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Impco HHI, Service Manual

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57

GASOLINE MULTIPORT FUEL INJECTION 
SYSTEM (MFI)

The primary components of the Gasoline Multiport 
Fuel Injection (MFI) fuel system are the gasoline 
fuel tank, electric fuel pump, fuel 

filter, fuel rails, 

fuel pressure regulator, fuel injectors, O2 sensors, 
engine control module and a catalytic converter.

GASOLINE FUEL STORAGE TANK 

The gasoline fuel storage tank location may vary on 
equipment applications.  The fuel tank may be inte-
grated into the chassis frame or may be a 
standalone vessel mounted on the equipment.  For 
precise location for the equipment application refer 
to the OEMs vehicle manual.

GASOLINE FUEL PUMP 

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

The fuel pump is an emission control com-
ponent. If the fuel pump fails to operate, 
replace only with an OEM replacement part.  
The fuel pump is calibrated to supply the 
correct amount of fuel to the injectors. Re-
placing the pump with anything other than 
the recommended OEM replacement pump 
could cause damage to the fuel system 
and/or fuel tank.

FUEL FILTER

The fuel is drawn into the fuel pump and then 
through the fuel 

filter to trap and remove small pa

r-

ticles and prevent injectors from becoming 
damaged.  Maintenance of the fuel 

filter is required 

as indicated in the Recommended Maintenance 
Schedule. A more frequent replacement of the 

filter 

may be required if the equipment operates in a dus-
ty or dirty environment.

FUEL METERING BODY AND PRESSURE 
REGULATOR 

The gas 

flows from the fuel filter to the fuel

pres-

sure regulator block.  Regulated fuel is then sent to 
the fuel inlet pipe and through the fuel metering 
body to the injectors.  Excess fuel is returned to the 
fuel tank for recirculation.  The fuel pressure regula-
tor has no adjustments and is integrated into the 
fuel block assembly.  The fuel inlet pipe contains a 
Schrader valve which is utilized to test the regu-
lated pressure of the fuel system

.

FUEL INJECTOR

Gasoline Fuel Injector

The fuel pressure is maintained on the top of the 
injector by the fuel pressure regulator.  The injector 
is fed a “pulse” signal through the wire harness 
which causes the injector to open.  The ECM con-
trols the opening and duration of the injector.  
During lower RPM operation the injector signals or 
“pulses” are shorter than when the engine is oper-
ating at higher rpms.  The certi

fied engine has been 

calibrated to deliver the precise amount of fuel for 
optimum performance and emission control.

THROTTLE CONTROL DEVICE—DRIVE BY 
WIRE

Drive By Wire Engine speed control is maintained 
by the amount of pressure applied to the foot pedal 
located in the engine compartment. In a Drive By 

Summary of Contents for HHI

Page 1: ...2007 2009 LPG Bi 2 0L Service Manual HHI 2009 Emission Certified Bi Fuel System 2 0L Engine Service Manual Revision A June 2009 Emission Certified System Service Manual...

Page 2: ...stic Trouble Codes DTCs Application schematic and DTC specific code information Table of Contents of this Service Manual General maintenance and maintenance interval information An overview of the LPG...

Page 3: ...rvicing the Fuel System Step by step instructions on how repair and or replace fuel related components Definitions of phrases and acronyms used throughout this Service Manual Definitions of phrases an...

Page 4: ...4...

Page 5: ...5 General Information...

Page 6: ...hnologies Inc emission warranty only work performed by IMPCO or OEM trained technicians using only IMPCO speci fied parts will qualify for reimbursement Refer to the IMPCO Labor Time Guide for ad diti...

Page 7: ...njury Do not allow LPG to contact the skin LPG is stored in the fuel tank as a liq uid When LPG contacts the atmosphere it immediately expands into a gas resulting in a refrigeration effect that can c...

Page 8: ...equired to perform the ne cessary procedures to safely remove and replace a failed component The installed IMPCO fuel system has been certified with the Environmental Pro tection Agency EPA and the Ca...

Page 9: ...ways 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...

Page 10: ...10...

Page 11: ...11 Maintenance...

Page 12: ...l based anti freeze or plain water are not recommended for use in the cooling system at anytime SERPENTINE BELT SYSTEM Serpentine belts utilize a spring loaded tensioner to keep the belt properly adju...

Page 13: ...arness connectors are cor rectly locked in by pushing in and then pulling the connector halves outward Inspect primary ignition coil wires for harden ing cracking arcing chafing burning separation spl...

Page 14: ...ve cover 7 Add the required amount of oil to bring the level up to but not over the FULL mark on the dipstick Reinstall the oil ller cap to the valve rocker arm cover and wipe any excess oil clean CHA...

Page 15: ...engine utilizes an in line replaceable fuel lter element This element should be replaced at the intervals speci ed in the recommended maintenance sche dule When inspecting the fuel lter check the foll...

Page 16: ...drained at every engine oil change if contaminated or subs tandard fuel is suspected or known to have been used or in use with the emission complaint fuel system This is known as special maintenance...

Page 17: ...Verify Throttle Body return action to ensure throttle shaft is not sticking Repair if neces sary Check for leaks at the Throttle Body and in take manifold EXHAUST SYSTEM AND CATALYTIC CONVERTER INSPE...

Page 18: ...ty environments Replace PCV Valve X Replace inline LPG fuel filter X X X X X Check LPG shut off solenoid valve function X X Replace fuel filter Bi fuel only X X X X X Inspect Shut off Valve for leaks...

Page 19: ...19 LPG Fuel System...

Page 20: ...20 LPG FUEL SYSTEM OPERATION...

Page 21: ...rning the handle to its open position fuel ows out of the tank and into the service line The service valve is also equipped with a safety feature called an excess ow check valve This feature reduces t...

Page 22: ...ontrol module ECM ELECTRONIC PRESSURE REGULATOR EPR The EPR is a combination vaporizer and pressure regulating device The EPR functions as a nega tive pressure two stage regulator that is normally clo...

Page 23: ...w speed mixture adjustment retained in a tamper proof housing The mixer has been preset at the factory and should not require adjustment In the event that the idle adjustment should need to be adjuste...

Page 24: ...nti ed by a Diagnostic Trouble Code DTC number In addi tion to notifying the operator of the malfunction in the system the controller also stores the informa tion about the malfunction in its memory A...

Page 25: ...atmospheric pressure The ECM monitors the resistance of the sensor to determine engine load the vacuum drops when the engine is under load or at wide open throttle When the engine is under load the co...

Page 26: ...a closed loop emission system OIL PRESSURE SENDER SWITCH The Oil Pressure Switch is Mounted on the side of the Engine Block The Engine Oil Pressure switch or sender is de signed to ensure adequate lub...

Page 27: ...27 LPG Closed Loop Schematic...

Page 28: ...28...

Page 29: ...29 LPG System Diagnosis...

Page 30: ...ately negative 38 1 mm 1 5 of water column when vacuum from the engine draws in fuel The fuel is then drawn in from the secondary chamber of the EPR by the vacuum generated by air owing through the Mi...

Page 31: ...ESSURE GAUGES 0 10 Water Column Gauge 0 10 PSI Gauge TEST DESCRIPTION The numbers below refer to step numbers on the Diagnostic Table 1 This step checks the base mechanical EPR output pressure by disa...

Page 32: ...assembly and all intake duct ing between intake manifold and air cleaner Check air cleaner and all vehicle intake ducting for restric tions Check exhaust system for flow obstructions or leaks Check th...

Page 33: ...Remove the spark plugs and check for the following Correct plug type for LPG application Wet electrodes oil fouling Cracks Wear Improper gap Burned electrodes Heavy deposits Were any faulty condition...

Page 34: ...the MIL With the engine idling observe the pressure reading on the secondary pressure test port gauge Is the pressure reading within specifications 1 0 to 2 0 WC Go to Step 15 Go to Step 13 12 Turn O...

Page 35: ...vehicle to original condition Operate the vehicle under all load and driving conditions for at least 10 minutes Park the vehicle with the engine running and connect the DST to the vehicle s DLC conne...

Page 36: ...nd mixer gaskets or o rings for leaks All vacuum hoses and fittings for leaks Exhaust system for leaks NOTE Exhaust system leaks allow for excess O2 to dilute the HEGO sensors giving a false reading E...

Page 37: ...orrection 3 Raise the engine speed to approximately 2500 rpm Is the Adaptive 1 fuel correction within the specified range at idle and 2500 rpms 15 to 15 Go to Step 9 Go to Step 6 6 1 Check all vacuum...

Page 38: ...38...

Page 39: ...39 LPG Symptom Diagnostics...

Page 40: ...ting correctly at that time 5 Take a data snapshot using the DST under the condition that the symptom occurs to review at a later time Visual and Physical Checks Check all ECM system fuses and circuit...

Page 41: ...eable See section Wiring Schematics Checking for poor terminal to wire connections requires removing the terminal from the connector body Operational Test If a visual and physical check does not locat...

Page 42: ...ake system leakage between the mixer and the throttle body Verify proper operation of the low pressure lock off solenoids Verify proper operation of the fuel control solenoids Check the fuel system pr...

Page 43: ...g Low compression Improper valve clearance Worn rocker arms Broken or weak valve springs Worn camshaft lobes Exhaust System Checks Check the exhaust system for a possible restriction Inspect the exhau...

Page 44: ...lve is not tripped or that the LPG tank valve is not closed Check mixer assembly for proper installation and leakage Verify proper operation of the low pressure lock off solenoid Verify proper operati...

Page 45: ...per valve clearance Worn rocker arms Broken or weak valve springs Worn camshaft lobes Check the intake and exhaust manifolds for casting ash Exhaust System Checks Check the exhaust system for a possib...

Page 46: ...he following Ignition wires for arcing and proper routing Cross ring Primary ignition coil wires for cracks or carbon tracking Engine Mechanical Checks Perform a cylinder compression check Check the e...

Page 47: ...racy Check Shut Off electrical connection Check the mixer air valve for sticking or binding Check the mixer assembly for proper installation and leakage Check the EPR Ignition System Checks Note LPG b...

Page 48: ...wire in question If the meter reads over 30 000 ohms replace the wires Check the connection at primary ignition coil wire Check for deteriorated spark plug wire insulation Remove the plugs and inspec...

Page 49: ...roper installation Check for fuel leaks between the EPR and the mixer Verify that the LPG tank valve is fully open Verify that liquid fuel not vapor is being delivered to the EPR Sensor Checks Check t...

Page 50: ...eck the fuel economy and or suggest that a different operator use the equipment and record the results Fuel System Checks Check the EPR fuel pressure Refer to LPG Fuel System Diagnosis Check the fuel...

Page 51: ...EPR Perform a cylinder compression test Refer to Engine Mechanical in the Service Manual Check the EPR fuel pressure Refer to the LPG Fuel System Diagnosis Check mixer assembly for proper installatio...

Page 52: ...RECT IDLE STALLING Checks Action Engine Mechanical Check Check the engine for Broken motor mounts Improper valve timing Low compression Improper valve clearance Worn rocker arms Broken or weak valve s...

Page 53: ...ion exists Refer to LPG Fuel System Diagnosis Verify proper fuel control solenoid operation Verify that the LPG tank valve is fully open Check the in line fuel lter for restrictions Ignition System Ch...

Page 54: ...54...

Page 55: ...55 Gasoline Fuel System...

Page 56: ...56 GAS FUEL SYSTEM OPERATION...

Page 57: ...fuel tank FUEL FILTER The fuel is drawn into the fuel pump and then through the fuel lter to trap and remove small par ticles and prevent injectors from becoming damaged Maintenance of the fuel lter...

Page 58: ...s system which is designed and calibrated to meet the emission standards in effect for 2007 2009 The exhaust gases pass through the honeycomb catalyst which is coated with a mixture of metals such as...

Page 59: ...the mixture If the ECM determines that a rich or lean condition is present for an extended period of time which cannot be corrected the ECM will set a diagnostic code and turn on the MIL light in the...

Page 60: ...at when the air is cool the signal reads a higher voltage and lower when warm On cold starts the ECM richens the fuel air mixture COOLANT TEMPERATURE SENSOR The Engine Coolant Temperature sensor or EC...

Page 61: ...61 Gasoline Closed Loop Control Schematic...

Page 62: ...62...

Page 63: ...63 Gasoline System Diagnosis...

Page 64: ...lower than at mospheric pressure which creates a high vacuum This vacuum will offset the pressure regulator diaphragm resulting in a lower fuel pressure Fuel pressure at idle will vary some what depe...

Page 65: ...dition and may set a DTC Drivability conditions can include hard starting when cold hesitation and lack of power or mis re 15 Restricting the fuel return pipe may cause the fuel pressure to build abov...

Page 66: ...NOT start the engine Command the fuel pump ON with the DST or fuel pump test circuit Observe the fuel pressure gage with the fuel pump commanded ON Is the fuel pressure within the specified range TBD...

Page 67: ...he fuel pressure remain constant Go to Step 17 Go to Step 9 9 Turn OFF the ignition Open the fuel feed pipe shut off valve Turn ON the ignition with the engine OFF Command the fuel pump relay ON and t...

Page 68: ...el pump test circuit Slowly close the valve in the fuel return pipe shut off adapter while the fuel pump is oper ating Does the fuel pressure increase to more than the specified value TBD kPa TBD psi...

Page 69: ...uel tank Did you complete the repair Go to Step 23 21 Inspect for a missing or damaged O ring seal before replacing the fuel pressure regulator If the O ring seal is not missing or damaged replace the...

Page 70: ...70...

Page 71: ...71 Gasoline Symptom Diagnostics...

Page 72: ...sed loop and operating cor rectly at that time 5 Use the DST to take a snapshot under the condition that the symptom occurs Go to Engine Scan Tool Data List to verify normal sensor values and paramete...

Page 73: ...ction Wiring Schematics Checking for poor terminal to wire connections requires removing the terminal from the connector body Operational Test If a visual and physical check does not locate the cause...

Page 74: ...Fuel System Diagnosis Ignition System Checks Check for the proper ignition voltage output with J 26792 or the equiva lent Verify that the spark plugs are the correct type and properly gapped Check the...

Page 75: ...ctrical circuit Verify proper fuel pump pressure Verify proper fuel rail pressure Check the in line fuel lter for restrictions Refer to the Gasoline Fuel System Diagnosis Ignition System Checks Check...

Page 76: ...t system for a possible restriction Inspect the exhaust system for damaged or collapsed pipes Inspect the muffler for signs of heat distress or for possible internal failure Check for possible plugged...

Page 77: ...y inspect the secondary ignition for the following Ignition wires for arcing and proper routing Cross ring Primary ignition coil wires for cracks or carbon tracking Engine Mechanical Checks Perform a...

Page 78: ...ine Fuel System Diagnosis Check electrical connections of fuel injectors Ignition System Checks Check for the proper ignition voltage output with J 26792 or the equiva lent Remove Spark Plugs Verify t...

Page 79: ...the wires Check the connection at primary ignition coil wire Check for deteriorated spark plug wire insulation Check the spark plugs Remove the plugs and inspect them for the following conditions Wet...

Page 80: ...eck the Heated Exhaust Gas Oxygen Sensor HEGO for contamina tion and performance Check for proper operation of the MAP sensor Check for proper operation of the TPS and FPP sensors Exhaust System Check...

Page 81: ...el tank and to recheck the fuel econo my and or suggest that a different operator use the equipment and record the results Fuel System Checks Refer to Gas Fuel System Diagnosis Check the fuel system f...

Page 82: ...ine fuel lter for restrictions Refer to the Gas Fuel System Diagnosis Ignition System Checks Check for the proper ignition output voltage using the spark tester J26792 or the equivalent Remove the plu...

Page 83: ...oblem Check the fuel pressure while the condition exists Refer to Gas Fuel System Diagnosis Check the in line fuel lter for restrictions Ignition System Checks Check for the proper ignition output vol...

Page 84: ...84...

Page 85: ...85 Electrical Section...

Page 86: ...86...

Page 87: ...87 Diagnostic Scan Tool...

Page 88: ...es and descriptions of parts and servicing procedures will be updated based on trade brand or common description to more accurately describe the part or service pro cedure DST INSTALLATION INSTRUCTION...

Page 89: ...89 Open the DST_Series III folder Open the Latest_GCP_Display folder...

Page 90: ...e to start the windows installer If a previous version of the GCP software is installed the uninstaller may remove the previous version and exit You will be required to start the installer again to in...

Page 91: ...91 Click Next to continue Click Next to continue...

Page 92: ...92 Click the Finish box to complete the installation Click Yes to restart your computer...

Page 93: ...93 Once installed the software can be accessed from Start Menu Programs Impco GCP Display Impco GCP Display...

Page 94: ...ADAPTER DRIVER If your computer does not have an RS232 serial port you will need to install the USB adapter driver You do not need to install this driver if you plan to use the ECOM DLC cable Open the...

Page 95: ...iver The ECOM USB cable is designed to replace both the serial DLC and the USB adapter cables It also provides communication to the ECM on the CAN line for systems that are CAN enabled It requires the...

Page 96: ...96 Double click on setup exe application file Click Next to continue...

Page 97: ...97 Select install ECOM drivers only Click Next and follow the on screen prompts...

Page 98: ...serial number and permits authorized service personnel to make changes or view information for a specific ECM 3 In most instances the top all serial number boxes should be used for password entry In t...

Page 99: ...number for which the Single Serial Number Access password applies NOTE Leading zeros included in the serial number are not required Save Password and S N Checkbox Retains the password and serial numb...

Page 100: ...ftware will load but will not connect to the target ECM Figure 4 Not Authorized to Connect Message In the event you receive this error message call your OEM support group for more information CONNECTI...

Page 101: ...l sche matic The DLC is located on the engine harness The new 8 pin DLC requires the use of the 4 to 8 pin adapter included in the late model ITK test kits Turn the computer ON Start Windows From the...

Page 102: ...You will now need to configure the ECOM communication protocol Select the CAN for systems with CAN enabled or serial for all others Then select OK You are now ready to connect using the ECOM USB DLC c...

Page 103: ...103 DST SERVICE PAGES Gauge Page Provides system data in large easy to read displays Displays ECM configuration information for the ECM software hardware serial numbers and calibration dates...

Page 104: ...104 Raw Volts Page The raw volts page displays the sensor inputs and outputs in a raw voltage format This page is most commonly used to check values in the diagnostic trouble shooting charts Service 1...

Page 105: ...ttle command will lock into the position it was in when the test mode was entered If the Spark System Test mode is selected with the engine running above 1000 rpm the throttle will continue to operate...

Page 106: ...DBW Drive by Wire test mode allows the technician to control the throttle directly with the foot pedal or throttle input and is used during the diagnostic routines specified for FPP and TPS for Spec t...

Page 107: ...er to graphically plot or numerically log variables that have been tagged for plotting logging To plot or log variables a tag must be assigned to each variable of interest A variable is tagged for plo...

Page 108: ...8 Figure 5 Tagged Variables for Plot Log Once the variables have been tagged as highlighted by the green color fill select the Plot Log func tion in the top menu bar as shown below in figure 6 Figure...

Page 109: ...o a snapshot that may be panned zoomed scrolled and saved Close Button Close the DST Plot interface Load Setup Button Load tags from a previously saved plot plt file to allow for similar plots and log...

Page 110: ...110 Figure 7 DST Plot Click on the Start button to start the DST plot function Click on the variable selector button to view selected sensors Variable selector Start plot...

Page 111: ...111 Figure 8 DST Plot Snapshot Click on the Save button to save the snapshot as a file To replay the saved file open the edis_saplot program from the windows start menu...

Page 112: ...T KEY FUNCTIONS Command Function Single left click on trace Snap closest cursor to data Ctrl Up Down Arrows Move pan plot along y axis Ctrl Left Right Arrows Move pan plot along t axis Ctrl Shift Up D...

Page 113: ...t file may then be viewed by any standard Windows text editor reader program To create a log file select the Log Tags in the drop down menu as shown in figure 6 Figure 9 DST Log Interface REPROGRAMMIN...

Page 114: ...nnected to the ECM From the File menu select Reprogram target Navigate to the media where you have stored the MOT file In the example above the MOT file was stored on the on the floppy A drive Highlig...

Page 115: ...her functions on the computer while the download takes place Do not disconnect the DLC remove power or use the PC for any other func tion during this process Any interruption during this reprogram pro...

Page 116: ...116 Message is displayed confirming the update was successful...

Page 117: ...to fail the test the lamp will stay illuminated and the DTC is stored as an active DTC If the self test runs and passes the DTC will be stored as historic DTC All DTCs are stored as historic faults u...

Page 118: ...n follow the DTC diagnostic chart rec ommendations for that specific DTC BLINK CODE FUNCTION Although the DST is considered a required tool to access the DTC codes codes may be retrieved with out a la...

Page 119: ...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...

Page 120: ...120...

Page 121: ...121 Engine Wire Schematic...

Page 122: ...122 HHI 2007 2009 Emission Certified LPG Bi Fuel System 2 0L Engine...

Page 123: ...MP 776286 1 Gold Pin 16 Manifold Assy Female 4P AMP 368162 1 17 Injector 1 Female 2P KET MG641152 KUM PU465 02127 18 Injector 2 Female 2P KET MG641152 KUM PU465 02127 19 Injector 3 Female 2P KET MG641...

Page 124: ...124...

Page 125: ...125 Engine Wire Harness Repair...

Page 126: ...xible connectors used to probe terminals during diagnosis Fuse remover and test tool BT 8616 or equivalent is used for re moving a fuse and to adapt fuse holder with a meter for diagnosis Do not solde...

Page 127: ...wire is inserted through the seal and connector the terminal is crimped on the wire and then pulled back into the connector to seat it in place Metri Pack Series 150 Terminal Removal 1 Slide the seal...

Page 128: ...n ordinary pick there is a good chance that the terminal will be bent or deformed Unlike standard blade type terminals these terminals cannot be straigh tened once they are bent Verify that the connec...

Page 129: ...129 Diagnostic Trouble Codes DTCs...

Page 130: ...onization MIL Command ON Circuit Description The Crankshaft position sensor is a 5 volt powered sensor mounted in the engine block A pulse wheel located on the crankshaft is used to measure engine rpm...

Page 131: ...CM connector CN1 Using a DVOM check for continuity on the crank signal circuit 125 between CKP con nector CN9 and ECM connector CN1 Do you have continuity between them Go to Step 5 Repair the circuit...

Page 132: ...After operating the engine within the test pa rameters of DTC 16 check for any stored codes Does the engine operate normally with no stored codes System OK Go to Step 9 11 Remove all test equipment e...

Page 133: ...133...

Page 134: ...re and pressure sensor located in the gasoline delivery system that provides accurate gasoline supply information to the ECM It is used to measure the temperature and pressure of the supplied fuel Thi...

Page 135: ...0 volts Go to Step 4 Go to Step 6 4 Check wire harness and FRP sensor con nector for damage corrosion or contamination Any problems found Repair the circuit as ne cessary See wire harness repair sec t...

Page 136: ...n or contami nation Any problems found Repair the circuit as ne cessary See wire harness repair sec tion Go to Step 10 10 Replace the ECM Is the replacement complete Go to Step 11 11 Remove all test e...

Page 137: ...137...

Page 138: ...ption The Manifold Absolute Pressure sensor is a pressure transducer connected to the intake mani fold It is used to measure the pressure of air in the intake manifold This reading is used in conjunct...

Page 139: ...4 50 volts or greater Go to Step 4 Go to Step 8 4 Inspect MAP connector and pins for cor rosion contamination or mechanical damage Any problems found Repair the circuit as necessary Refer to Wir ing R...

Page 140: ...sary Refer to Wir ing Repairs in Engine Electrical 10 Check for continuity between MAP sensor connector CN4 5 volt reference circuit 119 and engine ground Do you have continuity Repair the circuit as...

Page 141: ...Replace ECM Refer to ECM replacement in the Engine Controls Section Is the replacement complete Go to Step 18 17 Replace MAP sensor Is the replacement complete Go to Step 18 18 Remove all test equipm...

Page 142: ...lute Pressure sensor is a pressure transducer connected to the intake mani fold It is used to measure the pressure of air in the intake manifold This reading is used in conjunction with other inputs t...

Page 143: ...ector CN4 Key ON Does the DST display MAP pressure less than 0 05 psia Go to Step 4 Go to Step 6 4 Probe MAP connector CN4 ground circuit 120 with a test light connected to battery vol tage Does the t...

Page 144: ...11 10 Correct MAP mechanical connection Has the MAP mechanical connection problem been corrected Go to Step 11 11 Remove all test equipment except the DST Connect any disconnected components fus es e...

Page 145: ...145...

Page 146: ...ut in conjunction with other sensors is used to determine the airflow to the engine The ECM provides a voltage di vider circuit so that when the air is cool the signal reads higher voltage and lower w...

Page 147: ...f high inlet air temperature is a problem with the inlet air system Ensure that the air inlet is not obstructed modified or damaged Inspect the air inlet system for cracks or breaks that may allow unw...

Page 148: ...ature sensitive resistor is used in the TMAP located in the intake manifold of the engine It is used to monitor incoming air temperature and the output in conjunction with other sensors is used to det...

Page 149: ...4 90 volts or greater Go to Step 4 Go to Step 5 4 Replace TMAP sensor Is the replacement complete Go to Step 9 5 Key OFF Disconnect ECM wire harness connector CN1 Check for continuity between TMAP se...

Page 150: ...nts fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe...

Page 151: ...151...

Page 152: ...re sensitive resistor is used in the TMAP located in the intake manifold of the engine It is used to monitor incoming air temperature and the output in conjunction with other sensors is used to determ...

Page 153: ...N4 signal circuit 136 to engine ground Key ON Does DST display IAT voltage of 0 10 volts or less 0 10 volts or less Go to Step 7 Go to Step 6 5 Replace TMAP sensor Is the replacement complete Go to St...

Page 154: ...s found Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 8 11 Remove all test equipment except the DST Connect any disconnected components fus es etc Using th...

Page 155: ...155...

Page 156: ...enrichment and to enable other temperature dependant features The ECM provides a voltage divider circuit so that when the coolant is cool the signal reads higher voltage and lower when warm This fault...

Page 157: ...t lines and hoses water pump engine block radiator etc Insure the radiator cap is in good repair and maintaining suitable cooling system pressure Compare the ECM measured temperature value with an ana...

Page 158: ...lculation gasoline cold enrichment and to ena ble other temperature dependant features The ECM provides a voltage divider circuit so that when the coolant is cool the signal reads higher voltage and l...

Page 159: ...oltage of 4 90 volts or greater Go to Step 4 Go to Step 5 4 Replace ECT sensor Is the replacement complete Go to Step 8 5 Key OFF Disconnect ECM wire harness connector CN1 Check for continuity between...

Page 160: ...nts fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe...

Page 161: ...161...

Page 162: ...n gasoline cold enrichment and to enable other temperature dependant features The ECM provides a voltage divider circuit so that when the coolant is cool the signal reads higher voltage and lower when...

Page 163: ...DST and com pare the reading at a known temperature to the chart Is the resistance value correct See resis tance chart vs tempera ture in the DTC 118 circuit de scription Go to Step 6 Go to Step 5 5 R...

Page 164: ...nd 137 for damage corrosion or contamination Did you find a problem Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 11 11 Replace ECM Is the replacement comp...

Page 165: ...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 th...

Page 166: ...e throttle that use variable resistors to deter mine signal voltage based on throttle plate position TPS 1 will read low voltage when closed and TPS 2 will read high voltage when closed The TPS 1 and...

Page 167: ...Step 4 4 Key OFF Disconnect ECM wiring harness connector CN1 Key ON Using a DVOM check for voltage between ECM connector CN1 TPS 1 signal circuit 147 and engine ground Do you have voltage Repair the T...

Page 168: ...in Engine Elec trical 10 Inspect ECM connector terminals for damage corrosion or contamination Any problems found Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to...

Page 169: ...169...

Page 170: ...within the throttle that use variable resistors to deter mine signal voltage based on throttle plate position TPS1 will read lower voltage when closed and TPS2 will read higher voltage when closed Th...

Page 171: ...circuit 119 and TPS 1 signal circuit 147 together at the throt tle connector CN3 Key ON Does DST display TPS 1 voltage of 4 0 volts or greater Go to Step 7 Go to Step 5 5 Key OFF Disconnect ECM wire...

Page 172: ...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 th...

Page 173: ...173...

Page 174: ...used within the throttle that use variable resistors to deter mine signal voltage based on throttle plate position TPS1 will read lower voltage when closed and TPS2 will read higher voltage when close...

Page 175: ...to Step 5 5 Key OFF Disconnect ECM wire harness connector CN1 Key ON Using a DVOM check for voltage between TPS 1 signal circuit 147 at the ECM connec tor CN1 and engine ground Do you have voltage Re...

Page 176: ...Engine Elec trical 11 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 second...

Page 177: ...177...

Page 178: ...ensor A temperature sensitive resistor is used in the TMAP located in the intake manifold of the engine It is used to monitor incoming air temperature and the output in conjunction with other sensors...

Page 179: ...of high inlet air temperature is a problem with the inlet air system Ensure that the air inlet is not obstructed modified or damaged Inspect the air inlet system for cracks or breaks that may allow un...

Page 180: ...Fault Condition BP less than 8 30 psia MIL On for active fault Adaptive Disabled Circuit Description The BP Barometric Pressure is estimated from the TMAP sensor The barometric pressure value is used...

Page 181: ...blems found Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 5 5 Key OFF Disconnect ECM connector CN1 Check for continuity between TMAP sensor connector CN4 c...

Page 182: ...er to Wir ing Repairs in Engine Elec trical Go to Step 11 11 Inspect TMAP and ECM connector pins for corrosion contamination or mechanical damage Any problems found Repair the circuit as ne cessary Re...

Page 183: ...18 17 Replace TMAP sensor Is the replacement complete Go to Step 18 18 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from...

Page 184: ...e Disabled during active fault Closed Loop Disabled during active fault Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen cont...

Page 185: ...sconnect EGO 1 connector CN11 Key ON Using a DVOM check for voltage at the EGO 1 connector CN11 between circuits 812 and 162 Check must be made within 30 seconds or before power relay shuts down Do yo...

Page 186: ...k for continuity on the sensor ground circuit 120 between EGO 1 connector CN5 and ECM connector CN1 Do you have continuity Go to Step 10 Repair open EGO 1 signal ground 10 Replace EGO 1 sensor Is the...

Page 187: ...187...

Page 188: ...sensor cold persistently more than 55 seconds MIL On during active fault Adaptive Disabled during active fault Closed Loop Disabled during active fault Circuit Description The EGO 2 sensor is used to...

Page 189: ...r CN12 circuits 812 and 161 Check must be made within 30 seconds or before power relay shuts down Do you have voltage Go to Step 8 Go To Step 4 4 Key OFF Using a DVOM check for voltage between EGO 2 c...

Page 190: ...ontinuity Go to Step 10 Repair open EGO 2 signal ground 10 Replace EGO 2 sensor Is the replacement complete Go to Step 11 11 Remove all test equipment except the DST Connect any disconnected component...

Page 191: ...191...

Page 192: ...ystem diagnostic checks before using the following diagnostic chart Diagnostic Aid Oxygen Sensor Wire Heated Oxygen sensor wires may be mis routed and contacting the ex haust manifold Vacuum Leaks Vac...

Page 193: ...codes before pro ceeding with this chart Always repair existing codes starting with the lowest numerical code set first Have any other DTC codes been detected diag nosed and repaired Go to Step 9 Go...

Page 194: ...ave continuity Go to Step 8 Repair the open EGO heater ground 8 Replace EGO 1 sensor Is the replacement complete Go to Step 9 9 Remove all test equipment except the DST Connect any disconnected compon...

Page 195: ...195...

Page 196: ...perly High fuel pressure due to a faulty fuel regulator or obstructed fuel return line will cause the system to run rich Ignition noise Open or poor ground circuit to or in the ignition system or ECM...

Page 197: ...rounds for being clean and tight Fuel system diagnostic checks Was a repair made Go to Step 6 Go to Step 4 3 Diagnose any other DTC codes before pro ceeding with this chart Have any other DTC codes be...

Page 198: ...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 th...

Page 199: ...199...

Page 200: ...et of the elec tronic pressure regulator It is used to help determine fuel charge density for accurate fuel mixture control The ECM provides a voltage divider circuit so that when the sensor is cool t...

Page 201: ...display FT voltage of 4 90 volts or greater Go to Step 4 Go to Step 5 4 Replace FT sensor Is the replacement complete Go to Step 8 5 Key OFF Disconnect ECM wire harness connector CN1 Check for continu...

Page 202: ...nents fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Obser...

Page 203: ...203...

Page 204: ...d in the gasoline supply line It is used to help determine fuel charge density for accurate fuel mixture control The ECM provides a voltage divider circuit so that when the sensor is cool the signal r...

Page 205: ...ance be tween the two terminals of the FT sensor and compare the resistance reading to the chart Is the resistance value correct See tem perature vs resistance chart in the DTC 183 schematic page Go t...

Page 206: ...Using a DVOM check for continuity on the sensor ground circuit 120 between fuel tem perature sensor and ECM connector Do you have continuity between them Go to Step 10 Repair the circuit as ne cessar...

Page 207: ...cor rosion or contamination Did you find a problem Repair the cir cuit as necessary Refer to Wiring Repairs in En gine Electrical Go to Step 11 14 Remove all test equipment except the DST Connect any...

Page 208: ...el outlet of the electronic pressure regulator It is used to help determine fuel charge density for accu rate fuel mixture control The ECM provides a voltage divider circuit so that when the sensor is...

Page 209: ...T voltage of 4 90 volts or greater Go to Step 4 Go to Step 5 4 Replace FT sensor Is the replacement complete Go to Step 8 5 Key OFF Disconnect ECM wire harness connector CN1 Check for continuity betwe...

Page 210: ...nents fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Obser...

Page 211: ...211...

Page 212: ...the fuel outlet of the electronic pressure regulator It is used to help determine fuel charge density for accu rate fuel mixture control The ECM provides a voltage divider circuit so that when the se...

Page 213: ...ween the two terminals of the FT sensor and compare the resistance reading to the chart Is the resistance value correct See tem perature vs resistance chart in the DTC 188 schematic page Go to Step 6...

Page 214: ...Using a DVOM check for continuity on the sensor ground circuit 120 between fuel tem perature sensor and ECM connector Do you have continuity between them Go to Step 10 Repair the circuit as ne cessar...

Page 215: ...corrosion or contamination Did you find a problem Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical Go to Step 11 14 Remove all test equipment except the DST Connect any...

Page 216: ...gasoline cold enrichment and to enable other temperature dependant features The ECM provides a voltage divider circuit so that when the coolant is cool the signal reads higher voltage and lower when w...

Page 217: ...lines and hoses water pump engine block radiator etc Insure the radiator cap is in good repair and maintaining suitable cooling system pressure Compare the ECM measured temperature value with an anal...

Page 218: ...for Setting the DTC Max Govern Speed Override Check Condition Engine Running Fault Condition Engine rpm greater than 3900 MIL On during active fault Circuit description This fault will set anytime the...

Page 219: ...the ECM to ensure the correct calibration is in use Is the Service Part Number Correct Go to Step 6 Go to Step 5 5 Replace ECM with correct service part num ber Is the replacement complete Go to Step...

Page 220: ...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 th...

Page 221: ...221...

Page 222: ...gnal voltage based on throttle plate position TPS 1 will read lower voltage when closed and TPS 2 will read higher voltage when closed The TPS 1 and TPS 2 percentages are calcu lated from these voltag...

Page 223: ...o Step 4 4 Key OFF Disconnect ECM wiring harness connector CN1 Key ON Using a DVOM check for voltage between ECM connector TPS 1 signal circuit 148 and engine ground Do you have voltage Repair the TPS...

Page 224: ...airs in Engine Elec trical 10 Inspect ECM connector terminals for damage corrosion or contamination Any problems found Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical G...

Page 225: ...225...

Page 226: ...sed within the throttle that use variable resistors to deter mine signal voltage based on throttle plate position TPS1 will read lower voltage when closed and TPS2 will read higher voltage when closed...

Page 227: ...circuit 119 and TPS 2 signal circuit 148 together at the throt tle connector CN3 Key ON Does DST display TPS 2 voltage of 4 0 volts or greater Go to Step 7 Go to Step 5 5 Key OFF Disconnect ECM wire...

Page 228: ...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 th...

Page 229: ...229...

Page 230: ...thin the throttle that use variable resistors to deter mine signal voltage based on throttle plate position TPS1 will read lower voltage when closed and TPS2 will read higher voltage when closed The T...

Page 231: ...to Step 7 Go to Step 5 5 Key OFF Disconnect ECM wire harness connector CN1 Key ON Using a DVOM check for voltage between electronic throttle connector TPS 2 signal cir cuit 148 and engine ground Do y...

Page 232: ...Elec trical 11 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start...

Page 233: ...233...

Page 234: ...Disabled Circuit Description System battery voltage is supplied to each fuel injector The ECM controls each fuel injector by providing a ground signal to pulse the injector ON This fault will set if t...

Page 235: ...degrees F Does the DVOM display a resistance value of 20 ohms or less 20 ohms or less Go to Step 5 Go to Step 4 4 Replace the Fuel Injector Is the replacement complete Go to Step 8 5 Disconnect the in...

Page 236: ...ST 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 dr...

Page 237: ...237...

Page 238: ...uit Description System battery voltage is supplied to each fuel injector The ECM controls each fuel injector by providing ground to pulse the injector This fault will set if the ECM detects high feedb...

Page 239: ...stance between the fuel injector pins at the fuel metering body at an ambient tem perature of 50 to 90 degrees F Does the DVOM display a resistance value of 5 ohms or more Greater than 5 0 Ohms Go to...

Page 240: ...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 th...

Page 241: ...241...

Page 242: ...Disabled Circuit Description System battery voltage is supplied to each fuel injector The ECM controls each fuel injector by providing a ground signal to pulse the injector ON This fault will set if t...

Page 243: ...degrees F Does the DVOM display a resistance value of 20 ohms or less 20 ohms or less Go to Step 5 Go to Step 4 4 Replace the Fuel Injector Is the replacement complete Go to Step 8 5 Disconnect the in...

Page 244: ...ST 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 dr...

Page 245: ...245...

Page 246: ...uit Description System battery voltage is supplied to each fuel injector The ECM controls each fuel injector by providing ground to pulse the injector This fault will set if the ECM detects high feedb...

Page 247: ...re the resistance between the fuel injector pins at the fuel metering body at an ambient tem perature of 50 to 90 degrees F Does the DVOM display a resistance value of 5 ohms or more Greater than 5 0...

Page 248: ...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 th...

Page 249: ...249...

Page 250: ...Disabled Circuit Description System battery voltage is supplied to each fuel injector The ECM controls each fuel injector by providing a ground signal to pulse the injector ON This fault will set if t...

Page 251: ...t an ambient tem perature of 50 to 90 degrees F Does the DVOM display a resistance value of 20 ohms or less 20 ohms or less Go to Step 5 Go to Step 4 4 Replace the Fuel Injector Is the replacement com...

Page 252: ...ST 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 dr...

Page 253: ...253...

Page 254: ...uit Description System battery voltage is supplied to each fuel injector The ECM controls each fuel injector by providing ground to pulse the injector This fault will set if the ECM detects high feedb...

Page 255: ...stance between the fuel injector pins at the fuel metering body at an ambient tem perature of 50 to 90 degrees F Does the DVOM display a resistance value of 5 ohms or more Greater than 5 0 Ohms Go to...

Page 256: ...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 th...

Page 257: ...257...

Page 258: ...Disabled Circuit Description System battery voltage is supplied to each fuel injector The ECM controls each fuel injector by providing a ground signal to pulse the injector ON This fault will set if t...

Page 259: ...of 50 to 90 degrees F Does the DVOM display a resistance value of 20 ohms or less 20 ohms or less Go to Step 5 Go to Step 4 4 Replace the Fuel Injector Is the replacement complete Go to Step 8 5 Disc...

Page 260: ...ST 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 dr...

Page 261: ...261...

Page 262: ...cuit Description System battery voltage is supplied to each fuel injector The ECM controls each fuel injector by providing ground to pulse the injector This fault will set if the ECM detects high feed...

Page 263: ...stance between the fuel injector pins at the fuel metering body at an ambient tem perature of 50 to 90 degrees F Does the DVOM display a resistance value of 5 ohms or more Greater than 5 0 Ohms Go to...

Page 264: ...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 th...

Page 265: ...265...

Page 266: ...800 ms MIL On during active fault Adaptive Disabled Circuit Description The Crankshaft position sensor is a 5 volt powered sensor mounted to the lower front engine block A pulse wheel located on the c...

Page 267: ...nect ECM connector CN1 Using a DVOM check for continuity between CKP connector circuit 125 and ECM connec tor circuit 125 Do you have continuity between them Go to Step 5 Repair the circuit as ne cess...

Page 268: ...After operating the engine within the test pa rameters of DTC 336 check for any stored codes Does the engine operate normally with no stored codes System OK Go to Step 9 11 Remove all test equipment e...

Page 269: ...269...

Page 270: ...ive Disabled Circuit Description The Crankshaft position sensor is a 5 volt powered sensor mounted to the lower front engine block A pulse wheel located on the crankshaft is used to measure engine rpm...

Page 271: ...to Step 4 Repair the circuit as necessary Refer to Wir ing Repairs in Engine Electrical 4 Key OFF Disconnect ECM connector CN1 Using a DVOM check for continuity on crank signal circuit 125 between CK...

Page 272: ...icle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 337 check for any stored codes Does the eng...

Page 273: ...273...

Page 274: ...r Running Fault Condition 1 invalid cam re sync in 700ms or less Adaptive learn disabled MIL On Circuit Description The CMP Camshaft Position Sensor is used to synchronize the fuel and ignition system...

Page 275: ...CM connector CN1 Using a DVOM check for continuity on the CMP signal circuit 127 between CMP con nector CN2 and ECM connector CN1 Do you have continuity between them Go to Step 5 Repair the circuit as...

Page 276: ...After operating the engine within the test pa rameters of DTC 341 check for any stored codes Does the engine operate normally with no stored codes System OK Go to Step 9 11 Remove all test equipment e...

Page 277: ...277...

Page 278: ...5 cycles with engine speed greater than 1000 rpm MIL On for active fault Adaptive Disabled Circuit Description The CMP Camshaft Position Sensor is used to synchronize the fuel and ignition systems Th...

Page 279: ...u have voltage 5 0 volts Go to Step 4 Repair the circuit as ne cessary Refer to wir ing harness repair sec tion 4 Key OFF Disconnect ECM connector CN1 Using a DVOM check for continuity on the CMP sign...

Page 280: ...e to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC 342 check for any stored codes Does the engine...

Page 281: ...281...

Page 282: ...seconds MIL On Circuit Description The LPG shut off valve is supplied system battery power from the VSW fused source The ECM then provides a path to ground to turn the valve on This fault will set in...

Page 283: ...e until the engine stops THIS MAY TAKE SEVERAL MINUTES Did the engine ever stop Intermittent problem See intermittent problems in the electrical section of this manual Go to Step 4 4 Replace the LPG s...

Page 284: ...the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and drivability After operating the...

Page 285: ...285...

Page 286: ...Disabled during active fault Closed Loop Disabled during active fault Circuit Description The catalyst monitor test is run under certain operating conditions to determine if the catalyst is functionin...

Page 287: ...system for visual signs of damage leaks or modification and repair if necessary Insure the pre catalyst and post catalyst oxygen sensors are mounted correctly and wiring is not damaged melted or corr...

Page 288: ...ommunicate a low oil pressure condition to the ECM En gine damage can occur if the engine is operated with low oil pressure The ECM uses an analog voltage input with an internal voltage reference If t...

Page 289: ...he engine to shut down Go to Step 4 Intermittent problem Go to Inter mittent section 4 Key OFF Disconnect the oil pressure switch harness connector CN8 and ground it to a good en gine ground Clear DTC...

Page 290: ...to Step 9 9 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the...

Page 291: ...291...

Page 292: ...M less than 9 0 MIL On for active fault Adaptive Disabled Circuit Description The battery voltage powers the ECM and must be measured to correctly to properly operate in jector drivers solenoid valves...

Page 293: ...Check charging system Is it OK Go to Step 5 Repair charg ing System 5 Key OFF Disconnect the ECM connector CN1 Using a DVOM check the voltage between ECM connector CN1 circuits 160 and 179 and engine...

Page 294: ...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 th...

Page 295: ...295...

Page 296: ...ve Disabled Circuit Description The battery voltage powers the ECM and must be measured to correctly operate injector driv ers trim valves and ignition coils This fault will set if the ECM detects vol...

Page 297: ...m Is it greater than 16 volts Go to Step 4 Go to Step 5 4 Repair the charging system Has the charging system been repaired Go to Step 6 5 Replace ECM Is the replacement complete Go to Step 6 6 Remove...

Page 298: ...ate level 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex ecuted Several different things can happen within the microprocessor that will...

Page 299: ...K Go to Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Replace ECM Is the replacement complete Go to Step 5 5 Remove all test equipment except the DST Connect...

Page 300: ...2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex ecuted Several different things can happen within the microprocessor that will cause th...

Page 301: ...o Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Replace ECM Is the replacement complete Go to Step 5 5 Remove all test equipment except the DST Connect any d...

Page 302: ...ion The ECM has several internal checks that must be satisfied each time an instruction is ex ecuted Several different things can happen within the microprocessor that will cause this fault The ECM wi...

Page 303: ...tep 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Replace ECM Is the replacement complete Go to Step 5 5 Remove all test equipment except the DST Connect any disc...

Page 304: ...switches power out to the fuel pump for operation on gasoline fuel This fault will set if the ECM detects an open circuit on the relay control output Diagnostic Aid Relay coil resistance changes with...

Page 305: ...place ECM fuse Go to Step 5 5 Disconnect ECM connector CN1 Using a DVOM check for continuity between ECM connector CN1 circuit 178 and fuel pump relay circuit 178 Do you have continuity Go to Step 6 R...

Page 306: ...DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and d...

Page 307: ...307...

Page 308: ...pump relay switches power out to the fuel pump for operation on gasoline fuel This fault will set if the ECM detects a short to ground on the relay control output Diagnostic Aid Relay coil resistance...

Page 309: ...again between ECM connector circuit 178 and engine ground Is the resistance less than 60 ohms Repair the shorted to ground relay control circuit as necessary See wiring harness re pairs Go to Step 5...

Page 310: ...switches power out to the fuel pump for operation on gasoline fuel This fault will set if the ECM detects a short circuit to power on the relay control output Diagnostic Aid Relay coil resistance cha...

Page 311: ...uity between them Go to Step 3 Go to Step 5 5 Key OFF Disconnect ECM wire harness connector CN1 Using a DVOM check for power between ECM connector circuit 178 and engine ground with the key ON Do you...

Page 312: ...DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and d...

Page 313: ...313...

Page 314: ...rcuit Description The external 5 volt supply powers many of the sensors and other components of the fuel sys tem The accuracy of the 5 volt supply is very important to the accuracy of the powered sens...

Page 315: ...lace ECM Is the replacement complete Go to Step 7 5 While monitoring DVOM for continuity be tween ECM 5 volt reference circuit 119 and engine ground Disconnect each sensor below one at a time to find...

Page 316: ...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 th...

Page 317: ...317...

Page 318: ...nal 5 volt supply powers many of the sensors and other components in the fuel sys tem The accuracy of the 5 volt supply is very important to the accuracy of the powered sensors and fuel control by the...

Page 319: ...M connector CN1 Key ON Using DVOM check for Voltage between ECM connector CN1 circuit 119 and engine ground Do you have voltage Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec...

Page 320: ...us sensors actuators and solenoids in the fuel system This fault will set if the ECM detects an open circuit on the relay control output Diagnostic Aid Relay coil resistance changes with temperature T...

Page 321: ...use Go to Step 5 5 Disconnect ECM connector CN1 Using a DVOM check for continuity between ECM connector CN1 circuit 173 and power relay circuit 173 Do you have continuity Go to Step 6 Repair the open...

Page 322: ...DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and d...

Page 323: ...323...

Page 324: ...ower out to various sensors actuators and solenoids in the fuel system This fault will set if the ECM detects a short to ground on the relay control output Diagnostic Aid Relay coil resistance changes...

Page 325: ...een ECM connector circuit 173 and engine ground Is the resistance less than 60 ohms Repair the shorted to ground relay control circuit as necessary See wiring harness re pairs Go to Step 5 5 Replace t...

Page 326: ...various sensors actuators and solenoids in the fuel system This fault will set if the ECM detects a short circuit to power on the relay control output Diagnostic Aid Relay coil resistance changes wit...

Page 327: ...them Go to Step 3 Go to Step 5 5 Key OFF Disconnect ECM wire harness connector CN1 Using a DVOM check for power between ECM connector circuit 173 and engine ground with the key ON Do you have power Sy...

Page 328: ...DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and d...

Page 329: ...329...

Page 330: ...ine Running Fault Condition Engine rpm greater than 4 000 MIL On during active fault Circuit Description This fault will set anytime Engine rpm is greater than 4 000 When these conditions are met the...

Page 331: ...umber on the ECM to ensure correct calibration is in use Is the service part number correct Go to Step 6 Go to Step 5 5 Replace ECM with the correct service part number Is the replacement complete Go...

Page 332: ...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...

Page 333: ...333...

Page 334: ...Condition Engine RPM greater than 4200 MIL On during active fault Engine Shut Down Circuit description This fault will set anytime the engine RPM exceeds 3900 During this condition the ECM will shut o...

Page 335: ...correct calibration is in use Is the service part number Correct Go to Step 6 Go to Step 5 5 Replace ECM with correct service part Num ber Is the replacement complete Go to Step 9 6 Check the mechanic...

Page 336: ...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...

Page 337: ...337...

Page 338: ...ify the fuel flow within its limits Diagnostic Aid Oxygen Sensor Wire Heated Oxygen sensor wires may be mis routed and contacting the ex haust manifold Vacuum Leaks Large vacuum leaks and crankcase le...

Page 339: ...C codes before pro ceeding with this chart Always repair existing codes starting with the lowest numerical code set first Have any other DTC codes been detected diag nosed and repaired Go to Step 9 Go...

Page 340: ...Do you have continuity Go to Step 8 Repair the open EGO heater ground 8 Replace EGO 1 sensor Is the replacement complete Go to Step 9 9 Remove all test equipment except the DST Connect any disconnecte...

Page 341: ...341...

Page 342: ...r This fault sets if the Closed Loop multiplier exceeds the limits of normal operation When the multiplier cannot correctly modify the fuel flow within its limits it is limited at 35 Diagnostic Aid Fu...

Page 343: ...ng clean and tight Run the fuel system diagnostic checks Was a repair made Go to Step 6 Go to Step 4 3 Diagnose any other DTC codes before pro ceeding with this chart Have any other DTC codes been det...

Page 344: ...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...

Page 345: ...345...

Page 346: ...stem diagnostic checks before using the following diagnostic chart Diagnostic Aid Oxygen Sensor Wire Heated Oxygen sensor wires may be mis routed and contacting the ex haust manifold Vacuum Leaks Vacu...

Page 347: ...ne Electrical Power and Ground Distri bution Fuel System Diagnostics Refer to Fuel Sys tem Diagnostics Was a repair made Go to Step 9 Go to Step 4 3 Diagnose any other DTC codes before pro ceeding wit...

Page 348: ...ir ing Repairs in Engine Elec trical Go to Step 7 7 Using a high impedance DVOM check for continuity between EGO 1 heater ground pin D and ECM pin 72 Do you have continuity Go to Step 8 Repair the ope...

Page 349: ...349...

Page 350: ...y High fuel pressure due to a faulty fuel regulator or obstructed fuel return line will cause the system to run rich Ignition noise Open or poor ground circuit to or in the ignition system or ECM wiri...

Page 351: ...n and tight Run the fuel system diagnostic checks Was a repair made Go to Step 6 Go to Step 4 3 Diagnose any other DTC codes before pro ceeding with this chart Have any other DTC codes been detected d...

Page 352: ...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...

Page 353: ...353...

Page 354: ...before using the following diagnostic chat Diagnostic Aid Oxygen Sensor Wire Heated Oxygen sensor wires may be mis routed and contacting the ex haust manifold Vacuum Leaks Large vacuum leaks and cran...

Page 355: ...e Electrical Power and Ground Distri bution Fuel System Diagnostics Refer to Fuel Sys tem Diagnostics Was a repair made Go to Step 9 Go to Step 4 3 Diagnose any other DTC codes before pro ceeding with...

Page 356: ...ine Elec trical Go to Step 7 7 Using a high impedance DVOM check for continuity on the EGO 1 heater control circuit 162 between EGO 1 connector CN11 and ECM connector CN1 Do you have continuity Go to...

Page 357: ...357...

Page 358: ...multiplier This fault will set if the adaptive multiplier exceeds the limits of normal operation Always run the fuel system diagnostics before using the following diagnostic chart Diagnostic Aid Fuel...

Page 359: ...being clean and tight Fuel system diagnostic checks Was a repair made Go to Step 6 Go to Step 4 3 Diagnose any other DTC codes before pro ceeding with this chart Have any other DTC codes been detected...

Page 360: ...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...

Page 361: ...361...

Page 362: ...ring active fault Closed Loop Disabled during active fault Circuit Description The catalyst monitor test is run under certain operating conditions to determine if the catalyst is functioning correctly...

Page 363: ...r visual signs of damage leaks or modification and repair if necessary Insure the pre catalyst and post catalyst oxygen sensors are mounted correctly and wiring is not damaged melted or corroded and r...

Page 364: ...el mixer Pressure readings are sent over the CAN to the ECM and in re turn the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control This code will se...

Page 365: ...trical connector pins C018 for damage corrosion or contamina tion Did you find a problem Repair the circuit as ne cessary Refer to wire harness re pair section Go to Step 5 5 Replace or repair the EPR...

Page 366: ...the fuel mixer Pressure readings are sent over the CAN to the ECM and in re turn the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control This code...

Page 367: ...lectrical connector CN15 for damage corrosion or contamination Did you find a problem Repair the circuit as ne cessary Refer to wire harness re pair section Go to Step 5 5 Replace or repair the EPR Is...

Page 368: ...disabled Circuit Description The EPR Electronic Pressure Regulator unit measures and controls the amount of fuel that is able to pass to the fuel mixer Pressure readings are sent over the CAN to the...

Page 369: ...T function or check before ECM relay control times out Do you have power System bat tery voltage Go to Step 7 Go to Step 4 4 Check the fuses Is the fuse open Go to Step 5 Go to Step 6 5 Replace damage...

Page 370: ...tep 11 Repair the open circuit as necessary Refer to wir ing repairs in engine elec trical 11 Using a DVOM check for continuity on the EPR ground circuit 181 between EPR con nector CN15 and ECM connec...

Page 371: ...r any stored codes Does DTC1173 still re set Go to Step 16 System OK 16 Replace the ECM Is the replacement complete Go to Step 17 _ 17 Remove all test equipment except the DST Connect any disconnected...

Page 372: ...over the CAN to the ECM and in re turn the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control This code will set if the EPR internal supply voltag...

Page 373: ...two of them 1 volt Go to Step 4 Go to Step 5 4 Replace the EPR Is the replacement complete Go to Step 6 5 Replace the ECM Is the replacement complete Go to Step 6 6 Remove all test equipment except th...

Page 374: ...e turn the ECM sends back a control signal to the EPR to increase or decrease pressure for precise mixture control This code will set if the internal EPR supply voltage is low Adaptive is disabled and...

Page 375: ...ivate relay control ON using the DST function or check before ECM relay control times out Using a DVOM check the system battery power at the battery terminals and record the voltage reading Are the re...

Page 376: ...CM 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 engi...

Page 377: ...377...

Page 378: ...the amount of fuel that is able to pass to the fuel mixer Pressure readings are sent over the CAN to the ECM and in re turn the ECM sends back a control signal to the EPR to increase or decrease press...

Page 379: ...t the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1176 check f...

Page 380: ...ount of fuel that is able to pass to the fuel mixer Pressure readings are sent over the CAN to the ECM and in re turn the ECM sends back a control signal to the EPR to increase or decrease pressure fo...

Page 381: ...rt the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1177 check...

Page 382: ...amount of fuel that is able to pass to the fuel mixer Pressure readings are sent over the CAN to the ECM and in re turn the ECM sends back a control signal to the EPR to increase or decrease pressure...

Page 383: ...tart the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveability After operating the engine within the test pa rameters of DTC1178 chec...

Page 384: ...evel 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex ecuted Several different things can happen within the microprocessor that will caus...

Page 385: ...o Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Replace ECM Is the replacement complete Go to Step 5 5 Remove all test equipment except the DST Connect any d...

Page 386: ...evel 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex ecuted Several different things can happen within the microprocessor that will caus...

Page 387: ...o Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Replace ECM Is the replacement complete Go to Step 5 5 Remove all test equipment except the DST Connect any d...

Page 388: ...evel 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex ecuted Several different things can happen within the microprocessor that will caus...

Page 389: ...o Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Replace ECM Is the replacement complete Go to Step 5 5 Remove all test equipment except the DST Connect any d...

Page 390: ...vel 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex ecuted Several different things can happen within the microprocessor that will cause...

Page 391: ...Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Replace ECM Is the replacement complete Go to Step 5 5 Remove all test equipment except the DST Connect any di...

Page 392: ...te level 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex ecuted Several different things can happen within the microprocessor that will...

Page 393: ...Go to Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Replace ECM Is the replacement complete Go to Step 5 5 Remove all test equipment except the DST Connect a...

Page 394: ...communicate with other digital devices used throughout the fuel system Information is sent over the CAN bus in digital infor mation packets that contain information for various control functions Indi...

Page 395: ...epeat Step 3 until all CAN devices have been disconnected one at a time Contact the CAN device manufacturer for additional CAN address information Go to Step 4 4 Has the CAN device been replaced or ad...

Page 396: ...on Dual throttle Position Sensors are used within the throttle that use variable resistors to deter mine signal voltage based on throttle plate position TPS 1 will read low voltage when closed and TPS...

Page 397: ...t ECM wire harness connector CN1 Key ON Using a DVOM check for voltage between throttle connector TPS 1 signal circuit 147 and engine ground Do you have voltage Repair the circuit as ne cessary Refer...

Page 398: ...Engine Elec trical Go to Step 12 12 Replace throttle Is the replacement complete Go to Step 13 13 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST...

Page 399: ...399...

Page 400: ...uit Description Dual throttle Position Sensors are used within the throttle that use variable resistors to deter mine signal voltage based on throttle plate position TPS 1 will read low voltage when c...

Page 401: ...greater Go to Step 4 Go to Step 8 4 Check throttle bore for foreign object Did you find a problem Go to Step 5 Go to Step 6 5 Remove the foreign object Has the object been removed Go to Step 11 6 Che...

Page 402: ...complete Go to Step 11 11 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 se...

Page 403: ...403...

Page 404: ...di cates an at idle condition The two conditions conflict indicating a fault in the FPP or IVS circuits The MIL command is ON and power derate 2 is in effect during this code set limiting full power o...

Page 405: ...CN21 Do you have continuity Repair circuit as necessary See wiring harness re pair section Go to Step 6 5 Disconnect the System Interface connector CN21 Check for continuity between circuits 154 and...

Page 406: ...n the test pa rameters of DTC 2123 check for any stored codes Does the engine operate normally with no stored codes System OK Go to Step 9 11 Remove all test equipment except the DST Connect any disco...

Page 407: ...407...

Page 408: ...y is on If the voltage exceeds 4 00 volts the FPP is considered to be out of specification The MIL command is ON Forced idle and low rev limit will be in effect during this code set limiting full powe...

Page 409: ...0 200 volts 0 200 volts or less Go to Step 5 Go to Step 6 5 Replace FPP sensor Is the replacement complete Go to Step 10 6 Key OFF Disconnect ECM connector CN1 Disconnect system interface connector C...

Page 410: ...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 th...

Page 411: ...411...

Page 412: ...n If the voltage drops below 0 300 volts the FPP is considered to be out of specification The MIL command is ON Forced idle and low rev limit will be in effect during this code set limiting full power...

Page 413: ...Does the DST now show FPP 1 voltage above 0 300 volts Greater than 0 300 volts Go to Step 5 Go to Step 7 5 Inspect FPP 1 and CN21 connectors for damage corrosion or contamination Did you find a probl...

Page 414: ...e wiring har ness repair section Go to Step 11 11 Replace ECM Is the replacement complete Go to Step 12 12 Remove all test equipment except the DST Connect any disconnected components fus es etc Using...

Page 415: ...415...

Page 416: ...Dual throttle Position Sensors are used within the throttle that use variable resistors to deter mine signal voltage based on throttle plate position TPS 1 will read low voltage when closed and TPS 2...

Page 417: ...an 4 5 volts Go to Step 4 Repair circuit 119 as neces sary Refer to Wiring Re pairs in Engine Elec trical 4 Using a DVOM check the voltage between circuit 119 and circuit 120 at the throttle con necto...

Page 418: ...engine performance and driveability After operating the engine within the test pa rameters of DTC 2112 check for any stored codes Does the engine operate normally with no stored codes System OK Go to...

Page 419: ...419...

Page 420: ...an off idle state The two conditions conflict indicating a fault in the FPP or IVS circuit The MIL command is ON and power derate level two are in effect during this code set limiting full power outpu...

Page 421: ...heck for continuity between circuits 153 and 120 at the system interface connector CN21 Do you have continuity Repair circuit as necessary See wiring harness re pair section Go to Step 6 5 Disconnect...

Page 422: ...After operating the engine within the test pa rameters of DTC 2123 check for any stored codes Does the engine operate normally with no stored codes System OK Go to Step 9 11 Remove all test equipment...

Page 423: ...423...

Page 424: ...Fault Condition BP greater than 16 psia MIL On for active fault Adaptive Disabled Circuit Description The BP Barometric Pressure is estimated from the TMAP sensor The barometric pressure value is used...

Page 425: ...MAP sensor Is the repair complete Go to Step 4 4 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignit...

Page 426: ...r cranking Fault condition Adaptive dwell greater than 2 0ms or total dwell greater than 14 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers i...

Page 427: ...FORE THE POWER RELAY CIRCUIT SHUTS DOWN Do you have voltage Go to Step 6 Repair the open power circuit See wiring har ness repairs 6 Key OFF Disconnect the ignition module connector CN6 Using a DVOM c...

Page 428: ...of DTC 2300 check for any stored codes Does the engine operate normally with no stored codes System OK Go to Step 11 11 Replace the ECM Is the replacement complete Go to Step 12 12 Remove all test equ...

Page 429: ...429...

Page 430: ...tion Adaptive dwell less than 2 0ms or total dwell less than 4 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers the ignition coil 1 ignition b...

Page 431: ...1 Crank the engine Does DTC 2301 re set Go to Step 3 Intermittent problem See Intermittent problems in the electrical section 3 Key OFF Disconnect ECM connector CN1 Disconnect ignition module connecto...

Page 432: ...des Does the engine operate normally with no stored codes System OK Go to Step 6 6 Replace the ECM Is the replacement complete Go to Step 7 7 Remove all test equipment except the DST Connect any disco...

Page 433: ...433...

Page 434: ...r cranking Fault condition Adaptive dwell greater than 2 0ms or total dwell greater than 14 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers i...

Page 435: ...DOWN Do you have voltage Go to Step 6 Repair the open power circuit See wiring har ness repairs 6 Key OFF Disconnect the ignition module connector CN6 Using a DVOM check for voltage between ignition m...

Page 436: ...es Does the engine operate normally with no stored codes System OK Go to Step 11 11 Replace the ECM Is the replacement complete Go to Step 12 12 Remove all test equipment except the DST Connect any di...

Page 437: ...437...

Page 438: ...tion Adaptive dwell less than 2 0ms or total dwell less than 4 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers the ignition coil 2 ignition b...

Page 439: ...4 Crank the engine Does DTC 2304 re set Go to Step 3 Intermittent problem See Intermittent problems in the electrical section 3 Key OFF Disconnect ECM connector CN1 Disconnect ignition module connecto...

Page 440: ...des Does the engine operate normally with no stored codes System OK Go to Step 6 6 Replace the ECM Is the replacement complete Go to Step 7 7 Remove all test equipment except the DST Connect any disco...

Page 441: ...441...

Page 442: ...r cranking Fault condition Adaptive dwell greater than 2 0ms or total dwell greater than 14 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers i...

Page 443: ...FORE THE POWER RELAY CIRCUIT SHUTS DOWN Do you have voltage Go to Step 6 Repair the open power circuit See wiring har ness repairs 6 Key OFF Disconnect the ignition module connector CN6 Using a DVOM c...

Page 444: ...of DTC 2306 check for any stored codes Does the engine operate normally with no stored codes System OK Go to Step 11 11 Replace the ECM Is the replacement complete Go to Step 12 12 Remove all test equ...

Page 445: ...445...

Page 446: ...tion Adaptive dwell less than 2 0ms or total dwell less than 4 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers the ignition coil 1 ignition b...

Page 447: ...Crank the engine Does DTC 2307 re set Go to Step 3 Intermittent problem See Intermittent problems in the electrical section 3 Key OFF Disconnect ECM connector CN1 Disconnect ignition module connector...

Page 448: ...des Does the engine operate normally with no stored codes System OK Go to Step 6 6 Replace the ECM Is the replacement complete Go to Step 7 7 Remove all test equipment except the DST Connect any disco...

Page 449: ...449...

Page 450: ...r cranking Fault condition Adaptive dwell greater than 2 0ms or total dwell greater than 14 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers i...

Page 451: ...FORE THE POWER RELAY CIRCUIT SHUTS DOWN Do you have voltage Go to Step 6 Repair the open power circuit See wiring har ness repairs 6 Key OFF Disconnect the ignition module connector CN6 Using a DVOM c...

Page 452: ...of DTC 2309 check for any stored codes Does the engine operate normally with no stored codes System OK Go to Step 11 11 Replace the ECM Is the replacement complete Go to Step 12 12 Remove all test equ...

Page 453: ...453...

Page 454: ...tion Adaptive dwell less than 2 0ms or total dwell less than 4 0ms MIL On during active fault Adaptive Disabled Closed Loop Disabled Circuit Description The ECM triggers the ignition coil 1 ignition b...

Page 455: ...0 Crank the engine Does DTC 2310 re set Go to Step 3 Intermittent problem See Intermittent problems in the electrical section 3 Key OFF Disconnect ECM connector CN1 Disconnect ignition module connecto...

Page 456: ...des Does the engine operate normally with no stored codes System OK Go to Step 6 6 Replace the ECM Is the replacement complete Go to Step 7 7 Remove all test equipment except the DST Connect any disco...

Page 457: ...457 Servicing the Fuel System...

Page 458: ...o 7 5 Nm 5 5 ft lbs 2 Plug connector into controller 3 Push lock into place 4 Reconnect the negative battery cable 5 Install Diagnostic Service Tool 6 Start the vehicle and let run until it reaches no...

Page 459: ...eaks at the ttings of the serviced or replaced component Use a commercially available liquid leak detector or an electronic leak detector When using both me thods use the electronic leak detector rst...

Page 460: ...the ignition OFF and wait 30 seconds 7 Start the vehicle and let run until it reaches normal operating temperature 8 If a DTC code is found refer to the Electrical Section for further diagnosis V OIL...

Page 461: ...the sensor threads 2 Install Engine Coolant Temperature Sensor Torque to 10 8 14 5 ft lbs 14 7 19 6 Nm 3 Refill the cooling system 4 Reconnect electrical connector 5 Reconnect the negative battery cab...

Page 462: ...V sealant for repair procedures Silicon contamination will cause a high but false HEGO signal vol tage rich exhaust indication The ECM will then reduce the amount of fuel delivery to the engine causin...

Page 463: ...cated Between Two Hoses as Shown Above 1 Locate the PCV connected to hoses as shown above 2 Remove the PCV 3 Insert a thin rod into the PCV against the plun ger and gently push Testing the PCV Action...

Page 464: ...o the exhaust stream will have a white powdery coating Always be sure to eliminate the cause of contamination before replacing the sensor 2 Place the quad seals and third O ring on the neck of the Thr...

Page 465: ...tings for leaks 7 Start the vehicle and check for leaks Let run until it reaches normal operating temperature 8 If a DTC code is found refer to the Electrical Section for further diagnosis XIII LPG FU...

Page 466: ...hen using both methods use the electronic leak detector rst to avoid contamination by the liquid leak detector XVII ELECTRONIC PRESSURE REGULATOR EPR REMOVAL PROCEDURE 1 Disconnect the negative batter...

Page 467: ...sensor exposed to the exhaust stream will have a white powdery coating Always be sure to eliminate the cause of contamination before replacing the sensor 6 Install the inlet and outlet water ttings Fu...

Page 468: ...ponents for the Spectrum III EPR Do not use any other components or regulator repair kits to service the Spectrum III EPR The Kit is specifically designed for the Spectrum III EPR and is not compatibl...

Page 469: ...ate and C clip from the primary valve pin 14 Turn the plate over and remove pin and spring Discard pin and keep the spring 15 Remove the secondary body gasket 16 Inspect the Regulator body and cover p...

Page 470: ...ever tab into the slot of the secondary diaphragm and align the Regulator to the Ac tuator Place the Regulator on top the Actuator aligning the screw holes 14 Insert the six screws through the Actuato...

Page 471: ...olant 6 Start engine and run until operation tempera ture is reached 7 Let engine cool and check coolant level XX SHUT OFF VALVE REPLACEMENT REMOVAL PROCEDURE 1 Disconnect the negative battery cable 2...

Page 472: ...ing the Manifold to the bracket 8 Remove eight bolts securing the Manifold to the side of the engine and remove 9 Remove Gasket INSTALLATION PROCEDURE 1 Place bolt through Intake Manifold and Gasket a...

Page 473: ...ng should not exceed 20 7 kPa 3 psi 5 If the back pressure at either speed exceeds speci cation a restricted exhaust system is indicated 6 Inspect the entire exhaust system for a col lapsed pipe heat...

Page 474: ...2 Check for any DTC codes and clear 3 Verify engine is in closed loop and no MIL lights are present XXVI VACUUM LINE REMOVAL PROCEDURE 1 Disconnect the negative battery cable 2 Remove the Vacuum Line...

Page 475: ...475 Definitions...

Page 476: ...n to de termine air fuel ratio Adjustments are made accordingly and checked by comparing the new oxygen sensor to previous signals No stored in formation is used CNG Compressed Natural Gas CKP Cranksh...

Page 477: ...pecific categories over a specific period of time Hydrocarbon A chemical compound made up of hydrogen and carbon HC Gasoline and almost all other fuels are hydrocarbons Hydrostatic Relief Valve A pres...

Page 478: ...omotive fuel system that produces a signal in accordance with the oxygen content of the exhaust gas See Lambda Sen sor Oxygenate Oxygenates such as MTBE ethanol and methanol added to gasoline to incre...

Page 479: ...sion Vehicle TMAP Combined Air Inlet and Manifold Pressure Sensor Toluene A liquid aromatic hydrocarbon C7H8 TPS Throttle Position Sensor TSB Technical Service Bulletin ULEV Ultra Low Emission Vehicle...

Page 480: ...480...

Page 481: ...481 TOOL KIT ACCESSORIES 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 482: ...tting Assembly Test Cap System II LPR Secondary Pressure Test Adapter 1 AF4 31105 6 Fitting 1 8 NPT 3 16Hs Nip Brass 2 F4 4 7 Assembly Fitting Test Cap 3 4 1 AF4 50254 002 8 Pin Retainer 10 P1 30559 9...

Page 483: ...483 Appendix...

Page 484: ...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...

Page 485: ...485 Ignition System Specifications Firing Order 1 3 4 2 Spark Plug Type Hyundai 27410 23400 NGK PFRN6N Champion RC8PYPB Spark Plug Gap 028 031 in 0 7 0 8mm...

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