems should be treated the same way. One excellent tool for finding
intermittent electrical problems is the DST plot/log function. Set up the plot for the code that sets. An example of this would be if an intermittent IAT code set, tag the IAT voltage and watch the plot. While
watching the plot, agitate the electrical wire connection at the sensor and ECM connector. The resolution
of the plot screen is such that you will be able to see any unstable voltages that you would otherwise not
see with a standard DVOM.
Caution should be used when pressure washing the under hood of any electrical system. Avoid direct
pressure spray on the system electrical connectors. They are splash proof, but if water is sprayed directly 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.
79
80
81
n"
III
5678
:;c.
":;j'
Zenner Diode
1.5KE39CA
>-
L<("' u o
U C!l<C
C035
IT
U Ol <C
C006
l gn Module
C004
Cam Sensor
lgn Coil
:;c.
o E
:1
"O
>I
.. .)' _,
>-" O
L'"- L'"coos
C007
INJ.I
Blk 16
IIEGO
Snsr
R,
c
INJ.2
"
>-O
T
C009
INJ.3
>-
!NJ
Engine Gnd
C002
LPG Solenoid
ilattcry +
Starter IJ+
Alt. 13+
Starter Solenoid
Diode
I 4003
10
nginc Gnd
A Itcnato
_r_
G nd
f"'"
1112
.-+- --------------------14
13
nJ
Ma-..:i Fuse
70/\ Alternator
II II
III
1 11 11 11 1
0 0 0"10\0\
u:;:< "' u
[;!
FUSE
BOX
l--l
FUSE
20A Ful Pmp p,,T
FUSE
FUSE
Compo'ile' nt
Powe r Relay
82
FUSE
20/\ Starter
FUSE
7.5A lgn S''
<D ----.
0
......
.............
......
-">-'
()
cD
(X)
......
......
0
<D_.
CX>
......
-.........
(])
......
(J'I
1\.)
......
...... 00
......
...... CJ)
(!)
-...J
1\. )
......
(J1
CAN
<
Pedal 2 +SV Supply
Pedal2 Gnd
(X)
.t:::.
Em pty
All. Lamp Out
Pedal I +S V Su pply
Pedal I G round
Pedal I Signal
Pedal 2 Signal
CAN L
MI L
Start Com mand
Oil Lamp
CA N I I
Coolant Gauge
A l t. La mp I n
Veh. lgn. Swi tch
CAN LJ
I :? I
R
cl
Ll Bl u 20
Tan 20
p r-vcl 16
N r-Q
- rg 20
M Tan 20
L r--W
' h t 20
K
Wh t 20
J
Ll Grn 20
H
Dk G rn 20
G
l'QI 18
F Dk Grn 20
E Ycl 20
D
20
C
Ycl 16
B []'nk 20
f-Gr,
II
II
rH
c-
'
1 1
1 I
Bl
B2
B3
B4
-Cl
C2
C3
C4
Kev Signal l!l] D l
02
03
_l I
04
II
IE l
II
1t
J
A '
'-
gl
LIJfRd..'-c-I1!.6!!.
- E2
_j E3
E4
Fl
Pcdal 2 +5V Su lv I F2
Peda l 2 Sianal
F3
Ped a l2 Gn{LJ F4
_j Gl
Pedal I +SV Suppl y G2
G3
::::J G4
_j HI
Ped al I SianaTl H2
Pedal I G ng H3
Ycl 1 6
---,
m
0
c
85
ON-VEHICLE SERVICE
WIRE HARNESS REPAIR
86
METRI-PACK
Some connectors use terminals called MetriPack Series 150. They are also called Pull-ToSeat 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.
Micropack Connector
1.
2.
3.
4.
Cable
Terminal
Locking Tang
Tool J33095/BT8234-A
87
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 straightened once
they are bent.
Verify that the connectors are properly seated
and all of the sealing rings in place, when connecting leads. The hinge type flap provides a
88
Diagnostic Trouble
Codes (DTCs)
89
Before using the Ignition Control Diagnostic chart be sure to check the following items:
Spark plug wires:
Be sure spark plug wires are in good condition. Check for cuts, breaks, burns, hardness or swelling.
LPG fuel requires much higher peak firing voltages compared to gasoline. Check spark plug electrical
continuity using a DVOM. Wires should ohm out to no more than 1,000 ohms per foot of wire length.
Distributor cap and rotor:
Check the cap and rotor assembly for moisture, corrosion or carbon tracking. The ignition timing is not
adjustable. Turning the distributor assembly will not change the ignition timing, but will alter the rotor
phase. Wipe away dust and debris from the ignition coil tower.
System power fuses:
Check the system power fuses. These sources supply the ignition coil and module system power.
Check that the power and ground terminals are clean and in the proper location.
90
Action
Value(s)
Yes
No
Go to Step
(2)
~125 RPM
Go to Step
(5)
Go to Step (3)
Go to Step
(16)
Go to Step (4)
Go to Step
(16)
Go to Step (5)
Go to Step(6)
Go to Step (10)
Go to Step
(7)
Go to Step
(8)
Go to Step (13)
Go to Step
(9)
Go to Step
(16)
System
voltage
System
voltage
91
Step
10
Action
Value(s)
Key OFF
Disconnect the connector ECU-C
Using a DVOM check for continuity between
ignition module connector pin B and ECM
connector pin K1
Do you have continuity between them?
Using a DVOM check for continuity between
ignition module connector pin B and engine
ground
11
Do you have continuity between them?
Replace ECM
12
13
14
15
16
92
Yes
No
Go to Step
(11)
Repair the
shorted to
ground ignition control
circuit. See
wiring harness
repair section.
Go to Step (12)
Go to Step
(16)
Go to Step
(14)
Go to Step
(15)
Go to Step
(16)
System OK
93
The electronic throttle body has two throttle position sensors TPS1 and TPS2. The voltage from these
sensors is used to determine the percentage throttle opening. The TPS sensors have a nominal output
range of 0.2 to 4.95 volts. From the throttle body itself TPS1 ranges from 0.2 to 4.95 volts as the throttle is
opened, TPS2 ranges from 4.95 to 0.2 volts for this same closed to open travel. The ECM rectifies TPS2
signal so both signals on the diagnostic monitor read from 0.2 to 4.95 as the throttle is opened. The travel
of the throttle plate from the fully closed to the fully open mechanical stops may not use this entire range of
voltages. The ECM learns the actual range of voltages used and adjusts the THROTTLE POSITION reading to range from 0 to 100% over this used range of voltages. The system looks at both TPS signals and if
the readings are outside of the upper and lower limits or do not agree with each within limits a code will be
set. The following failure combinations and resulting outcomes are possible:
a) TPS1 fails open or shorted: MIL illuminated, ECM uses TPS2, normal engine operation
b) TPS2 fails open or shorted: MIL illuminated, ECM uses TPS1, normal engine operation
c) TPS1 & 2 fail open or shorted: MIL illuminated, ECM stops controlling throttle, throttle goes to limp
home position and is non- responsive, engine will high idle or allow truck to move slowly.
d) TPS1 & 2 do not match: MIL illuminated, ECM will use the higher of the two TPS readings resulting in
normal or less than normal engine power.
94
Typical TPS and Throttle Position Readings (assumes 5.00 supply voltage):
Actual
Throttle
Position
Fully
closed
Open
Open
Fully Open
TPS1
reading at
Throttle
TPS2
reading at
Throttle
TPS1
reading
on Monitor
TPS2
reading
on Monitor
Throttle
Position
on Monitor
0.32
4.70
0.32
0.30
1.32
3.32
4.32
3.70
1.70
0.70
1.32
3.32
4.32
1.30
3.30
4.30
25
75
100
95
Action
Value(s)
Yes
No
Go to Step
(2)
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
TPS 1
<0.2V
TPS 2
>4.99V
Go to Step
(3)
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
Between
4.8-5.2V
Go to Step
(5)
Go to Step (4)
Verify that
there are no
codes for the
5 volt supply
before proceeding.
Replace the
ECU. Go to
Step (9)
Repair the
circuit as necessary. Refer
to Wire Harness Repair.
Go to Step (9)
2
Is the higher voltage minus the lower voltage divided by 5 then multiplied by 100 greater than 6.
NOTE: this is the formula the ECU uses to determine if the TPS readings are within the
specifications
Key OFF, disconnect C017 from the throttle
body.
Key ON, measure the voltage from C017 pin
6 to pin 2
Is the voltage between 4.8 and 5.2 volts?
Key OFF, disconnect ECU-B
Measure the resistance from C017 pin 2 to
ECU B pin G2
Measure the resistance from C017 pin 6 to
ECU B pin G4
Is the resistance less than 5?
NOTE: Do not probe wires without proper service tool. Permanent harness damage may
result.
96
Step
Action
Value(s)
With C017 disconnected, measure the resistance from pin 6 to pin 1 of the throttle
body.
Push the throttle plate to the fully closed position, and then observe the resistance sweep
while moving the throttle to the fully open
position
Repeat the test across pin 6 to pin 4.
Is the resistance change smooth with no observed glitches, and does the resistance vary
from 800 to 1500 for pin 6 to 1 and from 1400
to 300 for pin 6 to 4 as the throttle is moved from
fully closed to fully open?
Key OFF, disconnect ECU-B
Measure the resistance from C017 pin 1 to
ECU-B pin G3
Measure the resistance from C017 pin 4 to
ECU-B pin D3
Is the resistance less than 5?
97
<5
Yes
No
Go to Step
(6)
Replace the
throttle body
assembly. Go
to Step (7)
NOTE: Verify
that there are
no codes for
the 5 volt
supply before
proceeding.
Replace the
ECU. Got to
step 7
Repair the
circuit as necessary. Refer
to Wire Harness Repair.
Go to Step
(7).
System OK.
Go to On-Board
Diagnostics
System
Check/Malfuncti
on Indicator
lamp.
Limit
12 to
25 %
0.09
4.97
0.09
2.49
Comment
Varies with Pedal
Position
volts
volts
volts
volts
Circuit Description
There are two pedal position sensors on the electronic foot pedal to signal to the ECU exactly how much
throttle the driver has requested. The sensors are Hall Effect type not variable resistance sensors. The two
sensors are provided as a safety feature in case one sensor fails. While the system looks at both sensors,
sensor 1 is used to operate the system. The diagnostic tool allows the technician to monitor three signals
which relate to the foot pedal. The first is pedal position, the system automatically scales the full travel of the
pedal to equal 0 to 100 percent pedal position. The second and third signals are sensor 1 and sensor 2
voltages. Sensor 1 voltage can range from 0.66 to 4.95 volts but will usually be in the range of 1.0 to 3.6
volts. Sensor 2 voltage can range from 0.33 to 2.48 volts but will usually be in the range of 0.5 to 1.8 volts.
(Sensor 2 should read of sensor 1).
98
Action
Value(s)
Yes
Intermittent
problem. Go
to Preliminary
and Intermittent Checks.
Go to Step
(5)
Go to Step (4)
Refer to the
vehicle wiring
diagram and
check ground
back to ECU,
repair as
necessary.
Refer to the
vehicle wiring
diagram and
repair the
power supply
problem between here
and ECU.
Check for
possible ECU
5 volt problem. Refer to
codes 524260
and 524261
for diagnostic
aids.
Between 4.8
and 5.2V
99
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
If there is a
glitch in the
sweep, replace the
pedal position
sensor. Otherwise, go to
Step (3).
Step
Action
Value(s)
>0.09 and
<4.97 V
NOTE: Do not probe wires without proper service tool. Permanent harness damage may
result.
Key OFF, disconnect ECU-A
Measure the resistance from VIC 1 pin K to
ECU-A pin H2 and VIC 1 pin J to ECU-A pin
F3.
Is the resistance less than 5?
Connect the ECU-A and VIC 1 connectors.
With the monitor or DST connected, wiggle
the ECU-A connector.
Are any glitches observed while wiggling the
connector?
100
<5
Yes
No
Reinstall the
pins to the
proper positions in the
connector.
Go to step 6
Reinstall the
pins to the
proper positions in the
connector.
Replace pedal
position sensor. Go to
step 8.
Go to Step
(7)
Repair the
open in the
harness. Go
to Step (8)
Replace the
ECU. Go to
Step (8).
101
102
Action
Value(s)
103
Yes
No
Go to Step
(2)
Go to OBD
System.
Check Section
6 PSI
Go to Step
(3)
Repair faulty
Oiling System
Go to Step
(4)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(6)
Go to Step
(5)
Go to Step
(9)
Repair the
shorted to
ground oil
pressure circuit as
necessary.
Refer to Wiring Repairs.
Repair the
circuit as
necessary.
Refer to Wiring Repairs in
Engine Electrical.
Go to Step
(7)
Go to Step
(8)
Step
Action
Value(s)
Replace ECM
8
104
Yes
No
Go to Step
(9)
System OK
Go to OBD
System
Check
105
Key ON
Manifold Air Temp Short Circuit to High, MAT voltage greater than 4.95 V.
Manifold Air Temp Short Circuit to Ground, MAT voltage less than 0.05 V
Manifold Air Temp Open Circuit, MAT voltage greater than 4.88V but less than 4.94V
Circuit Description
The TMAP is a combined manifold air temperature (MAT) and manifold absolute pressure (MAP) sensor. A
temperature-sensitive resistor is used in the TMAP Sensor located in the intake manifold of the engine. It is
used to monitor incoming air temperature and pressure; and the output, in conjunction with other sensors,
is used to determine the airflow to the engine. The ECU provides a voltage divider circuit so that when the
air is cool, the signal reads higher voltage, and lower when warm.
106
Action
Value(s)
Yes
No
Go to Step
(2)
Perform OBD
System check
Go to Step
(3)
Intermittent
problem. Go
to Preliminary
and Intermittent Checks.
Go to Step
(4)
Go to Step
(5). If the 5
volt supply 2
is grounded,
an open code
will be set.
Replace the
ECU. Go to
step last
Replace the
TMAP sensor. Go to
step last
<5
Go to Step
(6)
Repair the
circuit as
necessary
>30M
Repair short
circuit as
necessary
Go to Step
(7)
2
Does Monitor display MAT at the default value of
214 degrees?
Key OFF.
Disconnect the TMAP sensor connector J8
from the TMAP sensor.
Key ON, measure the voltage across pins 1
and 2
3
Is the voltage between 4.8 and 5.2 volts?
Between 4.8
and 5.2V
NOTE: Do not probe wires without proper service tool. Permanent harness damage may
result
Key OFF.
Measure the resistance across the TMAP
sensor pins 1 and 2.
4
107
Step
Action
Value(s)
Yes
No
Repair the
circuit as
necessary
Go to Step
(8)
Go to Step
(9)
8
Is the replacement complete?
108
109
The Manifold Absolute Pressure sensor is a piezoelectric pressure sensor fitted to the manifold to measure
the pressure internal to the manifold. It is combined in one sensor with the manifold air temperature sensor
and referred to as the TMAP sensor. The MAP reading is used to determine the load and state of the engine. Because the sensor measures absolute pressure, with the Key ON, engine off, the reading should be
atmospheric pressure, displayed as kPa (approximately 100 kPa at sea level). The sensor operates on 5
volts and sends a signal voltage on the output circuit to the ECU. The ECU uses the signal to determine
correct fueling. Voltage varies from a low voltage when the MAP is low (below atmospheric) to high when
the MAP is close to or at atmospheric pressure. If there is a failure in the 5 volt reference to the TMAP sensor, a code will be set. Depending on the 5 volt failure mode, the system may go to the Limp Home mode.
110
kPa
34.47
68.94757
103.4214
137.8951
172.3689
206.8427
241.3165
275.7903
310.2641
344.7379
PSIa
0.725189
1.450377
2.175566
2.900754
3.625943
4.351131
5.07632
5.801508
6.526697
50 7.251885
PSIa
55
60
65
70
75
80
85
90
95
100
kPa
379.2116
413.6854
448.1592
482.633
517.1068
551.5806
586.0543
620.5281
655.0019
689.4757
PSIa
105
110
115
120
125
130
135
140
145
150
kPa
723.9495
758.4233
792.8971
827.3708
861.8446
896.3184
930.7922
965.266
999.7398
1034.214
kPa
55
60
65
70
75
80
85
90
95
100
PSIa
7.977074
8.702262
9.427451
10.15264
10.87783
11.60302
12.3282
13.05339
13.77858
14.50377
kPa
105
110
115
120
125
130
135
140
145
150
PSIa
15.22896
15.95415
16.67934
17.40452
18.12971
18.8549
19.58009
20.30528
21.03047
21.75566
100
MAP in kPa
80
60
40
20
0
0
3
Voltage
111
Action
Value(s)
Yes
Go to Step (2)
No
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
Intermittent
problem. Go
to Preliminary
and Intermittent Checks.
508 kPa
Go to Step (3)
Between
4.8 and
5.2V
Go to Step (4)
Go to Step (5)
Go to Step (7)
Go to Step (5)
<5
Go to Step (6)
Repair open
in the wiring
and Go to
Step (7)
Between
4.8 and
5.2V
Go to Step (7)
Replace the
ECU. Go to
Step (7)
NOTE: Do not probe wires without proper service tool. Permanent harness damage may
result.
Key OFF, disconnect ECU-B
Check resistance between C011 pin 1 and
ECU-B pin H4, C011 pin 3 and ECU-B pin
H2, and C011 pin 4 and ECU-B pin H3.
Is resistance less than 5?
Refer to diagnostics for 5 volt reference voltage. See codes DTC 524260
Retest for 5 volts at Co11 pins 1 and 3
Is voltage now between 4.8 and 5.2 volts?
112
Step
Action
Value(s)
113
Yes
No
System OK.
Go to OnBoard Diagnostics
System
Check/Malfun
ction Indicator
lamp.
DTC 110-ECT/Low/High/Short/Open
The Coolant Temperature Sensor is a Negative Coefficient (as the temperature rises, the resistance drops) temperature sensitive resistor located in the Cylinder Head.
The ECM uses the reading to determine temperature related operating condition requirements for the engine. Five volts is applied across the sensor and voltage drop is
measured to determine the temperature.
114
Temp
(deg F)
242.4
231.9
211.6
201.4
181.9
163.1
144.9
127.4
102.4
78.9
49.9
23.5
-5.7
-21.2
-30.8
-40.0
Ohms
101
121
175
209
302
434
625
901
1,556
2,689
5,576
11,562
28,770
49,715
71,589
99,301
DTC 110-ECT/Low/High/Short/Open
Step
Action
No
Intermittent
fault. See wiring
schematics
and check
circuits from
C034 to ECUB for possible
short to
ground.
Go to step2
Go to Step
(3)
Go to Step
(4)
Between 4.8
and 5.2 V
Replace the
sensor. Go
to Step (5)
Go to Step
(4)
<5 and
>30M
Replace the
ECU. Go to
Step (5)
Repair fault in
harness. Go to
Step (5)
Yes
Value(s)
NOTE: Do not probe wires without proper service tool. Permanent harness damage may
result.
With C034 and ECU-B disconnected, measure the resistance from C034 pin 1 to ECU-B
pin F2, C034 pin 2 to ECU-B pin F4 and
across C034 pins 1 and 2.
Is the resistance less than 5 ohms from C034 to
ECU-B and greater than 30M across C034?
115
FRP Sensor
Check Condition-Key ON
Fault Condition-FRP voltage greater than 4.94 volts
Fault Condition-FRP voltage less than 0.25 volts
MIL-ON
Circuit Description
The FRP (Fuel Rail Pressure) is a sensor that monitors the state of the LP fuel in the fuel rail. A pressure
sensor located on the fuel rail monitors the fuel pressure. The output in conjunction with other sensors is
used to determine the appropriate injector pulse to deliver the fuel. A lower output voltage indicates a lower pressure, and higher voltage for higher pressure. This fault will set if the signal voltage is less than 0.25
or greater than 4.94 volts.
116
Action
Value(s)
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Less than
0.20 volts?
Go to Step
(4)
Go to Step
(3)
Greater
than 4.90
volts
Go to Step
(6)
Go to Step
(5)
Repair the
circuit as
necessary.
See wire
harness repair section.
Go to Step
(5)
Key ON
DST (Diagnostic Scan Tool) connected
with the Voltages and Service windows
displayed.
Does the DST display FRP (Fuel Rail Pressure) voltage less than 0.20 volts?
Key OFF
Disconnect the FRP sensor connector
C016 from the wiring harness.
Jump the 5 volt reference B and FRP signal circuit C together.
Key ON
Does the DST display FRP voltage greater
than 4.90 volts?
Inspect FRP connector and pins for corrosion,
contamination or mechanical damage.
Go to Step
(12)
Key ON
Using a DVOM check for voltage between
FRP connector 5 volt reference ECU-B J2
and sensor ground pin A.
Key OFF
Disconnect ECU-B connector
Check for continuity between FRP sensor
connector C and ECM signal pin J3.
117
Greater
than 4.90
volts
Repair the 5
volt reference circuit
as necessary. See
wire harness
repair section
Go to Step
(7)
Go to Step
(8)
Repair the
open signal
circuit. See
wire harness
repair section.
Step
Action
Value(s)
Using a DVOM check for continuity between FRP sensor connector signal A
and sensor ground K2.
8
Do you have continuity?
Using a DVOM check for continuity between FRP sensor connector B and
engine ground.
9
Do you have continuity?
10
Any problems found?
11
12
No
Go to Step
(9)
Go to Step
(10)
Go to Step
(11)
Replace ECM.
Go to Step
(12)
Yes
Repair the
shorted to
ground signal circuit.
See wire
harness repair section.
Repair the
shorted to
ground signal circuit.
See wire
harness repair section.
Repair harness and
connector as
necessary.
See wire
harness repair section.
118
System OK
Go to OBD
System
Check
119
System Voltage
Check Condition-Ignition ON
Voltage high: battery voltage above 18.5 volts with the Key ON.
Voltage low: battery voltage below 5.29 volts while the engine is running
MIL-On
Circuit Description
The system monitors battery voltage and will set a code if the voltage is out of range.
120
Action
Value(s)
No
Repair as
necessary
Go to step 2
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
Go to Step
(3)
Check all
grounds and
repair as
necessary.
Go to Step
(7)
Go to Step
(4)
Go to Step
(6)
Go to Step
(5)
Replace the
power latch
relay. Go to
Step (7).
Repair open
in harness as
necessary.
Refer to Wire
Harness
Repair. Go to
Step (7).
Yes
121
System
Voltage
The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. This diagnostic applies
to internal microprocessor integrity conditions within the engine control module (ECM). This diagnostic also addresses if the ECM is not programmed or the program checksum does not match or has become
corrupted. Always verify that the ECM was flashed with the proper calibration files before using the following diagnostic chat.
122
Action
Value(s)
No
Go to step 2
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
Yes
123
Go to Step
(3)
System OK.
Go to OnBoard Diagnostics
System
Check/Malfun
ction Indicator
lamp.
The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. This diagnostic applies
to internal microprocessor integrity conditions within the engine control module (ECM). This diagnostic also addresses if the ECM is not programmed or the program checksum does not match or has become
corrupted. Always verify that the ECM was flashed with the proper calibration files before using the following diagnostic chat.
124
Action
Value(s)
No
Go to step 2
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
Yes
125
Go to Step
(3)
System OK.
Go to OnBoard Diagnostics
System
Check/Malfun
ction Indicator
lamp.
Short to B+
Open Circuit
Short to Ground
Circuit Description
126
Action
Value(s)
No
Go to Step
(2)
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
Yes
>0V
Go to Step
(4)
>0V
Replace
ECU. Go to
Step (14)
Repair short
to power in
the harness.
Go to step14
Battery
Voltage
Go to Step
(8)
Go to Step
(6)
Battery
Voltage
2 .5
8
Is resistance 2 .5?
127
Repair open
in harness
between
C007 and injector
connector.
Go to Step
(14)
Refer to the
wiring diagram for your
truck and repair power
supply problem. Go to
Step (14)
Go to Step
(9)
Go to Step
(7)
Repair open
in the harness. Go to
Step (14)
Replace injector. Go to
Step (14)
Step
Action
10
11
12
Is resistance 2 .5?
Measure resistance from the injector connector pin 1 of the affected cylinder to
ground.
13
14
128
Value(s)
Yes
No
<5
Go to Step
(10)
Repair open
in the harness. Go to
Step (14)
<5
Replace
ECU. Go to
Step (14)
Repair open
in the harness. Go to
Step (14)
2 .5
Go to Step
(12)
Replace the
injector. Go to
Step (14)
>30
Replace the
ECU. Go to
Step (14)
Go to Step
(13)
>30
Repair the
short to
ground in the
harness. Go
to Step (14)
Replace the
ECU. Go to
Step (14)
System OK.
Go to OnBoard Diagnostics
System
Check/Malfun
ction Indicator
lamp.
129
Short to B+
Open Circuit
Short to Ground
Circuit Description
130
Action
Value(s)
No
Go to Step
(2)
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
Yes
>0V
Go to Step
(4)
>0V
Replace
ECU. Go to
Step (14)
Repair short
to power in
the harness.
Go to
Step(14)
Battery
Voltage
Go to Step
(8)
Go to Step
(6)
Battery
Voltage
2 .5
8
Is resistance 2 .5?
131
Repair open
in harness
between
C008 and injector
connector.
Go to Step
(14)
Refer to the
wiring diagram for your
truck and repair power
supply problem. Go to
Step (14)
Go to Step
(9)
Go to Step
(7)
Repair open
in the harness. Go to
Step (14)
Replace injector. Go to
Step (14)
Step
Action
10
11
12
Is resistance 2 .5?
Measure resistance from the injector connector pin 1 of the affected cylinder to
ground.
13
14
132
Value(s)
Yes
No
<5
Go to Step
(10)
Repair open
in the harness. Go to
Step (14)
<5
Replace
ECU. Go to
Step (14)
Repair open
in the harness. Go to
Step (14)
2 .5
Go to Step
(12)
Replace the
injector. Go to
Step(14)
>30
Replace the
ECU. Go to
Step (14)
Go to Step
(13)
>30
Repair the
short to
ground in the
harness. Go
to Step (14)
Replace the
ECU. Go to
Step (14).
System OK.
Go to OnBoard Diagnostics
System
Check/Malfun
ction Indicator
lamp.
133
Short to B+
Open Circuit
Short to Ground
Circuit Description
134
Action
Value(s)
No
Go to Step
(2)
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
Yes
>0V
Go to Step
(4)
>0V
Replace
ECU. Go to
Step (14)
Repair short
to power in
the harness.
Go to step14
Battery
Voltage
Go to Step
(8)
Go to Step
(6)
Battery
Voltage
2 .5
8
Is resistance 2 .5?
135
Repair open
in harness
between
C009 and injector
connector.
Go to Step
(14)
Refer to the
wiring diagram for your
truck and repair power
supply problem. Go to
Step (14)
Go to Step
(9)
Go to Step
(7)
Repair open
in the harness. Go to
Step (14)
Replace injector. Go to
Step (14)
Step
Action
Value(s)
10
11
12
Is resistance 2 .5?
Measure resistance from the injector connector pin 1 of the affected cylinder to
ground.
13
14
136
Yes
No
Go to Step
(10)
Repair open
in the harness. Go to
Step (14)
<5
Replace
ECU. Go to
Step (14)
Repair open
in the harness. Go to
Step (14)
<5
Go to Step
(12)
Replace the
injector. Go to
step14
2 .5
Replace the
ECU. Go to
Step (14)
Go to Step
(13)
>30
Repair the
short to
ground in the
harness. Go
to Step (14)
Replace the
ECU. Go to
Step (14).
System OK.
Go to OnBoard Diagnostics
System
Check/Malfun
ction Indicator
lamp.
>30
137
Short to B+
Open Circuit
Short to Ground
Circuit Description
138
Action
Value(s)
No
Go to Step
(2)
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
Yes
>0V
Go to Step
(4)
>0V
Replace
ECU. Go to
Step (14)
Repair short
to power in
the harness.
Go to step14
Battery
Voltage
Go to Step
(8)
Go to Step
(6)
Battery
Voltage
2 .5
8
Is resistance 2 .5?
139
Repair open
in harness
between
C010 and injector
connector.
Go to Step
(14)
Refer to the
wiring diagram for your
truck and repair power
supply problem. Go to
Step (14)
Go to Step
(9)
Go to Step
(7)
Repair open
in the harness. Go to
Step (14)
Replace injector. Go to
Step (14)
Step
Action
10
12
13
11
14
140
Value(s)
Yes
No
<5
Go to Step
(10)
Repair open
in the harness. Go to
Step (14)
<5
Replace
ECU. Go to
Step (14)
Repair open
in the harness. Go to
Step (14)
2 .5
Go to Step
(12)
Replace the
injector. Go to
step14
>30
Replace the
ECU. Go to
Step (14)
Go to Step
(13)
>30
Repair the
short to
ground in the
harness. Go
to Step (14)
Replace the
ECU. Go to
Step (14).
System OK.
Go to OnBoard Diagnostics
System
Check/Malfun
ction Indicator
lamp.
141
The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. This diagnostic applies
to internal microprocessor integrity conditions within the engine control module (ECM). This diagnostic also addresses if the ECM is not programmed or the program checksum does not match or has become
corrupted. Always verify that the ECM was flashed with the proper calibration files before using the following diagnostic chat.
142
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
System Data Mode
Clear system fault code
Ignition OFF
Ignition ON
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Refer to Wiring Repairs in
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
143
Circuit Description
The Spectrum Fuel system is equipped with OBD (On-Board Diagnostics). The system has a
dash mounted MIL (Malfunction Indicator Lamp). The MIL serves as notification of an emissions related problem. It will display DTCs that have been stored due to a possible system
malfunction. The following DTC charts in this manual will instruct the technician to perform the
OBD system check. This simply means to verify the operation of the MIL. The lamp 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 lamp does not illuminate with the
vehicle Key ON and engine OFF, repair it as soon as possible. Once the engine is in start or
run mode, the lamp should go off. If the lamp stays on while the engine is in the start or run
mode, a current diagnostic trouble code may be set or a problem may exist with the MIL electrical wiring. The electrical schematic above shows the MIL power source supplied to the
lamp. The ECM completes the circuit to ground to turn the lamp ON.
144
145
Dual throttle position sensors (TPS) are used with the electronic throttle control (ETC) to determine
throttle plate position. The TPS values are used by the ECM to determine if the throttle is opening and
closing as commanded. The ECM runs several checks at ignition on to validate the working condition of
the ETC. This fault will set if the ECM detects a problem with the ETC internal return spring.
146
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
data stream mode.
Clear DTC 522614
Ignition OFF
Ignition ON
Ignition OFF
Disconnect electronic throttle connector
C017
Disconnect ECM wire harness connector
ECU-B
Using a DVOM check for continuity between
all electronic throttle connector pins and engine ground
147
Yes
No
Go to Step
(2)
Go to OBD
System Check
Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Remove the
foreign object
or replace the
throttle if
damage is
found. Go to
Step (17)
Go to Step (4)
Repair the
shorted to
ground TPS
circuit as
necessary.
Refer to Wiring Repairs
Go to Step (5)
Go to Step
(6)
Go to Step
(7)
Go to Step
(8)
Repair the
open circuit as
necessary.
Refer to Wiring Repairs.
Repair the
open circuit as
necessary.
Refer to Wiring Repairs
Repair the
open circuit as
necessary.
Refer to Wiring Repairs
Step
Action
Value(s)
12
13
Is the replacement complete?
148
Yes
Go to Step
(9)
Go to Step
(10)
Go to Step
(11)
No
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Go to Step
(12)
System OK
Go to Step
(13)
Go to Step
(14)
Step
Action
14
Value(s)
149
Yes
No
System OK
Go to OBD
System Check
Dual throttle position sensors (TPS) are used with the electronic throttle control (ETC) to determine
throttle plate position. Although the actual voltage values between them are inverse, the calculated position
values should remain very close. The TPS values are used by the ECM to determine if the throttle is opening and closing as commanded. This fault will set if the ECM detects more than a 10% difference in
calculated values between TPS 1 and TPS 2.
150
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
data stream mode.
Clear DTC 522616
Ignition OFF
Ignition ON
Ignition OFF
Disconnect electronic throttle connector
C017
Disconnect ECM wire harness connector
ECU-B
Using a DVOM check for continuity between
all electronic throttle connector pins and engine ground
151
Yes
No
Go to Step
(2)
Go to OBD
System Check
Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Remove the
foreign object
or replace the
throttle if
damage is
found. Go to
Step (17)
Go to Step (4)
Repair the
shorted to
ground TPS
circuit as
necessary.
Refer to Wiring Repairs
Go to Step (5)
Go to Step
(6)
Go to Step
(7)
Go to Step
(8)
Repair the
open circuit as
necessary.
Refer to Wiring Repairs.
Repair the
open circuit as
necessary.
Refer to Wiring Repairs
Repair the
open circuit as
necessary.
Refer to Wiring Repairs
Step
Action
Value(s)
12
13
Is the replacement complete?
152
Yes
Go to Step
(9)
Go to Step
(10)
Go to Step
(11)
No
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Go to Step
(12)
System OK
Go to Step
(13)
Go to Step
(14)
Step
Action
14
Value(s)
153
Yes
No
System OK
Go to OBD
System Check
Dual throttle position sensors (TPS) are used with the electronic throttle control (ETC) to determine
throttle plate position. Although the actual voltage values between them are inverse, the calculated position
values should remain very close. The TPS values are used by the ECM to determine if the throttle is opening and closing as commanded. This fault will set if the ECM detects more than a 10% difference in
calculated values between TPS 1 and TPS 2.
154
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
data stream mode.
Clear DTC 522617
Start the engine
Ignition OFF
Disconnect electronic throttle connector
C017
Disconnect ECM wire harness connector
ECU-B
Using a DVOM check for continuity between
all electronic throttle connector pins and engine ground
8
Does the DVOM show continuity?
155
Yes
No
Go to Step
(2)
Go to OBD
System Check
Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Remove the
foreign object
or replace the
throttle if
damage is
found. Go to
Step (17)
Go to Step (4)
Repair the
shorted to
ground TPS
circuit as
necessary.
Refer to Wiring Repairs
Go to Step (5)
Go to Step
(6)
Go to Step
(7)
Go to Step
(8)
Go to Step
(9)
Repair the
open circuit as
necessary.
Refer to Wiring Repairs.
Repair the
open circuit as
necessary.
Refer to Wiring Repairs
Repair the
open circuit as
necessary.
Refer to Wiring Repairs
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Step
Action
Value(s)
12
13
Is the replacement complete?
156
Yes
Go to Step
(10)
Go to Step
(11)
No
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Go to Step
(12)
System OK
Go to Step
(13)
Go to Step
(14)
Step
Action
14
Value(s)
157
Yes
No
System OK
Go to OBD
System Check
158
Action
Value(s)
Yes
159
No problems
at this time.
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
Go to Step
(3)
Repair as required. Go to
step last
Go to Step
(4)
Go to Step
(6)
Go to Step
(5)
Go to Step
(6)
Replace the
Regulator, Go
to Step (8).
Replace
faulty injector
Go to Step
(8)
Repair circuit
to the injector. Go to
step last
Step
7
Action
Value(s)
160
System OK.
Yes
No
Replace the
regulator. Go
to Step (8)
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
161
162
Action
Value(s)
Yes
163
No problems
at this time.
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
Go to Step
(3)
Repair as required. Go to
step last
Go to Step
(4)
Go to Step
(6)
Go to Step
(5)
Go to Step
(6)
Replace the
vaporizer, Go
to Step (8).
Replace
faulty injector
Go to Step
(8)
Repair circuit
to the injector. Go to
step last
Step
7
Action
Value(s)
164
System OK.
Yes
No
Replace the
regulator. Go
to Step (8)
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
165
166
Action
Value(s)
Yes
167
No problems
at this time.
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
Go to Step
(3)
Repair as required. Go to
step last
Go to Step
(4)
Go to Step
(6)
Go to Step
(5)
Go to Step
(6)
Replace the
Regulator, Go
to Step (8).
Replace
faulty injector
Go to Step
(8)
Repair circuit
to the injector. Go to
step last
Step
7
Action
Value(s)
168
System OK.
Yes
No
Replace the
regulator. Go
to Step (8)
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
169
170
Action
Value(s)
Yes
171
No problems
at this time.
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
Go to Step
(3)
Repair as required. Go to
step last
Go to Step
(4)
Go to Step
(6)
Go to Step
(5)
Go to Step
(6)
Replace the
Regulator.
Go to Step
(8).
Replace
faulty injector
Go to Step
(8)
Repair circuit
to the injector. Go to
step last
Step
7
Action
Value(s)
172
System OK.
Yes
No
Replace the
regulator. Go
to Step (8)
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
173
CAN Rx
Check Condition-Engine running
Fault Condition-CAN error packets lost, not received or corrupt
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 information packets that
contain information for various control functions. This fault will set if the ECM detects continuous CAN
communications hardware errors or CAN policy violations.
174
Action
Value(s)
Yes
175
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
Go to Step
(3)
System OK.
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. This diagnostic applies
to internal microprocessor integrity conditions within the engine control module (ECM). This diagnostic also addresses if the ECM is not programmed or the program checksum does not match or has become
corrupted. Always verify that the ECM was flashed with the proper calibration files before using the following diagnostic chat.
176
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
System Data Mode
Clear system fault code
Ignition OFF
Ignition ON
177
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Refer to Wiring Repairs in
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. This diagnostic applies
to internal microprocessor integrity conditions within the engine control module (ECM). This diagnostic also addresses if the ECM is not programmed or the program checksum does not match or has become
corrupted. Always verify that the ECM was flashed with the proper calibration files before using the following diagnostic chat.
178
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
System Data Mode
Clear system fault code
Ignition OFF
Ignition ON
179
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Refer to Wiring Repairs in
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. This diagnostic applies
to internal microprocessor integrity conditions within the engine control module (ECM). This diagnostic also addresses if the ECM is not programmed or the program checksum does not match or has become
corrupted. Always verify that the ECM was flashed with the proper calibration files before using the following diagnostic chat.
180
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
System Data Mode
Clear system fault code
Ignition OFF
Ignition ON
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Refer to Wiring Repairs in
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
181
The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. This diagnostic applies
to internal microprocessor integrity conditions within the engine control module (ECM). This diagnostic also addresses if the ECM is not programmed or the program checksum does not match or has become
corrupted. Always verify that the ECM was flashed with the proper calibration files before using the following diagnostic chat.
182
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
System Data Mode
Clear system fault code
Ignition OFF
Ignition ON
183
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Refer to Wiring Repairs in
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. This diagnostic applies
to internal microprocessor integrity conditions within the engine control module (ECM). This diagnostic also addresses if the ECM is not programmed or the program checksum does not match or has become
corrupted. Always verify that the ECM was flashed with the proper calibration files before using the following diagnostic chat.
184
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
System Data Mode
Clear system fault code
Ignition OFF
Ignition ON
185
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Refer to Wiring Repairs in
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. This diagnostic applies
to internal microprocessor integrity conditions within the engine control module (ECM). This diagnostic also addresses if the ECM is not programmed or the program checksum does not match or has become
corrupted. Always verify that the ECM was flashed with the proper calibration files before using the following diagnostic chat.
186
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
System Data Mode
Clear system fault code
Ignition OFF
Ignition ON
187
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Refer to Wiring Repairs in
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. This diagnostic applies
to internal microprocessor integrity conditions within the engine control module (ECM). This diagnostic also addresses if the ECM is not programmed or the program checksum does not match or has become
corrupted. Always verify that the ECM was flashed with the proper calibration files before using the following diagnostic chat.
188
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
System Data Mode
Clear system fault code
Ignition OFF
Ignition ON
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Refer to Wiring Repairs in
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
189
The electronic throttle body has two throttle position sensors TPS1 and TPS2. The voltage from these
sensors is used to determine the percentage throttle opening. The TPS sensors have a nominal output
range of 0.2 to 4.95 volts. From the throttle body itself TPS1 ranges from 0.2 to 4.95 volts as the throttle is
opened, TPS2 ranges from 4.95 to 0.2 volts for this same closed to open travel. The ECM rectifies TPS2
signal so both signals on the diagnostic monitor read from 0.2 to 4.95 as the throttle is opened. The travel
of the throttle plate from the fully closed to the fully open mechanical stops may not use this entire range of
voltages. The ECM learns the actual range of voltages used and adjusts the THROTTLE POSITION reading to range from 0 to 100% over this used range of voltages. The system looks at both TPS signals and if
the readings are outside of the upper and lower limits or do not agree with each within limits a code will be
set. The following failure combinations and resulting outcomes are possible:
a) TPS1 fails open or shorted, - MIL illuminated, ECM uses TPS2, normal engine operation
b) TPS2 fails open or shorted, - MIL illuminated, ECM uses TPS1, normal engine operation
c) TPS1 & 2 fail open or shorted, - MIL illuminated, ECM stops controlling throttle, throttle goes to limp
home position and is non-responsive, engine will high idle or allow truck to move slowly.
d) TPS1 & 2 do not match, - MIL illuminated, ECM will use the higher of the two TPS readings resulting in
normal or less than normal engine power.
190
Typical TPS and Throttle Position Readings (assumes 5.00 supply voltage):
Actual
Throttle
Position
Fully
closed
Open
Open
Fully Open
TPS1
reading at
Throttle
TPS2
reading at
Throttle
TPS1
reading
on Monitor
TPS2 reading
on Monitor
Throttle
Position on
Monitor
0.32
4.70
0.32
0.30
1.32
3.32
4.32
3.70
1.70
0.70
1.32
3.32
4.32
1.30
3.30
4.30
25
75
100
A short circuit code will set if the TPS1 (as shown on the diagnostic monitor) is greater than 99.02% of
the 5 Volt Power Supply 1 (approx. 4.95 volts)
A short circuit code will set if the TPS2 (as shown on the diagnostic monitor) is greater than 99.8% of
the 5 Volt Power Supply 1 (approx. 4.99 volts)
An open circuit code will set if the TPS1 (as shown on the diagnostic monitor) is less than 4% of the 5
Volt Power Supply 1 (approx. 0.2 volts)
An open circuit code will set if the TPS2 (as shown on the diagnostic monitor) is less than 4% of the 5
Volt Power Supply 1 (approx. 0.2 volts)
191
Action
Value(s)
Yes
No
Go to Step
(2)
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
Go to Step
(3)
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
Go to Step
(5)
Go to Step (4)
Verify that
there are no
codes for the
5 volt supply
before proceeding.
Replace the
ECU. Go to
Step (9)
Repair the
circuit as necessary. Refer
to Wire Harness Repair.
Go to Step (9)
2
Is the higher voltage minus the lower voltage divided by 5 then multiplied by 100 greater than 6?
NOTE: this is the formula the ECU uses to determine if the TPS readings are within the
specifications
Key OFF, disconnect C017 from the throttle
body.
Key ON, measure the voltage from C017 pin
6 to pin 2
Is the voltage between 4.8 and 5.2 volts?
Key OFF, disconnect ECU-B
Measure the resistance from C017 pin 2 to
ECU B pin G2
Measure the resistance from C017 pin 6 to
ECU B pin G4
4
Is the resistance less than 5?
NOTE: Do not probe wires without proper service tool. Permanent harness damage may
result.
192
Step
Action
Value(s)
With C017 disconnected, measure the resistance from pin 6 to pin 1 of the throttle
body.
Push the throttle plate to the fully closed position, and then observe the resistance sweep
while moving the throttle to the fully open
position
Repeat the test across pin 6 to pin 4.
Is the resistance change smooth with no observed glitches, and does the resistance vary
from 800 to 1500 for pin 6 to 1 and from 1400
to 300 for pin 6 to 4 as the throttle is moved from
fully closed to fully open?
Key OFF, disconnect ECU-B
Measure the resistance from C017 pin 1 to
ECU-B pin G3
Measure the resistance from C017 pin 4 to
ECU-B pin D3
Is the resistance less than 5?
193
Yes
No
Go to Step
(6)
Replace the
throttle body
assembly. Go
to Step (7)
NOTE: Verify
that there are
no codes for
the 5 volt
supply before
proceeding.
Replace the
ECU. Go to
Step (7)
Repair the
circuit as necessary. Refer
to Wire Harness Repair.
Go to Step
(7).
System OK.
Go to On-Board
Diagnostics
System
Check/Malfuncti
on Indicator
lamp.
The electronic throttle body has two throttle position sensors TPS1 and TPS2. The voltage from these
sensors is used to determine the percentage throttle opening. The TPS sensors have a nominal output
range of 0.2 to 4.95 volts. From the throttle body itself TPS1 ranges from 0.2 to 4.95 volts as the throttle is
opened, TPS2 ranges from 4.95 to 0.2 volts for this same closed to open travel. The ECM rectifies TPS2
signal so both signals on the diagnostic monitor read from 0.2 to 4.95 as the throttle is opened. The travel
of the throttle plate from the fully closed to the fully open mechanical stops may not use this entire range of
voltages. The ECM learns the actual range of voltages used and adjusts the THROTTLE POSITION reading to range from 0 to 100% over this used range of voltages. The system looks at both TPS signals and if
the readings are outside of the upper and lower limits or do not agree with each within limits a code will be
set. The following failure combinations and resulting outcomes are possible:
a) TPS1 fails open or shorted, - MIL illuminated, ECM uses TPS2, normal engine operation
b) TPS2 fails open or shorted, - MIL illuminated, ECM uses TPS1, normal engine operation
c) TPS1 & 2 fail open or shorted, - MIL illuminated, ECM stops controlling throttle, throttle goes to limp
home position and is non-responsive, engine will high idle or allow truck to move slowly.
d) TPS1 & 2 do not match, - MIL illuminated, ECM will use the higher of the two TPS readings resulting in
normal or less than normal engine power.
194
Typical TPS and Throttle Position Readings (assumes 5.00 supply voltage):
Actual
Throttle
Position
Fully
closed
Open
Open
Fully Open
TPS1
reading at
Throttle
TPS2
reading at
Throttle
TPS1
reading
on Monitor
TPS2 reading
on Monitor
Throttle
Position on
Monitor
0.32
4.70
0.32
0.30
1.32
3.32
4.32
3.70
1.70
0.70
1.32
3.32
4.32
1.30
3.30
4.30
25
75
100
195
Action
Value(s)
Yes
No
Go to Step
(2)
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
Go to Step
(3)
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
Go to Step
(5)
Go to Step (4)
Verify that
there are no
codes for the
5 volt supply
before proceeding.
Replace the
ECU. Go to
Step (9)
Repair the
circuit as necessary. Refer
to Wire Harness Repair.
Go to Step (9)
4
Is the resistance less than 5?
NOTE: Do not probe wires without proper service tool. Permanent harness damage may
result.
196
Step
Action
Value(s)
With C017 disconnected, measure the resistance from pin 6 to pin 1 of the throttle
body.
Push the throttle plate to the fully closed position, and then observe the resistance sweep
while moving the throttle to the fully open
position
Repeat the test across pin 6 to pin 4.
Is the resistance change smooth with no observed glitches, and does the resistance vary
from 800 to 1500 for pin 6 to 1 and from 1400
to 300 for pin 6 to 4 as the throttle is moved from
fully closed to fully open?
Key OFF, disconnect ECU-B
Measure the resistance from C017 pin 1 to
ECU-B pin G3
Measure the resistance from C017 pin 4 to
ECU-B pin D3
Is the resistance less than 5?
197
Yes
No
Go to Step
(6)
Replace the
throttle body
assembly. Go
to Step (7)
NOTE: Verify
that there are
no codes for
the 5 volt
supply before
proceeding.
Replace the
ECU. Go to
Step (7)
Repair the
circuit as necessary. Refer
to Wire Harness Repair.
Go to Step
(7).
System OK.
Go to OnBoard Diagnostics
System
Check/Malfunc
tion Indicator
lamp.
Code
91-2
522712-3
522712-4
522713-3
5227132-4
Limit
12 to
25 %
0.09
4.97
0.09
2.49
Comment
Varies with Pedal
Position
volts
volts
volts
volts
Circuit Description
There are two pedal position sensors on the electronic foot pedal to signal to the ECU exactly how much
throttle the driver has requested. The sensors are Hall Effect type not variable resistance sensors. The two
sensors are provided as a safety feature in case one sensor fails. While the system looks at both sensors,
sensor 1 is used to operate the system. The diagnostic tool allows the technician to monitor three signals
which relate to the foot pedal. The first is pedal position, the system automatically scales the full travel of the
pedal to equal 0 to 100 percent pedal position. The second and third signals are sensor 1 and sensor 2
voltages. Sensor 1 voltage can range from 0.66 to 4.95 volts but will usually be in the range of 1.0 to 3.6
volts. Sensor 2 voltage can range from 0.33 to 2.48 volts but will usually be in the range of 0.5 to 1.8 volts.
(Sensor 2 should read of sensor 1).
198
Action
Value(s)
Yes
Intermittent
problem. Go
to Preliminary
and Intermittent Checks.
Between 4.8
and 5.2
volts?
Go to Step
(5)
Go to Step (4)
Refer to the
vehicle wiring
diagram and
check ground
back to ECU,
repair as
necessary.
Refer to the
vehicle wiring
diagram and
repair the
power supply
problem between here
and ECU.
Check for
possible ECU
5 volt problem. Refer to
codes 524260
and 524261
for diagnostic
aids.
Between 4.8
and 5.2
volts?
199
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
If there is a
glitch in the
sweep, replace the
pedal position
sensor. Otherwise, go to
Step (3).
Step
Action
Value(s)
Yes
No
Reinstall the
pins to the
proper positions in the
connector.
Go to step 6
Reinstall the
pins to the
proper positions in the
connector.
Replace pedal
position sensor. Go to
step 8.
<5?
Go to step 7
Repair the
open in the
harness. Go
to step 8
Repair or
replace the
harness. Go
to Step (8)
Replace the
ECU. Go to
Step (8).
System OK.
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
NOTE: Do not probe wires without proper service tool. Permanent harness damage may
result.
Key OFF, disconnect ECU-A
Measure the resistance from VIC 1 pin K to
ECU-A pin H2 and VIC 1 pin J to ECU-A pin
F3.
Is the resistance less than 5?
Connect the ECU-A and VIC 1 connectors.
With the monitor or DST connected, wiggle
the ECU-A connector.
Are any glitches observed while wiggling the
connector?
Remove all test equipment except the monitor.
Using the monitor, reset the adaptive learn.
Connect any disconnected components, fuses, etc.
Using the monitor, 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 parameters of code, check for any stored
codes.
Does the engine operate normally with no stored
codes?
200
201
Code
91-2
522712-3
522712-4
522713-3
5227132-4
Limit
12 to
25 %
0.09
4.97
0.09
2.49
Comment
Varies with Pedal
Position
volts
volts
volts
volts
Circuit Description
There are two pedal position sensors on the electronic foot pedal to signal to the ECU exactly how much
throttle the driver has requested. The sensors are Hall Effect type not variable resistance sensors. The two
sensors are provided as a safety feature in case one sensor fails. While the system looks at both sensors,
sensor 1 is used to operate the system. The diagnostic tool allows the technician to monitor three signals
which relate to the foot pedal. The first is pedal position, the system automatically scales the full travel of the
pedal to equal 0 to 100 percent pedal position. The second and third signals are sensor 1 and sensor 2
voltages. Sensor 1 voltage can range from 0.66 to 4.95 volts but will usually be in the range of 1.0 to 3.6
volts. Sensor 2 voltage can range from 0.33 to 2.48 volts but will usually be in the range of 0.5 to 1.8 volts.
(Sensor 2 should read of sensor 1).
202
Action
Value(s)
Yes
Intermittent
problem. Go
to Preliminary
and Intermittent Checks.
Between 4.8
and 5.2 volts
Go to Step
(5)
Go to Step (4)
Refer to the
vehicle wiring
diagram and
check ground
back to ECU,
repair as
necessary.
Refer to the
vehicle wiring
diagram and
repair the
power supply
problem between here
and ECU.
Check for
possible ECU
5 volt problem. Refer to
codes 524260
and 524261
for diagnostic
aids.
Between 4.8
and 5.2 volts
203
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
If there is a
glitch in the
sweep, replace the
pedal position
sensor. Otherwise, go to
Step (3).
Step
Action
Value(s)
NOTE: Do not probe wires without proper service tool. Permanent harness damage may
result.
Key OFF, disconnect ECU-A
Measure the resistance from VIC 1 pin K to
ECU-A pin H2 and VIC 1 pin J to ECU-A pin
F3.
Is the resistance less than 5?
Connect the ECU-A and VIC 1 connectors.
With the monitor or DST connected, wiggle
the ECU-A connector.
Are any glitches observed while wiggling the
connector?
204
Yes
No
Reinstall the
pins to the
proper positions in the
connector.
Go to Step
(6)
Reinstall the
pins to the
proper positions in the
connector.
Replace pedal
position sensor. Go to
Step (8).
Go to Step
(7)
Repair the
open in the
harness. Go
to Step (8)
Replace the
ECU. Go to
Step (8).
Step
Action
205
Value(s)
Yes
System OK.
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
No
The EGO sensor (Exhaust Gas Oxygen) sensor is used to determine if the fuel flow to the engine is
correct by measuring the oxygen content in the exhaust gas. The EGO sensor uses an internal heating
element to keep the sensor active. This fault will set if the ECM detects a short low or open in the HEGO
heater element or control circuit. NOTE: The HEGO sensor is sensitive to silicone and silicone-based
products and can become contaminated. Avoid using silicone sealers or hoses treated with silicone lubricant in the air stream or fuel supply lines.
206
Action
Value(s)
Ignition OFF
Disconnect HEGO connector C018
Ignition ON
Using a DVOM check for voltage between
EGO connector pins C and D
Ignition OFF
Disconnect ECU-C Connector
Using a DVOM check for continuity between
ECU-C connector pin L2 and HEGO connector pin D
Replace ECM
7
Is the replacement complete?
207
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(8)
Go To Step
(3)
Repair open
HEGO heater
supply circuit
from power
relay. See
wire harness
repair.
Repair open
HEGO
ground circuit. See
wire harness
repair.
Go to Step
(4)
Go to Step
(5)
Go to Step
(6)
Repair the
open HEGO
heater
ground. See
wire harness
repair.
Repair the
HEGO heater
ground shorted to voltage.
See wire harness Repair.
Go to Step
(7)
Go to Step
(10)
Step
Action
Using a DVOM measure the resistance of the
HEGO heater (sensor side) between pins C and
D.
Does the DVOM show a resistance value greater
than 25 Ohms?
Replace the HEGO sensor
10
208
Value(s)
Yes
No
Greater than
25 Ohms
Go to Step
(9)
Go to Step
(5)
Go to Step
(10)
System OK
Go to OBD
System
Check
209
Circuit Description
The system monitors the O2 sensor to ensure that the fuel control is functioning properly. The HEGO sensor is mounted in the exhaust system downstream of the engine. It is used to measure the amount of
oxygen present in the exhaust stream and communicates that to the ECM via an electrical signal. The
amount of oxygen present in the exhaust stream indicates whether the fuel air ratio is rich or lean. If the
HEGO sensor signal indicates that the exhaust stream is rich, the ECM will decrease or lean the fuel mixture by reducing the short term fuel correction value which reduces the injector on-time supplying less fuel. If
the mixture is lean, the ECM will richen the mixture or increase the short term fuel correction value which
will increase the pulse width to the injectors. Under normal steady operation the short term fuel correction
value should move up and down approx. 5%. This 5% movement may range within a plus 25 to minus 25
percent window. The ECM continuously monitors the HEGO sensor output. If a rich or lean condition is
present for an extended period of time and if the ECM cannot correct the condition, the ECM will set a diagnostic code and turn on the MIL light in the dash. The O2 sensor uses a heater circuit to bring it up to
operating temperature as quickly as possible, as well as maintaining the temperature during idle. The heater is controlled by the ECU, which will cycle the heater to prevent overheating of the sensor
210
Action
Did you perform the On-board diagnostics (OBD)
system check?
Value(s)
Go to Step
(2)
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
Go to Step
(3)
Repair open in
Component
Power Relay
circuit. Go to
Step (8)
9.6,
1.5 @
21C?
Go to Step
(4)
Replace the
O2 Sensor.
Go to Step
(8)
>30M
Go to Step
(5)
Replace the
O2 Sensor.
Go to Step
(8)
Go to Step
(6)
Repair the
open in the
circuit. Go to
Step (8)
Go to Step
(7)
Repair the
short to
ground in the
harness. Go
to Step (8)
Yes
NOTE: Do not probe wires without proper service tool. Permanent harness damage may
result.
Key OFF, disconnect ECU-C
Measure resistance from C018 pin C to
ECU-C pin L2
<5M
>30M
Is the resistance greater than 30M?
211
Replace the
ECU. Go to
Step (8)
Step
Action
Remove all test equipment except the monitor.
Using the monitor, reset the adaptive learn.
Connect any disconnected components, fuses, etc.
Using the monitor, 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 parameters of code, check for any stored
codes.
Does the engine operate normally with no
stored codes?
212
Value(s)
Yes
No
System OK.
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
213
214
Action
Value(s)
Between 4.8
and 5.2 volts
<5
>30M
>30M
Yes
No
Go to step 2
Perform OBD
System check
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
Go to Step
(3)
Go to Step
(4)
Go to Step
(5)
Go to Step
(5)
Replace Cam
Sensor, Go to
Step (9)
Go to Step
(6)
Repair the
circuit as
necessary.
Refer to Wire
Harness
Repair. Go to
Step (9)
Go to Step
(7)
Repair short
to ground as
necessary.
Refer to Wire
Harness
Repair. Go to
Step (9)
Go to Step
(8)
Repair short
in harness.
Refer to Wire
Harness repair. Go to
Step (9)
Go to Step
(9)
8
Is replacement completed?
215
Step
Action
Value(s)
216
Yes
No
System OK
Go to OnBoard Diagnostics
System
Check/Malfun
ction Indicator
lamp.
217
The Oil Pressure Switch is used to communicate a low oil pressure condition to the ECM. Engine
damage can occur if the engine is operated with low oil pressure. This fault will set if the oil pressure
switch remains closed with the engine running. The switch is set to open above 6 PSI.
Circuit Description
Never assume the fault is due to an electrical malfunction. Low oil pressure can damage the engine. Verify
oil pressure before proceeding with this diagnostic.
218
Action
Did you perform the On-Board (OBD) System
Check?
219
Value(s)
Yes
Go to Step
(2)
No
Go to OBD
System.
Check Section
Go to Step
(3)
Repair faulty
Oiling System
Go to Step
(4)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(6)
Go to Step
(5)
Go to Step
(9)
Repair the
shorted to
ground oil
pressure circuit as
necessary.
Refer to Wiring Repairs.
Repair the
circuit as
necessary.
Refer to Wiring Repairs in
Engine Electrical.
Go to Step
(7)
Go to Step
(8)
Step
Action
Value(s)
Replace ECM
8
220
Yes
No
Go to Step
(9)
System OK
Go to OBD
System
Check
221
ECU-A pin G2
ECU-B pin G1
ECU-B pin G2
ECU-C pin B3
ECU-A pin F2
ECU-B pin J2
ECU-B pin H2
222
Action
Value(s)
No
Go to Step
(2)
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
Go to Step
(3)
Go to Step
(5)
Yes
7
Does the fault return?
223
Between 4.8
and 5.2 volts
Go to Step
(4)
Repair as
necessary.
Go to Step
(8).
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
Replace the
sensor that
causes the
fault in the
voltage. Go to
step last
Repair as required. Go to
Step (8).
Go to Step
(6)
Replace the
ECU. Go to
Step (8)
Go to Step
(7)
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
Step
Action
Value(s)
224
Yes
No
System OK.
Go to OnBoard Diagnostics
System
Check/Malfun
ction Indicator
lamp.
225
ECU-A pin G2
ECU-B pin G1
ECU-B pin G2
ECU-C pin B3
ECU-A pin F2
ECU-B pin J2
ECU-B pin H2
226
Action
Value(s)
Yes
No
Go to Step
(2)
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
Go to Step
(3)
Go to Step
(5)
7
Does the fault return?
227
Between 4.8
and 5.2 volts
Go to Step
(4)
Repair as
necessary.
Go to Step
(8).
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
Replace the
sensor that
causes the
fault in the
voltage. Go to
step last
Repair as required. Go to
Step (8).
Go to Step
(6)
Replace the
ECU. Go to
Step (8)
Go to Step
(7)
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
Step
Action
Value(s)
228
Yes
No
System OK.
Go to OnBoard Diagnostics
System
Check/Malfun
ction Indicator
lamp.
229
Dual throttle position sensors (TPS) are used with the electronic throttle control (ETC) to determine
throttle plate position. The TPS values are used by the ECM to determine if the throttle is opening and
closing as commanded. This fault will set if the ECM detects a problem with the ETC TPS, malfunctioning
throttle control motor or sticking throttle valve assembly.
230
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
data stream mode.
Clear DTC 524266
Ignition OFF
Ignition ON
Ignition OFF
Disconnect electronic throttle connector
C017
Disconnect ECM wire harness connector
ECU-B
Using a DVOM check for continuity between
all electronic throttle connector pins and engine ground
231
Yes
No
Go to Step
(2)
Go to OBD
System Check
Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Remove the
foreign object
or replace the
throttle if
damage is
found. Go to
Step (17)
Go to Step (4)
Repair the
shorted to
ground TPS
circuit as
necessary.
Refer to Wiring Repairs
Go to Step (5)
Go to Step
(6)
Go to Step
(7)
Go to Step
(8)
Repair the
open circuit as
necessary.
Refer to Wiring Repairs.
Repair the
open circuit as
necessary.
Refer to Wiring Repairs
Repair the
open circuit as
necessary.
Refer to Wiring Repairs
Step
Action
Value(s)
12
13
Is the replacement complete?
232
Yes
Go to Step
(9)
Go to Step
(10)
Go to Step
(11)
No
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Go to Step
(12)
System OK
Go to Step
(13)
Go to Step
(14)
Step
Action
14
Value(s)
233
Yes
No
System OK
Go to OBD
System Check
Dual throttle position sensors (TPS) are used with the electronic throttle control (ETC) to determine
throttle plate position. The TPS values are used by the ECM to determine if the throttle is opening and
closing as commanded. This fault will set if the ECM detects a problem with the ETC TPS, malfunctioning
throttle control motor or sticking throttle valve assembly.
234
Action
Value(s)
Ignition ON
DST (Diagnostic Scan Tool) connected in
data stream mode.
Clear DTC 524286
Ignition OFF
Ignition ON
Ignition OFF
Disconnect electronic throttle connector
C017
Disconnect ECM wire harness connector
ECU-B
Using a DVOM check for continuity between
all electronic throttle connector pins and engine ground
8
Does the DVOM show continuity?
235
Yes
No
Go to Step
(2)
Go to OBD
System Check
Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Remove the
foreign object
or replace the
throttle if
damage is
found. Go to
Step (17)
Go to Step (4)
Repair the
shorted to
ground TPS
circuit as
necessary.
Refer to Wiring Repairs
Go to Step (5)
Go to Step
(6)
Go to Step
(7)
Go to Step
(8)
Go to Step
(9)
Repair the
open circuit as
necessary.
Refer to Wiring Repairs.
Repair the
open circuit as
necessary.
Refer to Wiring Repairs
Repair the
open circuit as
necessary.
Refer to Wiring Repairs
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Step
Action
Value(s)
12
13
14
236
Yes
Go to Step
(10)
Go to Step
(11)
No
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Repair the
shorted TPS
circuit to
ground as
necessary.
Refer to Wiring Repairs.
Go to Step
(12)
System OK
Go to Step
(13)
Go to Step
(14)
System OK
Go to OBD
System Check
237
I.
ECM
REMOVAL PROCEDURE
INSTALLATION PROCEDURE
1. Place the ECM in position and secure with
2.
3.
4.
5.
238
INSTALLATION PROCEDURE
V. DISTRIBUTOR
The Distributor
REMOVAL PROCEDURE
1. Disconnect negative battery cable.
2. Mark each Spark Plug Wire with its corresponding cylinder or position on the Distributor
239
Cap.
3. Remove Spark Plug Wires from the Distributor
Cap by pulling and twisting each Spark Plug
Wire boot turn.
4. Remove Ignition Coil wire.
5. Remove the electrical connector from the
base of the Distributor.
6. Remove the two Screws that hold the Distributor Cap to the housing and remove Cap.
7. Using a grease pencil or similar marking tool,
mark the location of the Rotor on the distributor housing and engine.
8. Remove the Distributor hold down bolt.
IMPORTANT
Do not engage the starter, or change the positions
of the cam or crankshaft, timing gears or any other internal engine components while the
distributor is removed. Any change in the position
of these components will alter the timing.
INSTALLATION PROCEDURE
1. Align the Rotor with the mark made on the
Distributor housing (the location of the rotor
when it was removed) and place into the engine ensuring the rotor, distributor housing
and the mark on the engine are all in alignment when the Distributor is fully seated.
2. Install the Distributor mounting clam Bolt and
tighten to 18 ft. lbs (25 Nm). Verify that the
rotor and Distributor housing remain in line
with the mark.
3. Install Distributor Cap.
TMAP Sensor
INSTALLATION PROCEDURE
1. Install the TMAP and secure with Retaining
Screw. Torque to 7-9 ft.lbs. (9.5-12.2 Nm).
2. Reconnect electrical connector.
3. Reconnect the negative battery cable.
4. Start engine and run until it reaches normal
operating temperature.
5. Check for MIL illumination. If a DTC code is
found, refer to the Electrical Section for further
diagnosis.
IMPORTANT
Do not reuse old Distributor Cap Screws. Use
new Screws only.
4. Connect the electrical connection to the base
of the Distributor.
5. Connect Spark Plug wires to the Distributor
Cap, ensuring the wires are connected to the
correct cylinder. NOTE that the firing order is
1-3-4-2. Refer to the IGNITION SYSTEM
SPECIFICATIONS in the Appendix for additional information.
6. Connect Ignition Coil wire to Distributor Cap.
7. Reconnect negative battery cable.
8. Start engine. Run engine through all throttle
ranges and under load to ensure normal operation.
9. Using the DST, clear DTC information from
the ECM.
240
REMOVAL PROCEDURE
1. Relieve the LPG fuel system pressure. Refer
to XVIII. LPG FUEL SYSTEM PRESSURE
RELIEF.
2. Disconnect the negative battery cable.
3. Locate the Fuel Temperature Sensor on the
fuel rail.
4. Remove the electrical connector from the
Sensor.
5. Unscrew the sensor from the Fuel Rail.
INSTALLATION PROCEDURE
1. Lubricate the O-ring on the Fuel Temperature
Sensor with a light coat of Vaseline or petroleum jelly. Do not contaminate the tip of the
sensor.
241
INSTALLATION PROCEDURE
REMOVAL PROCEDURE
1. Disconnect Negative battery cable.
2. Locate the Oxygen Sensor.
3. Disconnect the Oxygen sensor electrical connector.
XI. REGULATOR
Regulator
REMOVAL PROCEDURE
1. Relieve the LPG fuel system pressure. Refer
to XVIII. LPG FUEL SYSTEM PRESSURE
RELIEF.
2. Disconnect Negative battery cable.
3. Remove the electrical connector on the
Shutoff Valve.
4. Remove the Fuel Hose from the regulator.
5. Remove the LPG Fuel Line at the flare fitting
attached to the Shutoff Valve.
242
IMPORTANT:
Draining the Regulator when the engine is warm
will help the oils to flow freely and permit easier
removal from the Regulator.
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.
7. Reconnect negative battery cable. Turn ignition key to ON and check for leaks at the inlet
and outlet fittings using a commercial grade
soapy solution or an electronic leak detector.
If leaks are detected make repairs.
8. Start engine and check for fuel and coolant
leaks. If leaks are detected make repairs.
9. Check for MIL illumination.
10. Run engine to normal operating temperature
and turn key to OFF.
11. Check coolant level and add coolant if necessary.
243
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 sensor safe RTV sealant for repair
procedures. Silicon contamination will cause
a high but false HEGO signal voltage (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 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.
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.
10. Turn Key ON. Check for leaks at the inlet and
outlet fittings using a soapy solution or an
electronic leak detector. If leaks are detected
make repairs.
11. Start engine and check for leaks at all serviced fittings. If leaks are detected make
repairs.
INSTALLATION PROCEDURE
1. Install new filter (2) in port for fuel outlet fitting.
Install new O-ring (3) and fuel outlet fitting (4).
2. Install retaining screws (5) for fuel outlet fitting
(4). Tighten screws to 2 to 3 Nm (17.7 to
26.55 in. lb.).
244
3. Install the filter gasket (6), new paper filter element (7), new foam filter (8), and plastic body
(9).
4. Install the fuel inlet fitting (11) and O-ring (10).
Tighten to 18 to 20 Nm (13.3 to 14.75 ft.lbs.).
5. Connect the fuel inlet line to the LPG Regulator.
6. Connect the negative battery cable.
7. Slowly open the fuel valve on tank.
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.
REMOVAL PROCEDURE
1. Relieve the LPG fuel system pressure. Refer
to XVIII. LPG FUEL SYSTEM PRESSURE
RELIEF.
2. Disconnect the negative battery cable.
3. Remove the pin securing the fuel inlet hose,
then remove fitting from the fuel rail.
4. Remove Fuel Pressure Sensor electrical connection.
5. Remove two bolts securing the Fuel Rail.
6. Carefully pull the rail flush along the Fuel Rail
and away from the Fuel Injectors.
7. If rail is to be replaced, remove the Fuel Pressure Sensor. Refer to VII. FUEL PRESSURE
SENSOR.
INSTALLATION PROCEDURE
1. Install Fuel Pressure Sensor, if removed Refer
to VII. FUEL PRESSURE SENSOR.
2. Lubricate Fuel Injector O-rings with petroleum
jelly or Vaseline.
INSTALLATION PROCEDURE
1. Install new cartridge into LPG Regulator.
Tighten cartridge to 16 to 24 Nm (11.8 to 17.7
ft.lbs.).
2. Install solenoid and nut onto cartridge. Tighten nut to 7.85 Nm (69.5 in.lbs.).
3. Connect electrical connector to solenoid.
4. Connect the negative battery cable.
IMPORTANT:
The fuel cylinder manual valve contains an Excess Flow Check Valve. Open the manual valve
245
REMOVAL PROCEDURE
1. Relieve the LPG fuel system pressure. Refer
to XVIII. LPG FUEL SYSTEM PRESSURE
RELIEF.
2. Disconnect the negative battery cable.
3. Remove the Fuel Rail. Refer to XV. FUEL
RAIL.
4. Remove Injector electrical connector.
5. Remove Clip Retaining Fuel Injector (connecting it to the Injector Adapter).
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 sensor safe RTV sealant for repair
procedures. Silicon contamination will cause
a high but false HEGO signal voltage (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 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.
3. Carefully place the Fuel Rail over the injectors, sliding along the Fuel Rail Bracket.
Ensure the Fuel Injectors and O-rings are
properly seated.
4. Align holes on Fuel Rail with holes in the
bracket and insert screws. Torque to 7-9
ft.lbs. (9.5-12.2 Nm).
5. Connect Fuel Pressure Sensor electrical connection.
6. Insert fuel inlet port fitting and secure with pin.
7. Reconnect negative battery cable. Turn ignition key to ON and check for leaks at the inlet
and outlet fittings using a commercial grade
soapy solution or an electronic leak detector.
If leaks are detected make repairs.
8. Start engine and check leaks. If leaks are
detected make repairs.
9. Check for MIL illumination.
6. Remove Injector.
INSTALLATION PROCEDURE
1. Inspect the O-rings on the Injector and Injector
Adapter and replace if necessary. Lubricate
with Vaseline or petroleum jelly.
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 sensor safe RTV sealant for repair
procedures. Silicon contamination will cause
a high but false HEGO signal voltage (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 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.
246
take Manifold to prevent dirt or debris from entering the engine, possibly causing permanent
engine damage.
INSTALLATION PROCEDURE
1. Lubricate the O-rings on the Fuel Injector
Adapter with Vaseline or petroleum jelly and
place back on the Intake Manifold, ensuring it
is properly seated.
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 sensor safe RTV sealant for repair
procedures. Silicon contamination will cause
a high but false HEGO signal voltage (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 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.
247
Oil leaks
Oil in the air cleaner
Sludge in the engine
Rough Idle
Stalling
High idle speed
FUNCTIONAL CHECK
1. Close the LPG fuel tank manual shut-off valve
(MSV).
2. Start and run the vehicle until the engine stalls
from lack of fuel.
3. Turn the ignition switch to OFF.
4. Disconnect the negative battery cable.
REMOVAL PROCEDURE
1. Stop engine.
2. Drain coolant.
248
IMPORTANT
Hoses are designed for specific applications. DO
NOT use Hose material or length other than
specified by the OEM. DO NOT mix the inlet or
outlet ends of the Hose when reinstalling.
INSTALLATION PROCEDURE
3. Remove clamps from each end of the Hose
and remove Hose.
INSTALLATION PROCEDURE
IMPORTANT
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 ends of the Hose when reinstalling.
1. Slide Clamps over each end of the Hose.
2. Insert Port Fittings into each end of the Hose.
3. Slide Hose Clamp to a position approximately
from the end of the Hose and tighten.
4. Refill with coolant.
5. Start engine and let run until it reaches operating temperature.
6. Check for leaks. If leaks are detected, make
repairs.
7. Stop engine and allow to cool. Check coolant
level and add coolant as necessary.
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 sensor safe RTV sealant for repair
procedures. Silicon contamination will cause
a high but false HEGO signal voltage (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 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.
249
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.
REMOVAL
1. Relieve the LPG fuel system pressure. Refer
to XVIII. LPG FUEL SYSTEM PRESSURE
RELIEF.
2. Disconnect negative battery cable.
3. Remove retaining clip securing the Port Fitting
in the port and remove.
4. Loosen Hose Clamp securing the Port Fitting
in the Hose and pull Port Fitting from hose.
8. Turn Key to the ON position for several seconds, then turn back to OFF. Using a liquid
or electronic leak detection tool, inspect the
REGULATOR, fuel hoses and all serviced fittings for leaks.
9. Start engine and check for leaks.
XXIII. REGULATOR PRESSURE CHECK
INSTALLATION
IMPORTANT
Port Fittings are designed for specific applications,
DO NOT any other adapter or fitting other than the
part specified by the OEM.
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 sensor safe RTV sealant for repair
procedures. Silicon contamination will cause
a high but false HEGO signal voltage (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 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.
250
PROCEDURE:
REMOVAL PROCEDURE
1. Remove the Catalytic Converter using the
OEM end product processes
INSTALLATION PROCEDURE
IMPORTANT
The Catalytic Converter is specifically designed to
meet the emission control of the certified engine.
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.
4. If a DTC code is found, refer to the Electrical
Section for further diagnosis.
251
REMOVAL PROCEDURE
1. Remove the Vacuum Line from each fitting.
INSTALLATION PROCEDURE
IMPORTANT
DO NOT use a hose other than the OEM specified
part.
INSTALLATION PROCEDURE
A small amount of fuel may still be present in
the fuel line. Use gloves and proper eye protection to prevent burns. Make sure the
manual valve is fully closed.
IMPORTANT
Do no not reuse the old Distributor Cap, Rotor or
Cam Sensor Screws.
1. Mount Camshaft Sensor on Distributor and
secure with new Screws. Torque to 19 in.lbs.
(2.2 Nm)
2. Install the Rotor on the reluctor wheel and secure with new Rotor Screws. Torque to 18
in.lbs. (2.0 Nm).
252
253
254
255
2--@)
256
Description
Qty
4
4
1
2
1
257
IMPCO
Part Number
S1-30295-0655
W1-31039-006
A7-324
A7-245
B4-51980-001
258
Description
Qty
IMPCO
Part Number
1
2
3
1
2
1
A7-473
P1-30559
R8-51549-001
4
5
6
7
Pin, Retaining
O-Ring, Inlet
Spacer, O-ring
Injector, LPG/CNG
1
4
4
4
P1-30559
A7-657
A7-656
A7-654
8
9
10
O-ring, Adapter
Adapter, Fuel Injector
O-ring, FKM-75 .362 ID
4
4
4
A7-655
A4-51981-001
GMN-033
259
REGULATOR ASSEMBLY
260
REGULATOR ASSEMBLY
Item #
Description
Qty
1
1
1
1
1
1
1
5
12
13
261
IMPCO
Part Number
A7-434
A7-170
A7-172
A7-176
A7-171
A7-173
A7-175
262
Description
Qty
Fitting, Port
Clamp, Oetiker
Hose, Vacuum
Hose 3/8 ID Fuel/Oil
Hose, 5/8 Fuel/Oil
Clamp, Ear Oetiker
Pin, Retaining
Clamp, Worm Drive
Clamp, Oetiker
Hose, 5/8 ID Fuel/Oil
Bracket, Vapor Filter
Filter, LPG Vapor
Hose, Formed Gate
Hose, Formed Gate
Clamp, Worm Drive
Bolt, M8 x 1.25 x 25
Nut, Hex
1
2
1
1
1
2
1
4
4
1
1
1
1
1
1
2
2
263
IMPCO
Part Number
AF4-50733-001
C1-51552-07-170
H1-19231-001
H1-19231-004
H1-19231-006
C2-51552-05-113
P1-30559
0130845
C1-51552-07-256
H1-19231-006
A10-167
A8-367
H1-50599-001
A10-169
1510113
97330010
264
Description
Qty
Part Number
GM Part Number
1
2
3
4
Bolt
Thermostat Housing
Gasket, Thermostat Housing
Thermostat
2
1
1
1
90328100
7142071
7140310
7140340
09424320
14096853
10105135
10220957
265
266
Description
Qty
ECM, Liugong
A11-103
267
SENSORS
4
5
6
268
SENSORS
Item #
Description
1
2
3
4
5
6
7
HEGO
Crank Sensor
Sensor, TMAP
Oil Pressure Switch
Adapter, Oil Pressure Switch
Coolant Temp Switch
Adapter, Coolant Switch
Qty.
Used
1
1
1
1
1
1
1
269
IMPCO
Part Number
S8-50328-001
S8-51822-001
E1466001
S10-50352-001
7242360
7144790
7176570-06
GM Part
Number
12567712
DISTRIBUTOR
270
DISTRIBUTOR
Item #
Description
Qty.
Part Number
1
2
3
4
Distributor
Distributor Cap
Rotor
Module/Sensor
1
1
1
1
93442429
89060454
7241620
7245370
271
GM
Part Number
93442429
89060454
10467546
10485432
272
Description
Screw, Hex M4 x 16mm
Washer, Split Lock M4
Fuse Box Cover
Bracket, ECM
Screw, Hex Flange
Seal, Fuse Box
273
Qty.
Part Number
4
4
1
1
2
1
S1-30295-0416
W1-1988-003
C1-52520-001
B4-51789-001
90325088
S3-52522-001
IGNITION COIL
274
IGNITION COIL
Item #
1
Description
Coil, Ignition
275
Qty.
Part Number
10489421
MANIFOLDS
276
MANIFOLDS
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Description
Gasket, Int/Ext
Manifold, Exhaust GM 3.0L
Stud, 3/8-16 x 2
Bolt, Socket Head 3/8 x 16 Grade 8
Washer, Belleville 3/8
Screw, Hex Flange M5-0.8 8x8
Nut, Serrated
Washer, 3/8 Type A Hard
Screw, Hex Flange M6 x 12mm
Screw, Hex Flange M6-1.0x x 16mm
Screw Hex Flange M6-1.0 x 12mm
Shield, Heat-GM 3.0L 2 Piece
Heat Shield, RB Exhaust
Heat Shield, Alternator 3.0L
TMAP Sensor
Fitting, 1/8 NPT 3/8 Hose Brass
Fitting, 1/8 NPT .19 ID Hose
Bracket, Maxifuse Mount
Gasket, Exhaust Flange
Strap, Cnvlt Cdt 13mm
Sensor, O2
277
Qty.
Part Number
1
1
2
4
8
4
2
4
8
3
5
1
1
1
1
1
1
1
1
2
1
7152170
7152150
S3-50596-001
90368100
W1-50595-037
S1-50237-20-0508
N1-30876-037
92300101
S1-30871-02-0612
S1-30871-02-0616
S1-50237-02-0620
7152160
G4-50067-001
G4-50068-001
E1466001
2H-103B
F4-4
B4-51889-001
7152175
S17-51979-001
S8-50234-001
278
Manufacturer Part
Number
1054112
Littelfuse 1520007Z
Littelfuse 299070
Littelfuse 1520004Z
Item #
Description
Qty
1
2
3
4
Auxiliary
Power Fuse
Starter Fuse
VSW
Starter Relay
Power Relay
Shut Off
Valve Relay
Cover
Fuse 70A
Fuse Holder
Wire Harness, 4 Cyl
10A Minifuse
20A Minifuse
20A Minifuse
10A Minifuse
Starter Relay
Power Relay
1
1
1
1
1
1
1
1
1
1
AW-50727-001
914584
7381270
7381270
914584
885014
885014
Littelfuse 297010
Littelfuse 297020
Littelfuse 297020
Littelfuse 297010
3011CCR1U0112VDC
3011CCR1U0112VDC
Lock Off
885014
3011CCR1U0112VDC
279
280
Description
Qty
Part Number
GM Part
Number
1
2
3
4
Vent, Elbow
Grommet oil filter cap
PCV
Grommet, PCV Valve
1
1
1
1
F4-51936-001
G3-51937-001
V3-51806-001
7120140
06487779
14050440
06487779
14001875
281
MISCELLANEOUS ENGINE
4
5
16
15
282
MISCELLANEOUS ENGINE
Item #
1
2
3
4
5
6
7
8
9
10
11
12
Description
Engine, MY 2011-2010GM 3.0L
Sensor, Crank
Plug, 3/8 NPT Socket Head Brass
Fitting, Pipe Thread Reducer
Oil Filter PF454
Plug -14 NPT
Switch, Oil Pressure
Spark Plug, R44LTS
Plug, 14mm Fuel Rail Port
Fitting, 1/2NPT 5/8 NIP Brass
Strap, Lifting Eye
Screw, Hex Flange 3/8-16 x 1
283
Qty
Part Number
1
1
1
1
1
1
1
4
4
1
1
1
7044670
S8-51822-001
P3-12
7176570-06
7110851
7242360
S10-50352-001
E10-50075
P3-50597-001
F4-17920
7010130
90325100
ALTERNATOR
284
ALTERNATOR
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Description
3/8-16x1-1/2 Bolt Hx GR5
Washer, Lock 3/8
Washer, Flat 3/8
3/8-16x1 bolt Hx Gr5
5/16-18x1 Bolt Sched Grd 8
Sapcer, Fan Mount 3.0L
5/16-18x1 Bit Hx Gr5
Washer, Lock, M8
Bracket, Alternator
Alternator, 7SI
Nut, Hex Flange Serrated M5 x 1.0
Nut, 3/8-16 Grade 5
Spacer, Alternator Brkt
Bracket, Alt Lower
Bolt, Hex 3/8-16 x 4 Grade 5
Bolt, M8-1.25 Hx Head Grd 10.9
Washer, Lock, Med, M8, Zn
Washer, Flat Heavy 5/6
Pulley, Water Pump
Pulley, Crankshaf
3/8-24x2 bolt Hx Gr5
5/16-18 x Grade 5
3/8-16x3-1/2 Blt Sched Gr5
ASM Fan Hub 3.0L
Pulley Twin Belt
Ring Retaining OD 0.669
Pully ASM P/B Boos Pump Idler
Bracket Tensioner
Pulley, Water Pump-Mod
Bracket Fan Tensioner MTG
285
Qty
Part Number
2
15
5
2
4
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
8
1
1
1
1
1
1
1
1
90305150
93300000
92300000
90305125
90268100
7143890
90205125
93200000
7144570
7144070
N1-30876-M06
95300000
7244570
7244560
90305400
98333025
93930000
92200020
7144040
7071620
90315200
90215075
7144160
7144220
7144130
7144030
7030110
7144000
7144040
7143881
STARTER
11
13
12
10
286
STARTER
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
Description
Bolt
Nut Hex M5 x 0.8 Brass
Washer, Lock Bronze
Nut, Hex M8 x 1.25 Brass
Washer, lock med M8 Zn
Starter Motor
Bracket, Starter 2kW 3.0L
Nut Hex #10-24
Washer, Lock #10 Med
Washer Flat #10
5/16-18 Bolt Hex Gr5
Washer, Loc, Med 5/16
Washer, flat, SAE, 5/16
287
Qty
Part Number
2
1
1
1
1
1
1
1
1
1
1
1
1
7242530
97111000
93003000
97331000
93930000
7244520
B4-52110-001
95000000
93000000
92000000
9205075
93200000
92200000
10
11
12
13
14
Standard Oetiker Pliers, IMPCO P/N 14100037 and Injector Test Lamp OTC-6023 (not included in any IMPCO ITK kit)
288
Description
Test Kit Gauge 0-5 PSI (2-5205)
Test Kit-Gage 0-10" WC (2-5010)
Hose, 3/16" Id Vacuum, Bulk
Harness, Adapter Gen 2 DLC to Gen 1 DLC
Fitting Assembly, Test Cap (System II LPR
Secondary Pressure Test Adapter)
Fitting, 1/8 NPT 3/16Hs Nip Brass
Assembly, Fitting Test Cap 3/4
Pin, Retainer
Case, Metal, 14.25 x 9 x 4.25
Fitting, 1/8 NPT 1/4Hs El Nylon
Tool, 20IPR Torx-Plus Bit
Fitting, UNF, HS Vac Nip
Gauge, Test Fuel System
ASM, CAN Dongle (ECOM Cable)
289
Qty.
Used
1
1
1.5
1
AF4-31105
2
1
10
1
2
1
1
1
1
F4-4
AF4-50254-002
P1-30559
C9-50724-001
F4-8
T7-50172
F4-2
TG-31119-001
E2046002
The follow parts manual includes GM Service parts and their GM part numbers for the 3.0L 2011
engine. The IMPCO part number for the complete service block is:
7044670
290
291
3.0L UPPER
6_,
7-,
8-e
9
10
11_J1 /
13 u fl 12
15
14
:--1"
22
----?11
16
23
292
3.0L UPPER
Item #
Description
Qty
Part Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Cap, Oil
Bolt, Vlv
Reinforcement, Vlv Rkr Arm Cvr
Cover, Vlv Rkr Arm
Gasket, Vlv Rkr Arm Cvr
Rotator, Vlv
Key, Vlv Stem
Nut, Vlv Rkr Arm
Ball, Vlv Rkr Arm
Arm Kit, Vlv Rkr w/Ball
Rod, Vlv Push
Shield, Vlv Stem Oil
Stud, Vlv
Cap, Vlv Sprg
Seal, Vlv Stem Oil
Spring, Vlv
Bolt, Cyl Hd
Plug, Cyl Hd Core Hole
Gasket, Eng Cool Therm Hsg
Housing, Eng Cool Therm
Bolt, Eng Cool Therm Hsg
Lifter, Vlv
Head, Cyl Cmpl w/Valves, Springs, Retainers & Seals
Insert, Vlv Push Rod
Plug, Inj Hole
Valve, Int
Valve, Exh
Gasket, Cyl HD
1
5
5
1
1
4
16
8
8
8
8
12
8
8
8
8
10
2
1
1
3
8
93802366
09439930
03877670
02770089
14096154
14042575
24503856
12557390
93427660
05723551
93414888
10007818
03814692
10038209
10214034
94666172
10166832
03826506
10140501
93442430
09424320
05232720
93442423
8
4
4
4
1
NSS
P3-50597-001*
14075641
94665131
14096660
23
24
25
26
27
28
293
3.0L LOWER
88
294
3.0L LOWER
Item #
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Description
Qty
4
4
8
4
1
8
1
1
1
1
3
3
2
2
2
1
1
1
1
4
1
1
8
1
4
1
1
1
1
1
1
Part Number
88894219
12361570
14089026
93442974
93419821
10108688
00461372
12493123
12493124
00326312
03866766
10101256
88894247
09442184
NSS
11503663
09442895
09440366
00106751
09442008
10101744
02771369
12508079
00549631
14002525
02770015
25013759
00585927
03853870
12329955
12329954
10048778
12329774
00106751
12577710
02768986
14096156
03992251
03826280
295
Item #
Description
Qty
Part Number
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
1
1
1
10
10
10
1
1
1
14
4
4
1
1
1
1
1
3
1
NSS
00136857
10126796
12338130
09439510
09442895
See IMPCO Catalog
See IMPCO Catalog
93419740
09440033
00133043
09439510
03792507
03789970
03814903
03930824
03829433
09424877
NSS
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
1
12
1
1
1
1
1
1
1
1
1
8
4
1
1
14096637
09442895
14091485
03875950
03970417
93442002
09425113
11609328
09442946
12551790
02778192
03872781
03970194
09441003
14088556
67
68
69
2
2
1
1
2
1
14096659
14096658
12555771
03852870
14080362
10088158
70
71
72
296
Item #
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
Description
Gear, Flywhl Ring (Part of 78)
Washer, Flywhl
Bolt, Flywhl (7/16-20 x 31/32)
Bolt, Vlv Push Rod Cvr
Bearing, Clu Pilot
Flywheel, Eng (Includes 73)
Cover
Pin, Trans Loc (5/8 x 1 3/16)
Gasket, Vlv Push Rod Cvr
Plug, Eng Blk Oil Gal
Engine Block
Plug, CM/Shf
Plug, Eng Blk Core Hole
Plug, Oil
Plug, Eng Blk Oil
Tube, Oil Lvl
Indicator, Oil Lvl
Sealer, Vlv Push Rod Cvr
Stud, Vlv Push Rod Cvr
Nut, Vlv Push Rod Cvr
Washer, Vlv Push Rod Cvr
Ring, Cr/Shf Psn Sen Reluctor
Seal, Cr/Shf Psn Sen Conn
Sensor, Cr/Shf Posn
Bolt, Cr/Shf Posn Sen
Gasket, F/Pmp
Cover, F/Pmp OPG
Washer, F/Pmp MT
Bolt, F/Pmp
Plug, Eng Blk Core Hole
Qty
Part Number
1
1
6
4
1
1
1
2
1
1
1
1
AR
1
1
1
1
AR
4
4
4
1
1
1
1
1
1
2
2
2
03991408
00136857
00839756
03814350
14061685
93419731
93423830
01453658
12378521
14090911
NSS
110241154
03826505
NSS
03835577
93434708
14025224
12346286
00352169
00451399
02436163
NSS
NSS
12567712
11588712
93802517
93439184
02436162
09424877
88891749
297
298
299
INTRODUCTION
TIME ALLOWANCES
The labor times include the removal, disassembly, cleaning, re-assembly, installation and/or
adjustment of the affected component or assembly. Any cleaning time is limited to the
installation or replacement of components (such
as mating surfaces) and does not include cleaning other areas of the vehicle contaminated by
failure of the component (e.g. coolant sprayed
inside the engine compartment). Labor operations that require more than one technician are
adjusted to represent the total time for all technicians.
The warranty reimbursement for the labor operations can be calculated when used in conjunction
with the IMPCO Policy & Procedures Manual.
The labor times published in this Guide identify
labor operations and labor times required to perform a repair, replacement and/or adjustment
operation. These times represent those of an average technician in a typical dealership using
standard hand tools, equipment and some Special Service Tools. They are not intended to be
used as retail labor rates.
GLOSSARY OF TERMS
OPERATION DESCRIPTION
The Operation Description identifies the repair to
be performed and may include sub-headings
such as: ADD conditions, NOTES, INCLUDES
and other information. This information is essential for both the technician and warranty claim
processing personnel to properly complete a
warranty claim for accurate cost recovery.
Each failed or causal part must be coded to identify the manufacturers defect of the part as
accurately as possible (see Trouble Code chart).
The code selected by the repairing technician
identifies the manufacturers defect and/or workmanship condition qualifying the repair for
warranty coverage.
ADD CONDITIONS
Add Conditions may be required to complete or
supplement a labor operation and are included in
the Add sections under the Labor Operation Description. If an ADD is performed, the allowed
300
REPLACE
REPAIR DIAGNOSIS
R&R OR REPLACE
R&R refers to a part or assembly that is removed
and re-installed after the part has been aligned,
adjusted, repaired as a separate operation or
removed for a sublet repair. Replace means the
part or assembly can be replaced with a new (or
exchanged) part or assembly (see the Replace
paragraph above).
INCLUDES
The INCLUDES which follow some of the Labor
Descriptions are provided to assist in determining
whether or not certain items or functions are included within the operation (these are not all
encompassing to simplify the use of this Guide).
Examples include:
OVERLAPPING LABOR
Overlapping labor is labor time is where two operations include the same repair steps.
Overlapping time is not compensated; therefore,
the repeated labor time must be deducted from
the second labor operation so that the total time
entered is less than the sum of the combined labor times.
DUPLICATE LABOR
SYMPTOM DIAGNOSIS
Symptom Diagnosis is the process used to determine the source of the problem and is the
responsibility of both the technician and dealership management.
Symptom Diagnosis is
STRAIGHT TIME
Straight Time is applicable only when a labor operation is required and no labor operation
description or operation number exists in this
Guide. All Straight Time is governed by Policy
A and is subject to review and approval by
IMPCO before payment is reimbursed. Precise
301
labor step documentation indexed to time is required and must be recorded on the shop repair
order to identify and justify this expense. Prior
approval may be obtained by contacting IMPCO
Technical Assistance 1-866-473-2851.
POLICY CODES
Certain IMPCO Policy Codes apply to the Generic Labor Operations listed on page 7. Policy
codes and descriptions are:
Policy A Is subject to review by IMPCO before reimbursement.
Policy B Will require approval from IMPCO
before expense is incurred
Policy S Sublet of work to a facility outside
the normal OEM dealer network, and requires
approval from IMPCO prior to incurring the expense
All prior approvals may be obtained by contacting
IMPCO Technical Assistance at 1-866-473-2851.
TECHNICAL ASSISTANCE
Service technicians must call the OEM Technical
Assistance whenever extensive diagnosis or repair advice is required, or to verify a vehicles
warranty.
OEM Technical Assistance personnel must contact IMPCO Technical Service personnel to
obtain authorization for those repairs or additional labor that require prior authorization for
warranty compensation. IMPCO Technical Assistance may be contacted at (1-866-473-2851)
between the hours of 8:00 a.m. and 5:00 p.m.
Pacific Time Monday through Friday except holidays.
302
TIME
ALLOWED
E0050
0.8
E0057
0.3
E1015
0.9
E2015
1.5
J4226
0.4
J4227
0.7
J4207
0.3
COIL, IGNITIONREPLACEMENT
J4340
0.6
E3037
0.4
M1007
0.3
M0075
0.8
THROTTLE BODY/GASKETREPLACEMENT
E3012
0.8
J4360
0.2
J4380
0.2
J4530
0.8
303
TIME
ALLOWED
J4590
0.5
J4591
0.6
CAMSHAFT SENSOR-REPLACEMENT
E3019
0.6
J4592
0.7
F1015
0.7
E3002
0.5
N1002
0.8
304
OPERATION
NUMBER
TIME
ALLOWED
M1001
0.8
PRESSURE REGULATOR-REPLACEMENT
INCLUDES: Transfer of all fittings
PRESSURE REGULATOR REPAIR (SEE M1001 FOR REPLACEMENT)
0.9
E3005
0.3
E3041
0.5
E3042
0.3
E3052
0.3
E3009
0.5
1.0
E3044
0.2
0.1
0.1
E3046
0.3
G0004
0.2
M1006
0.3
F1003
0.8
305
TIME
ALLOWED
CATALYTIC CONVERTERREPLACEMENT
N1001
5.0
E3017
0.3
OPERATION
NUMBER
TIME
ALLOWED
T1001
0.7
E3047
0.3
E3048
0.4
E3049
0.2
Hoses
LABOR OPERATION DESCRIPTION
COOLANT HOSESREPLACE ALL
INCLUDES: Drain & Fill Radiator
COOLANT HOSE PORT FITTING-REPLACE
FUEL VAPOR HOSEREPLACE ALL
INCLUDES: Replacement of Vapor Hose Port Fittings
FUEL VAPOR HOSE PORT-FITTING-REPLACE
VACUUM LINE-REPLACE ONE
0.4
T1002
0.1
E3050
306
0.3
TIME
ALLOWED
J3480
0.7
STARTERREPLACEMENT
J4560
0.6
ALTERNATORREPLACEMENT
J4570
0.5
DRIVE BELTREPLACEMENT
J4571
0.5
J4580
0.4
FLYWHEEL/HARMONIC BALANCERREPLACEMENT
J0720
0.5
307
TIME
ALLOWED
J0210
1.0
J0108
1.0
J0308
0.3
ROCKER ARMREPLACEMENT
Includes: R&R intake manifold and rocker cover(s).
ADD: Replace all rocker arms:
J0358
J0388
0.5
0.3
J0508
2.3
CYLINDER HEAD-REPLACEMENT
Includes: R&R intake manifold, rocker cover(s) and compression test.
J0518
3.0
J0528
2.9
0.4
0.9
0.2
0.4
0.3
VALVERECONDITION OR REPLACEMENT
ADD: Each additional cylinder
ADD: To recondition all valves
ADD: To ream and fit guides for oversize stems
2.5
J0548
J0588
J0628
0.3
0.9
0.8
0.2
308
0.9
0.3
TIME
ALLOWED
J0750
0.7
J0780
2.0
TIMING CHAINREPLACEMENT
1.6
J0820
0.2
3.9
J0840
0.2
CAMSHAFTREPLACEMENT
J0850
6.0
J1000
2.2
J1020
2.5
J1120
2.8
4.1
J1200
309
0.5
1.2
0.3
1.2
OPERATION
NUMBER
TIME
ALLOWED
2.9
J1180
0.4
2.0
3.3
0.4
2.2
J1308
0.3
1.2
0.4
2.4
PLUG, EXPANSIONREPLACEMENT
Note: Use appropriate labor operation(s) for removal of necessary
component(s) to gain access to plug
J1600
0.3
J1640
0.3
310
OPERATION
NUMBER
TIME
ALLOWED
9.0
J1800
ENGINE, PARTIALREPLACEMENT
Includes: R& R all components, fluids and accessories
ADD: To recondition all valves and guides
J1820
ENGINE, ASSEMBLYREPLACEMENT
Includes: R&R all components, fluids and accessories
J1880
3.5
J1506
0.3
311
2.6
7.2
2.6
MISCELLANEOUS
OPERATION
NUMBER
TIME
ALLOWED
G0001
Policy B
0.5
G0003
0.1
DRIVE TESTS
G0006
0.2
G0007
Policy S
0.0
312
Design change in other components that affect the accessibility to the repaired component.
Final review and verification of times after receiving a Request for Review form.
Questions and/or suggestions regarding labor operations or time allowances in the Labor Time Guide
must be submitted on a Request for Review form. This form is the last page of this guide.
A properly completed form will provide IMPCO detailed information identifying the technicians difficulties
in performing a labor operation within the published labor time allowance. When completing this form, it
is important that all vehicle identification data affecting or influencing the operation in question be provided.
OEM RESPONSIBILITIES
Your request for review must include a detailed, step by step description of your labor procedure in the
space provided. This will allow IMPCO to both understand your concern and potential cause(s) for the
variance between your actual time and the published labor time.
When submitting a Request for Review, the following steps are required:
Verify that the technician has followed Service Manual Supplement procedure and utilized all necessary equipment and is properly trained.
Use one form for each labor allowance in question (or combination of standards representing one repair job).
Provide specific performance time for two repairs performed by the same technician to assist in determining average time.
Provide comments that may help in identifying the problem area including individual step times.
IMPCO RESPONSIBILITIES
Upon receipt of the Request for Review form, IMPCO will review the procedure and consider changing
the labor time. Changes in a labor time will appear as a Warranty Bulletin or the next revision of the Labor Time Guide.
313
314
State:
Telephone Number (
Zip Code
OPERATION NUMBER
Fax Number: (
CURRENT PUBLISHED
TIME
SUGGESTED TIME
VEHICLE INFORMATION:
Model Year
Mileage
Model Line
SERIAL#
Engine
TECHNICIAN INFORMATION:
Technicians Name
Are you certified in this area of repair?
Yes
No
Once
Yes
Twice
No
How many?
Describe the inaccuracy:
Yes
No
315
Labor Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
316
Watch Time
(Min/Sec)
Definitions
317
Air Valve Vacuum (AVV): The vacuum signal taken 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 mechanical needle to point to a value on a scale of
numbers. It is usually of the low impedance type
and used to measure voltage and resistance.
Aromatics: Pertaining to or containing the sixcarbon 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 (C6H6). Sometimes 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 compression 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, C4H10 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 colorless.
Carburetor: An apparatus for supplying an internal-combustion engine a mixture of vaporized fuel
and air.
Cathode Ray Tube: A vacuum tube in which cathode rays usually in the form of a slender beam
are projected on a fluorescent screen and produce a luminous spot.
Circuit: A path of conductors through which electricity flows.
Closed Loop Operation: Applies to systems utilizing an oxygen sensor. In this mode of operation,
the system uses oxygen sensor information to determine air/fuel ratio. Adjustments are made
accordingly and checked by comparing the new
oxygen sensor to previous signals. No stored information is used.
318
319
320
321
322
Appendix
323
Kilopascals
(kpa)
56-64
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
96-104
13.9-15.0
-1,000
101-105
14.6-15.2
324
1-6-5-4-3-2
11 lb ft (15 Nm)
325
Degrees C.
Ohms10%
302
150
47
284
140
60
266
130
77
248
120
100
230
110
132
212
100
177
194
90
241
176
80
332
158
70
467
140
60
667
122
50
973
113
45
1188
104
40
1459
95
35
1802
86
30
2238
77
25
2796
68
20
3520
59
15
4450
50
10
5670
41
7280
32
9420
23
-5
12300
14
-10
16180
-15
21450
-4
-20
28680
-22
-30
52700
-40
-40
100700
326
327