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Spectrum 3.0L GM, Parts & Service Manual

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Spectrum 3.0L GM Parts & Service Manual Download Page 287

 

287 

STARTER 

 

Item # 

Description 

Qty

Part Number 

1 Bolt 

2 

7242530 

2 

Nut Hex M5 x 0.8 Brass 

1 

97111000 

3 

Washer, Lock Bronze 

1 

93003000 

4 

Nut, Hex M8 x 1.25 Brass 

1 

97331000 

5 

Washer, lock med M8 Zn 

1 

93930000 

6 Starter 

Motor 

1 

7244520 

7 

Bracket, Starter 2kW 3.0L 

1 

B4-52110-001 

8 

Nut Hex #10-24 

1 

95000000 

9 

Washer, Lock #10 Med 

1 

93000000 

10 

Washer Flat #10 

1 

92000000 

11 

5/16-18  ¾” Bolt Hex Gr5 

1 

9205075 

12 

Washer, Loc, Med 5/16 

1 

93200000 

13 

Washer, flat, SAE, 5/16” 

1 

92200000 

Summary of Contents for 3.0L GM

Page 1: ...2011 Emission Certified LPG Fuel System 3 0L GM Engine Parts Service Manual Including Labor Time Guide Revision A March 2011 ...

Page 2: ...Maintenance 9 General maintenance and maintenance interval information Fuel System 17 An overview of the LPG fuel system and its components LPG Fuel System Diagnosis 27 How to identify a general problem LPG Symptom Diagnostics 35 How to correct a specific problem Electrical Section 51 Diagnostic Scan Tool 53 Using the DST for testing and trouble shooting ...

Page 3: ... 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 ...

Page 4: ...4 ...

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

Page 6: ...ontrol systems be new OEM replacement parts The use of other than genuine IMPCO replacement parts may im pair the effectiveness of emission control systems therefore the owner should assure that such parts are warranted by their manufacturer to be equiva lent to genuine IMPCO OEM parts in performance and durability FUEL QUALITY LPG engines and fuel systems are designed to operate on HD 5 or HD 10 ...

Page 7: ...hat sink downward Highly flammable air fuel mixtures may be present and can be ignited causing personal injury Always work in well ventilated areas WARNINGS CAUTIONS AND NOTES This manual contains several different Warnings Cautions and Notes that must be observed to prevent personal injury and or damage to the en gine the fuel system or personal property A WARNING is an advisement that by perform...

Page 8: ...essary procedures to safely remove and replace a failed compo nent 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...

Page 9: ...9 Maintenance ...

Page 10: ...ent belt Alcohol or Methanol 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 adjusted Serpentine belts should be checked according to the main tenance schedule in this section IMPORTANT The use of belt dressing or anti slipping agents on belts is not rec...

Page 11: ...place if necessary Inspect engine wire harness for rubbing chaf ing pinching burning and cracks or breaks in the wiring Verify that engine harness connectors are cor rectly locked in by pushing in and then pulling the connector halves outward Inspect ignition coil wire for hardening crack ing arcing chafing burning separation split boot covers Check spark plug wires for hardening crack ing chafing...

Page 12: ...he dipstick To ensure that you are not getting a false reading make sure the following steps are taken before checking the oil level 1 Stop engine 2 Allow approximately five minutes for the oil to drain back into the oil pan 3 Remove the dipstick Wipe with a clean cloth or paper towel and reinstall Push the dipstick all the way into the dipstick tube 4 Remove the dipstick and note the amount of oi...

Page 13: ...zontally mounted cylinders this will ensure the proper function of the cylinder relief valve When refueling or exchanging the fuel cylinder check the quick fill valve for thread damage Also verify O ring is in place and inspect for cracks chunking or separation If damage to the o ring is found replace prior to filling Check the ser vice line quick coupler for any thread damage IMPORTANT When refue...

Page 14: ...ount of oxygen present in the ex haust stream after combustion The measurement of oxygen in the exhaust stream is measured in voltage and sent to the ECM The ECM then makes corrections to the fuel air ratio to ensure the proper fuel charge and optimum catalytic performance Therefore it is important that the exhaust connections remain secured and air tight Contamination of the HEGO sensor can re su...

Page 15: ...ses for cracks swelling or deterioration X X X X X Replace coolant hoses and accessory drive belt Every 2 000 hours or two years whichever occurs first Engine Ignition System Inspect Battery case for leaks or damage X X X X X Inspect battery cables for damage corrosion or contamination X X X X X Check all electrical connector retainer locks X X X X X Replace spark plugs X X X Inspect crank sensor ...

Page 16: ...16 ...

Page 17: ...17 LPG Fuel System ...

Page 18: ...18 LPG FUEL SYSTEM OPERATION ...

Page 19: ...ine 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 Typical LPG Cylinder 1 Liquid Outage Fill Check Valve 2 Pressure Relief Valve 3 Liquid Outage valve w quick disconnect coupl ing 4 Filler Valve 5 Fuel Gauge 6 Vapor Withdrawal Tube when app...

Page 20: ...the amount of pres sure applied to the foot pedal located in the engine compartment however in this Drive By Wire DBW application the foot pedal has an electronic connection with the throttle and there is no direct mechanical cable connection between the pedal and the throttle shaft The ECM monitors the foot pedal position sensor when the engine is running When the operator depresses or releases t...

Page 21: ...tion Indicator Light MIL mounted in the dash Mal functions in the system are identified by a Diagnostic Trouble Code DTC number In addi tion to notifying the operator of the malfunction in the system the controller also stores the informa tion about the malfunction in its memory A technician can than utilize a computerized diag nostic scan tool to retrieve the stored diagnostic code and by using t...

Page 22: ...fer ence in pressure between the intake manifold and outside or atmospheric pressure The ECM monitors the resistance of the sensor to determine engine load the vacuum drops when the engine is under load or at wide open throttle and may alter the fuel mixture to improve performance and emissions 2 The Manifold Air Temperature MAT or IAT sensor is a variable resistance thermistor lo cated in the air...

Page 23: ...ender IGNITION SYSTEM The ignition system spark system uses a Crank Position and Camshaft Position sensor for engine timing A coil assembly contain an ignition coil and an ignition module supplies the ignition spark for the system The coil is fired for each cylinder over two engine revolutions The distributor routes each spark event to the appropriate cy linder spark plug The plug is fired near th...

Page 24: ...and an o ring and split spacer seal on the fuel rail side The fuel rail holds the injectors in place A Spectrum IV Gaseous Fuel Injector The 2011 saturated drive injectors operate on a two stage pilot actuated principal When the coil is ac tuated it pulls the primary seal off the primary orifice against the force of the flat return spring This al lows gas to flow out of the upper chamber of the in...

Page 25: ...25 LPG Closed Loop Schematic ...

Page 26: ...26 ...

Page 27: ...27 LPG System Diagnosis ...

Page 28: ...the vehicle will not continue to run refer to Hard Start for prelimi nary checks Before starting this procedure complete the following tasks to verify that liq uid fuel is being delivered to the EPR Inspect fuel tank to verify it has a sufficient amount of fuel Verify the manual shut off valve on the LPG tank is fully opened Verify that the excess flow valve has not been activated Inspect fuel tan...

Page 29: ...ced in pressure DIAGNOSTIC AIDS This procedure is intended to diagnose a vehicle operating on LPG If the vehicle will not continue to run on LPG 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 Regulator Inspect fuel tank to verify it has a sufficient amount of fuel Verify manual Shut Off val...

Page 30: ...take mani fold and air cleaner Check air cleaner and all vehicle intake ducting for restric tions Check exhaust system for flow obstructions or leaks Check the ignition wires for the following conditions Cracking or hardening Proper routing Bare or shorted wires Carbon tracking Check the wiring harness for the following conditions Proper connections Pinches Cuts or abrasions Were any faulty condit...

Page 31: ...t 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 conditions found in the ignition system check Correct the faulty condition and Go to Step 20 Go to Step 8 8 Perform a leak down test on the engine Are all cylinder leak down test results within specification ...

Page 32: ... pressure within the specified percen tage of the actual pressure indicated on the DST 15 kPa 2 2 PSI Go to Step 19 Go to Step 11 12 Turn OFF the manual shut off valve and let the engine run until it dies Turn the ignition OFF Go to Step 14 Go to Step 13 13 If turned OFF turn ON the manual shut off valve Disconnect the Lock off valve electrical connector 14 Apply 12V to the lock off valve terminal...

Page 33: ...conditions for at least 10 minutes Park the vehicle with the engine running and connect the DST to the vehicle s DLC connector Open the DST software and switch to the Faults Screen Let the vehicle idle with no load for at least 30 seconds and observe the Adaptive 1 fuel correction Did the Adaptive 1 fuel correction remain within the specified values 15 to 15 Go to Step 21 Go to Step 24 21 With eng...

Page 34: ...Intake manifold for leaks All throttle body 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 sensor giving a false reading Engine may exhibit signs of a rich running condition but the Adaptive 1 corrections will indicate an excessive positive fuel adjustment HEGO for correct switching char...

Page 35: ...35 Fuel Symptom Diagnostics ...

Page 36: ...op and operating correctly at that time 5 Take a data snapshot using the DST under the condition that the symp tom occurs to review at a later time Visual and Physical Checks Check all ECM system fuses and circuit breakers Check the ECM ground for being clean tight and in its proper location Check the vacuum hoses for splits kinks and proper connections Check thoroughly for any type of leak or res...

Page 37: ...e 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 locate the cause of the problem op erate the engine with the DST connected When the problem occurs an abnormal voltage or scan reading indicates a problem circuit Intermittent MIL Illumination The following co...

Page 38: ...stem Checks Verify proper operation of the Shut off solenoid Valves Important A closed Gas supply valve will create a no start condition Check for air intake system leakage around the Regulator and throttle body Check the fuel system pressures Refer to the Fuel System Diagnosis Ignition System Checks NOTE Natural Gas and Propane require higher secondary ignition system voltages for the equivalent ...

Page 39: ... leaks Venturi vacuum leaks Engine Vacuum leaks Improper valve timing 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 exhaust system for damaged or collapsed pipes Inspect the muffler for signs of heat distress or for possible internal fail ure ...

Page 40: ...on Check Venturi assembly for proper installation and leakage Verify proper operation of the Shut off solenoid Valves Verify proper operation of the system low pressure Regulator Check for air intake system leakage between the Throttle Body and Air Filter Assembly Check the fuel system pressures Refer to the Fuel System Diagnosis Ignition System Checks NOTE LPG requires higher secondary ignition s...

Page 41: ...ks Improper valve timing how 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 exhaust system for damaged or collapsed pipes Inspect the muffler for signs of heat distress or for possible internal fail ure Check for possible plugged catalytic converter Refe...

Page 42: ...n for the following Ignition wires for arcing and proper routing Cross firing Ignition coils for cracks or carbon tracking Engine Mechanical Checks Perform a cylinder compression check Check the engine for the following Improper valve timing Improper valve clearance Worn rocker arms Worn camshaft lobes Broken or weak valve springs Check the intake and exhaust manifold passages for casting flash Fu...

Page 43: ...ressure regulator or a restriction in the fuel system Check the TMAP sensor response and accuracy Check Shut Off electrical connections Check the Regulator Venturi and Throttle body for proper installation and leakage Ignition System Checks NOTE Natural Gas and Propane require higher secondary ignition system voltages for the equivalent gasoline operating conditions Check for the proper ignition v...

Page 44: ...eplace 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 Wet plugs oil fouling Cracks Wear Improper gap Burned electrodes Heavy deposits Engine Mechanical Check Important The LPG Fuel system is more sensitive to intake manifold leakage than a gasoline fuel supply system Check the engine f...

Page 45: ...ll 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 contamina tion and performance Check for proper operation of the TMAP sensor Check for proper operation of th...

Page 46: ...d acceleration Suggest to the owner to fill the fuel tank and to recheck the fuel economy and or suggest that a different operator use the equipment and record the results Fuel System Checks Check the Regulator fuel pressure Refer to Fuel System Diagnosis Check the fuel system for leakage Sensor Checks Check the TMAP sensor Ignition System Checks Verify that the spark plugs are the correct type an...

Page 47: ...inder compression test Refer to Engine Mechanical in the Service Manual Check the Regulator fuel pressure Refer to the Fuel System Diagnosis Check the Regulator Venturi and Throttle body for proper installation and leakage Ignition System Checks Check for the proper ignition output voltage using the spark tester J26792 or the equivalent Verify that the spark plugs are the correct type and properly...

Page 48: ...ecks Action Engine Mechani cal Check Check the engine for Broken motor mounts Improper valve timing Low compression Improper valve clearance Worn rocker arms Broken or weak valve springs Worn camshaft lobes ...

Page 49: ...uel System Diagnosis Verify proper fuel control solenoid operation Verify that the LPG manual shut off valve is fully open Check the in line fuel filter for restrictions Ignition System Checks Check for the proper ignition output voltage using the spark tester J26792 or the equivalent Verify that the spark plugs are the correct type and properly gapped Remove the plugs and inspect them for the fol...

Page 50: ...roper 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...

Page 51: ...51 Electrical Section ...

Page 52: ...52 ...

Page 53: ...53 DST Diagnostic Scan Tool ...

Page 54: ...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 Au gust 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 d...

Page 55: ...SB 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 ...

Page 56: ...56 Select the Next box to continue with the installation Enter your company name or organization and click the Next box Follow the next steps using the recommended defaults ...

Page 57: ...n 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 Win dows will now install the Ifak driver to your computer You should see a message confirming the driver was successfully installed as shown above ...

Page 58: ...58 Open the Start menu You should see the is CAN Configuration utility confirming the utility installation Select the is CAN Configurator Click the Add box ...

Page 59: ...59 Select the USB button then click the OK box Click on the Search attached device box ...

Page 60: ...he 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 ...

Page 61: ...rage Regardless of the delivery system please follow the instructions to install the DST software below If the files were supplied to you in a zip file format it is strongly recommended that the files are first unzipped before proceeding with the DST soft ware installation Insert the CD USB flash drive other storage media or find the location where the DST software has been saved on your computer ...

Page 62: ...s administrator box similar to the Ifak USB driver installation For all others click the Spectrum Engine Moni tor 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 Click the Next box ...

Page 63: ...he 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 recom mended that you re boot your computer ...

Page 64: ...ostic Link Connector or DLC to the Ifak adapter s 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 ...

Page 65: ...65 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 ...

Page 66: ...66 The Select CAN Device Channel dialog box will appear Select the Ifak device and then click the OK box Under the Connection drop down menu select Connect ...

Page 67: ...67 When connected the live data stream appears in the Value column ...

Page 68: ... both the MEFI industrial and S3000 mobile ECM applications The DST operates on an expandable platform and its functions are planned to increase in the future The functions are listed below Updating the ECM calibration using the s37 calibration file Provide graphical display interface for engine and sensors parameters Display DTC Diagnostic Trouble Codes Provide data stream information from engine...

Page 69: ...que to that particular s 37 file You will need the password to complete the re programming procedure Before re programming the ECM shut down any other programs running on your PC including wireless and e mail programs The PC must be dedicated to the re programming process at this time Be sure your PC bat tery is adequately charged Failure to follow these instructions may render the ECM not usable ...

Page 70: ...70 Use the Browse box to navigate to the location of the calibration file Enter the password that was supplied with the calibration file ...

Page 71: ...71 Select the Next box The progress bar shows the status updating Any interruption during the re programming process may render the ECM unusable in the field ...

Page 72: ...ng 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 ...

Page 73: ...t opens with the DST pro gram 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 ...

Page 74: ...hat 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 th...

Page 75: ...ns 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 ...

Page 76: ...76 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 ...

Page 77: ...re 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 low voltage connectors and ter minals When running electrical diagnostics avoid back probing the wire connectors as this may damage the wire seal When running the continuity checks use a wire probe to only touch ...

Page 78: ...78 ...

Page 79: ... Set up the plot for the code that sets An ex ample 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 ...

Page 80: ...80 ...

Page 81: ...81 Engine Wire Schematic ...

Page 82: ...82 2011 3 0L GM Engine IMPCO Emission Certified LPG Fuel System ...

Page 83: ...83 ...

Page 84: ...84 ...

Page 85: ...85 Engine Wire Harness Repair ...

Page 86: ...ible connectors used to probe terminals during diag nosis Fuse remover and test tool BT 8616 or equivalent is used for removing a fuse and to adapt fuse holder with a meter for diagnosis Do not solder oxygen sensor wire terminals as these wire ends are used for the sensors oxygen reference Open circuits are often difficult to locate by sight due to dirt oxidation or terminal misalignment Merely wi...

Page 87: ...e wire is inserted through the seal and connector the terminal is crimped on the wire and then pulled back into the connector to seat it in place Metri Pack Series 150 Terminal Removal 1 Slide the seal back on the wire 2 Insert tool BT 8518 or J 35689 or equiva lent as shown in insert A and B to release the terminal locking tab 2 3 Push the wire and terminal out through the connector If reusing th...

Page 88: ...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 straightened once they are bent Verify that the connectors are properly seated and all of the sealing rings in place when con necting leads The hinge type flap provides a backup or secondary locking feature for the connector They are used to improve the c...

Page 89: ...89 Diagnostic Trouble Codes DTCs ...

Page 90: ...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 ...

Page 91: ...he ignition module connector pin B and battery positive Crank the engine Does the LED test lamp flash while cranking the engine Go to Step 6 Go to Step 10 6 Using a DVOM check for power between the ignition module connector pin A and engine ground Do you have power System vol tage Go to Step 7 Repair the sys tem power circuit Check all system fuses and power relay connections 7 Disconnect the igni...

Page 92: ...pin C and engine ground Do you have continuity Go to Step 14 Repair the open ignition module ground circuit See wiring har ness repair 14 Using a DVOM check for continuity between the ignition module connector pin D and igni tion coil connector pin B Do you have continuity Go to Step 15 Repair the open ignition module circuit See wir ing harness repair 15 Replace the ignition module Is the replace...

Page 93: ...93 ...

Page 94: ...ate 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 read ing 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 wil...

Page 95: ...S1 and TPS2 disagree by greater than 5 96 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 diagnosti...

Page 96: ...tage di vided by 5 then multiplied by 100 greater than 6 NOTE this is the formula the ECU uses to de termine if the TPS readings are within the specifications TPS 1 0 2V TPS 2 4 99V Go to Step 3 Intermittent problem Go to Preliminary and Intermit tent Checks 3 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...

Page 97: ...3 Measure the resistance from C017 pin 4 to ECU B pin D3 Is the resistance less than 5Ω 5 Ω 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 ne cessary Refer to Wire Har ness Repair Go to Step 7 7 Remove all test equipment except the moni tor Using the monitor reset the adaptive learn Connect any disconnected components...

Page 98: ... 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 au...

Page 99: ...hecks If there is a glitch in the sweep re place the pedal position sensor Oth erwise go to Step 3 3 Check pedal position sensor Disconnect VIC 1 Key ON measure voltage from VIC 1 pins S and R Key ON measure voltage from VIC 1 pins M and L Is the voltage between 4 8 and 5 2 volts Go to Step 5 Go to Step 4 4 Key ON measure the voltage from VIC 1 pins S and M to ground Is the voltage between 4 8 and...

Page 100: ...ot probe wires without proper ser vice tool Permanent harness damage may result 0 09 and 4 97 V Reinstall the pins to the proper posi tions in the connector Go to step 6 Reinstall the pins to the proper posi tions in the connector Replace pedal position sen sor Go to step 8 6 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 res...

Page 101: ...101 ...

Page 102: ...oil pressure should not raise above 0 psig Due to the nature of this sensor an open ground wire with Key ON engine off may result in the signal voltage drifting up above 1 volt even at 0 psig oil pressure To sense this fault a diagnostic is triggered if at an engine speed of 0 rpm the sensor voltage is above 1 0 volts Circuit Description The engine has an internal oil pump which creates oil pressu...

Page 103: ...crease engine speed above 500 RPM Does DTC 100 reset Go to Step 4 Intermittent problem Go to Intermittent section 4 Clear DTC 100 Key OFF Disconnect oil pressure switch connector C012 and isolate the connector from engine ground Start and run the engine Does DTC 100 reset Go to Step 6 Go to Step 5 5 Replace oil pressure switch Is the replacement complete Go to Step 9 6 Ignition OFF Disconnect C012...

Page 104: ... etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and run to full operating temperature Observe the MIL Observe engine performance After operating the engine within the test pa rameters of DTC 100 check for any stored codes Does the engine operate normally with no stored codes System OK Go to OBD System Check ...

Page 105: ...105 ...

Page 106: ...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 vo...

Page 107: ...volts NOTE Do not probe wires without proper ser vice tool Permanent harness damage may result Between 4 8 and 5 2V Go to Step 4 Go to Step 5 If the 5 volt supply 2 is grounded an open code will be set 4 Key OFF Measure the resistance across the TMAP sensor pins 1 and 2 Is the resistance correct for the temperature as shown in the temperature resistance chart above Replace the ECU Go to step last ...

Page 108: ... Yes No 7 Recheck wire harness and TMAP sensor connectors for damage corrosion or contami nation Were any problems found Repair the circuit as ne cessary Go to Step 8 8 Replace the ECU Is the replacement complete Go to Step 9 ...

Page 109: ...109 ...

Page 110: ...nsor 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 en gine 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 ...

Page 111: ...45 310 2641 95 655 0019 145 999 7398 50 344 7379 100 689 4757 150 1034 214 kPa PSIa kPa PSIa kPa PSIa 5 0 725189 55 7 977074 105 15 22896 10 1 450377 60 8 702262 110 15 95415 15 2 175566 65 9 427451 115 16 67934 20 2 900754 70 10 15264 120 17 40452 25 3 625943 75 10 87783 125 18 12971 30 4 351131 80 11 60302 130 18 8549 35 5 07632 85 12 3282 135 19 58009 40 5 801508 90 13 05339 140 20 30528 45 6 5...

Page 112: ... 1 and 3 Is voltage between 4 8 and 5 2 volts Between 4 8 and 5 2V Go to Step 4 Go to Step 5 4 Replace known good MAP sensor and retest Is everything OK NOTE Do not probe wires without proper ser vice tool Permanent harness damage may result Go to Step 7 Go to Step 5 5 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...

Page 113: ... from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveabili ty After operating the engine within the test pa rameters of code check for any stored codes Does the engine operate normally with no stored codes System OK Go to On Board Diag nostics System Check Malfun ction Indi...

Page 114: ...efficient as the temperature ris es the resistance drops temperature sensitive resistor located in the Cylinder Head The ECM uses the reading to determine temperature related operating condition re quirements for the engine Five volts is applied across the sensor and voltage drop is measured to determine the temperature Temp deg F Ohms 242 4 101 231 9 121 211 6 175 201 4 209 181 9 302 163 1 434 14...

Page 115: ...ult Go to Step 3 Go to Step 4 3 With C034 disconnected measure the vol tage across C034 pins A and B Is voltage between 4 8 and 5 2 volts NOTE Do not probe wires without proper ser vice tool Permanent harness damage may result Between 4 8 and 5 2 V Replace the sensor Go to Step 5 Go to Step 4 4 With C034 and ECU B disconnected meas ure the resistance from C034 pin 1 to ECU B pin F2 C034 pin 2 to E...

Page 116: ...l 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 low er pressure and higher voltage for higher pressure This fault will set if the signal voltage is...

Page 117: ...volts Go to Step 6 Go to Step 5 4 Inspect FRP connector and pins for corrosion contamination or mechanical damage Any problems found Repair the circuit as necessary See wire harness re pair section Go to Step 5 5 Replace FRP Sensor Is the replacement complete Go to Step 12 6 Key ON Using a DVOM check for voltage between FRP connector 5 volt reference ECU B J2 and sensor ground pin A Does the DVOM ...

Page 118: ...nnector and wire harness connector terminals for corrosion conta mination or mechanical damage Any problems found Repair har ness and connector as necessary See wire harness re pair 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 fuses etc Using the DST clear DTC information from the ECM ...

Page 119: ...119 ...

Page 120: ...age 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 ...

Page 121: ...Intermit tent Checks Go to Step 3 3 Measure voltage from ECU B M2 to engine ground Is voltage within range Check all grounds and repair as ne cessary Go to Step 7 Go to Step 4 4 Remove Component Power Relay Measure voltage from pins E8 and D8 to en gine ground Is voltage within range System Vol tage Go to Step 6 Go to Step 5 6 Key OFF Disconnect ECU B Measure the resistance from ECU B pin M2 to Co...

Page 122: ...struction is executed Sev eral 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 al so 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 ...

Page 123: ... the monitor reset the adaptive learn Connect any disconnected components fus es 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 driveabili ty After operating the engine within the test pa rameters of code check for any stored code...

Page 124: ...struction is executed Sev eral 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 al so 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 ...

Page 125: ... the monitor reset the adaptive learn Connect any disconnected components fus es 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 driveabili ty After operating the engine within the test pa rameters of code check for any stored code...

Page 126: ...126 DTC 651 Injector Short Open Conditions for Setting the DTC Short to B Open Circuit Short to Ground Circuit Description The ECU injector circuit drives the LPG system ...

Page 127: ...zero 0V Repair short to power in the harness Go to step14 Replace ECU Go to Step 14 5 For affected cylinder disconnect injector connector Key ON Measure voltage from pin 1 to ground Is battery voltage present Battery Vol tage Go to Step 8 Go to Step 6 6 With C007 disconnected Key ON Measure voltage at C007 pin 2 Is battery voltage present Battery Vol tage Repair open in harness between C007 and in...

Page 128: ...e greater than 30MΩ 30Ω Replace the ECU Go to Step 14 Go to Step 13 13 Key OFF ECU B disconnected Measure the resistance from the control cir cuit to ground Is the resistance greater than 30MΩ 30Ω Repair the short to ground in the harness Go to Step 14 Replace the ECU Go to Step 14 14 Remove all test equipment except the moni tor Using the monitor reset the adaptive learn Connect any disconnected ...

Page 129: ...129 ...

Page 130: ...130 DTC 652 Injector Short Open Conditions for Setting the DTC Short to B Open Circuit Short to Ground Circuit Description The ECU injector circuit drives the LPG system ...

Page 131: ...hort to power in the harness Go to Step 14 Replace ECU Go to Step 14 5 For affected cylinder disconnect injector connector Key ON Measure voltage from pin 1 to ground Is battery voltage present Battery Vol tage Go to Step 8 Go to Step 6 6 With C008 disconnected Key ON Measure voltage at C007 pin 2 Is battery voltage present Battery Vol tage Repair open in harness between C008 and in jector connect...

Page 132: ...ance greater than 30MΩ 30Ω Replace the ECU Go to Step 14 Go to Step 13 13 Key OFF ECU B disconnected Measure the resistance from the control cir cuit to ground Is the resistance greater than 30MΩ 30Ω Repair the short to ground in the harness Go to Step 14 Replace the ECU Go to Step 14 14 Remove all test equipment except the moni tor Using the monitor reset the adaptive learn Connect any disconnect...

Page 133: ...133 ...

Page 134: ...134 DTC 653 Injector Short Open Conditions for Setting the DTC Short to B Open Circuit Short to Ground Circuit Description The ECU injector circuit drives the LPG system ...

Page 135: ...zero 0V Repair short to power in the harness Go to step14 Replace ECU Go to Step 14 5 For affected cylinder disconnect injector connector Key ON Measure voltage from pin 1 to ground Is battery voltage present Battery Vol tage Go to Step 8 Go to Step 6 6 With C009 disconnected Key ON Measure voltage at C009 pin 2 Is battery voltage present Battery Vol tage Repair open in harness between C009 and in...

Page 136: ...ter than 30MΩ 2Ω 5Ω Replace the ECU Go to Step 14 Go to Step 13 13 Key OFF ECU B disconnected Measure the resistance from the control cir cuit to ground Is the resistance greater than 30MΩ 30Ω Repair the short to ground in the harness Go to Step 14 Replace the ECU Go to Step 14 14 Remove all test equipment except the moni tor Using the monitor reset the adaptive learn Connect any disconnected comp...

Page 137: ...137 ...

Page 138: ...138 DTC 654 Injector Short Open Conditions for Setting the DTC Short to B Open Circuit Short to Ground Circuit Description The ECU injector circuit drives the LPG system ...

Page 139: ...zero 0V Repair short to power in the harness Go to step14 Replace ECU Go to Step 14 5 For affected cylinder disconnect injector connector Key ON Measure voltage from pin 1 to ground Is battery voltage present Battery Vol tage Go to Step 8 Go to Step 6 6 With C007 disconnected Key ON Measure voltage at C010 pin 2 Is battery voltage present Battery Vol tage Repair open in harness between C010 and in...

Page 140: ...e greater than 30MΩ 30Ω Replace the ECU Go to Step 14 Go to Step 13 13 Key OFF ECU B disconnected Measure the resistance from the control cir cuit to ground Is the resistance greater than 30MΩ 30Ω Repair the short to ground in the harness Go to Step 14 Replace the ECU Go to Step 14 14 Remove all test equipment except the moni tor Using the monitor reset the adaptive learn Connect any disconnected ...

Page 141: ...141 ...

Page 142: ...nstruction is executed Sev eral 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 al so 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...

Page 143: ...the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Re flash the ECM with the correct calibration file Repeat all in step 2 Does DTC 1635 still set Go to Step 5 Go to Step 6 5 Replace ECM Is the replacement complete Go to Step 5 6 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ...

Page 144: ...s 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...

Page 145: ...145 ...

Page 146: ...rcuit Description 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 r...

Page 147: ...ect ECM wire harness connector ECU B Using a DVOM check for continuity between all electronic throttle connector pins and en gine ground Does the DVOM show continuity Repair the shorted to ground TPS circuit as ne cessary Refer to Wir ing Repairs Go to Step 5 5 Using a DVOM check for continuity between electronic throttle connector pin 1 and ECU B connector pin G3 Does the DVOM show continuity Go ...

Page 148: ...e connector pin 6 and ECU B connector pin G4 Does the DVOM show continuity Go to Step 11 Repair the shorted TPS circuit to ground as ne cessary Refer to Wiring Re pairs 11 Replace electronic throttle Is the replacement complete Go to Step 12 12 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition ...

Page 149: ...information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and run to full operating temperature Observe the MIL Observe engine performance After operating the engine within the test pa rameters of DTC 522614 check for any stored codes Does the engine operate normally with no stored codes System OK Go to OBD System Check ...

Page 150: ...l 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 open ing and closing as commanded This fault will set if the ECM detects more than a 10 difference...

Page 151: ...ect ECM wire harness connector ECU B Using a DVOM check for continuity between all electronic throttle connector pins and en gine ground Does the DVOM show continuity Repair the shorted to ground TPS circuit as ne cessary Refer to Wir ing Repairs Go to Step 5 5 Using a DVOM check for continuity between electronic throttle connector pin 1 and ECU B connector pin G3 Does the DVOM show continuity Go ...

Page 152: ...e connector pin 6 and ECU B connector pin G4 Does the DVOM show continuity Go to Step 11 Repair the shorted TPS circuit to ground as ne cessary Refer to Wiring Re pairs 11 Replace electronic throttle Is the replacement complete Go to Step 12 12 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition ...

Page 153: ...information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and run to full operating temperature Observe the MIL Observe engine performance After operating the engine within the test pa rameters of DTC 522616 check for any stored codes Does the engine operate normally with no stored codes System OK Go to OBD System Check ...

Page 154: ...l 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 open ing and closing as commanded This fault will set if the ECM detects more than a 10 difference...

Page 155: ...nd en gine ground Does the DVOM show continuity Repair the shorted to ground TPS circuit as ne cessary Refer to Wir ing Repairs Go to Step 5 5 Using a DVOM check for continuity between electronic throttle connector pin 1 and ECU B connector pin G3 Does the DVOM show continuity Go to Step 6 Repair the open circuit as necessary Refer to Wir ing Repairs 6 Using a DVOM check for continuity between ele...

Page 156: ...cuit to ground as ne cessary Refer to Wiring Re pairs 11 Replace electronic throttle Is the replacement complete Go to Step 12 12 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and run to full operating temperature Observe the MIL Observe engine perfo...

Page 157: ...information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and run to full operating temperature Observe the MIL Observe engine performance After operating the engine within the test pa rameters of DTC 522617 check for any stored codes Does the engine operate normally with no stored codes System OK Go to OBD System Check ...

Page 158: ... 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 val...

Page 159: ... and condition of the ignition system Verify engine condition with a compression test Were any faults found Repair as re quired Go to step last Go to Step 4 4 Monitor connected with the engine running monitor the engine RPM One at a time disconnect each injector and observe the drop in engine speed Do one or more injectors not drop the engine speed when disconnected NOTE the engine speed will only...

Page 160: ...n Connect any disconnected components fus es 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 driveabili ty After operating the engine within the test pa rameters of code check for any stored codes Does the engine operate normally w...

Page 161: ...161 ...

Page 162: ...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 valu...

Page 163: ...nd condition of the ignition system Verify engine condition with a compression test Were any faults found Repair as re quired Go to step last Go to Step 4 4 Monitor connected with the engine running monitor the engine RPM One at a time disconnect each injector and observe the drop in engine speed Do one or more injectors not drop the engine speed when disconnected NOTE the engine speed will only d...

Page 164: ...n Connect any disconnected components fus es 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 driveabili ty After operating the engine within the test pa rameters of code check for any stored codes Does the engine operate normally w...

Page 165: ...165 ...

Page 166: ...ust 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...

Page 167: ...nd condition of the ignition system Verify engine condition with a compression test Were any faults found Repair as re quired Go to step last Go to Step 4 4 Monitor connected with the engine running monitor the engine RPM One at a time disconnect each injector and observe the drop in engine speed Do one or more injectors not drop the engine speed when disconnected NOTE the engine speed will only d...

Page 168: ...n Connect any disconnected components fus es 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 driveabili ty After operating the engine within the test pa rameters of code check for any stored codes Does the engine operate normally w...

Page 169: ...169 ...

Page 170: ...ust 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...

Page 171: ...nd condition of the ignition system Verify engine condition with a compression test Were any faults found Repair as re quired Go to step last Go to Step 4 4 Monitor connected with the engine running monitor the engine RPM One at a time disconnect each injector and observe the drop in engine speed Do one or more injectors not drop the engine speed when disconnected NOTE the engine speed will only d...

Page 172: ...n Connect any disconnected components fus es 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 driveabili ty After operating the engine within the test pa rameters of code check for any stored codes Does the engine operate normally w...

Page 173: ...173 ...

Page 174: ... 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 ...

Page 175: ...he monitor reset the adaptive learn Connect any disconnected components fus es 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 driveabili ty After operating the engine within the test pa rameters of code check for any stored codes ...

Page 176: ...n instruction is executed Sev eral 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 al so 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 pro...

Page 177: ...tep 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Re flash the ECM with the correct calibration file Repeat all in Step 2 Does DTC 522691 still set Go to Step 5 Go to Step 6 5 Replace ECM Is the replacement complete Go to Step 5 6 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from th...

Page 178: ...time an instruction is executed Sev eral 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 al so 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 t...

Page 179: ...o to Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Re flash the ECM with the correct calibration file Repeat all in Step 2 Does DTC 522692 still set Go to Step 5 Go to Step 6 5 Replace ECM Is the replacement complete Go to Step 5 6 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information f...

Page 180: ... instruction is executed Sev eral 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 al so 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 prop...

Page 181: ...ep 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Re flash the ECM with the correct calibration file Repeat all in Step 2 Does DTC 522694 still set Go to Step 5 Go to Step 6 5 Replace ECM Is the replacement complete Go to Step 5 6 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the...

Page 182: ...time an instruction is executed Sev eral 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 al so 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 t...

Page 183: ...o to Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Re flash the ECM with the correct calibration file Repeat all in Step 2 Does DTC 522695 still set Go to Step 5 Go to Step 6 5 Replace ECM Is the replacement complete Go to Step 5 6 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information f...

Page 184: ...n instruction is executed Sev eral 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 al so 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 pro...

Page 185: ...tep 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Re flash the ECM with the correct calibration file Repeat all in Step 2 Does DTC 522698 still set Go to Step 5 Go to Step 6 5 Replace ECM Is the replacement complete Go to Step 5 6 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from th...

Page 186: ...an instruction is executed Sev eral 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 al so 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 pr...

Page 187: ...Step 4 Repair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Re flash the ECM with the correct calibration file Repeat all in Step 2 Does DTC 522699 still set Go to Step 5 Go to Step 6 5 Replace ECM Is the replacement complete Go to Step 5 6 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from t...

Page 188: ... instruction is executed Sev eral 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 al so 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 prop...

Page 189: ...pair the circuit as ne cessary Refer to Wir ing Repairs in Engine Elec trical 4 Re flash the ECM with the correct calibration file Repeat all in Step 2 Does DTC 522700 still set Go to Step 5 Go to Step 6 5 Replace ECM Is the replacement complete Go to Step 5 6 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Tu...

Page 190: ...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 read ing 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 w...

Page 191: ...C 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 P...

Page 192: ...ge minus the lower voltage di vided by 5 then multiplied by 100 greater than 6 NOTE this is the formula the ECU uses to de termine if the TPS readings are within the specifications Go to Step 3 Intermittent problem Go to Preliminary and Intermit tent Checks 3 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 ...

Page 193: ...n G3 Measure the resistance from C017 pin 4 to ECU B pin D3 Is the resistance less than 5Ω 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 ne cessary Refer to Wire Har ness Repair Go to Step 7 7 Remove all test equipment except the moni tor Using the monitor reset the adaptive learn Connect any disconnected components f...

Page 194: ...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 read ing 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 w...

Page 195: ...C 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 P...

Page 196: ...r voltage minus the lower voltage divided by 5 then multiplied by 100 greater than 6 NOTE Do not probe wires without proper ser vice tool Permanent harness damage may result Go to Step 3 Intermittent problem Go to Preliminary and Intermit tent Checks 3 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 Go to S...

Page 197: ...n G3 Measure the resistance from C017 pin 4 to ECU B pin D3 Is the resistance less than 5Ω 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 ne cessary Refer to Wire Har ness Repair Go to Step 7 7 Remove all test equipment except the moni tor Using the monitor reset the adaptive learn Connect any disconnected components f...

Page 198: ...ly 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 ...

Page 199: ...e is a glitch in the sweep re place the pedal position sensor Oth erwise go to Step 3 3 Check pedal position sensor Disconnect VIC 1 Key ON measure voltage from VIC 1 pins S and R Key ON measure voltage from VIC 1 pins M and L Is the voltage between 4 8 and 5 2 volts Between 4 8 and 5 2 volts Go to Step 5 Go to Step 4 4 Key ON measure the voltage from VIC 1 pins S and M to ground Is the voltage be...

Page 200: ... 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 5Ω 5Ω Go to step 7 Repair the open in the harness Go to step 8 7 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 Repair or replace the harness Go to Step 8 Replace the ECU Go t...

Page 201: ...201 ...

Page 202: ...ly 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 ...

Page 203: ...ere is a glitch in the sweep re place the pedal position sensor Oth erwise go to Step 3 3 Check pedal position sensor Disconnect VIC 1 Key ON measure voltage from VIC pins S and R Key ON measure voltage from VIC pins M and L Is the voltage between 4 8 and 5 2 volts Between 4 8 and 5 2 volts Go to Step 5 Go to Step 4 4 Key ON measure the voltage from VIC 1 pins S and M to ground Is the voltage betw...

Page 204: ...NOTE Do not probe wires without proper ser vice tool Permanent harness damage may result Reinstall the pins to the proper posi tions in the connector Go to Step 6 Reinstall the pins to the proper posi tions in the connector Replace pedal position sen sor Go to Step 8 6 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...

Page 205: ...n from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveabili ty After operating the engine within the test pa rameters of code check for any stored codes Does the engine operate normally with no stored codes System OK Go to On Board Diagnostics System Check Malfunction Indic...

Page 206: ...he 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 w...

Page 207: ...lay See wire harness repair Go to Step 4 4 Using a DVOM check for voltage between HEGO connector pin D and battery positive Ignition ON Do you have voltage System Bat tery Voltage Repair open HEGO ground cir cuit See wire harness repair Go to Step 5 5 Ignition OFF Disconnect ECU C Connector Using a DVOM check for continuity between ECU C connector pin L2 and HEGO connec tor pin D Does the DVOM sho...

Page 208: ...te Go to Step 10 10 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the Ignition OFF and wait 30 seconds Start the engine and run to full operating temperature Observe the MIL Observe engine performance After operating the engine within the test pa rameters of DTC 522735 check for any stored codes Does th...

Page 209: ...209 ...

Page 210: ...aust stream is rich the ECM will decrease or lean the fuel mix ture 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 shou...

Page 211: ...place the O2 Sensor Go to Step 8 4 Measure the resistance from the O2 sensor heater circuit pins C and D to ground Is the resistance greater than 30MΩ NOTE Do not probe wires without proper ser vice tool Permanent harness damage may result 30MΩ Go to Step 5 Replace the O2 Sensor Go to Step 8 5 Key OFF disconnect ECU C Measure resistance from C018 pin C to ECU C pin L2 Is the resistance less than 5...

Page 212: ...n from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveabili ty After operating the engine within the test pa rameters of code check for any stored codes Does the engine operate normally with no stored codes System OK Go to On Board Diagnostics System Check Malfunction Indic...

Page 213: ...213 ...

Page 214: ...t position sensor CMP is a Hall Effect sensor used to synchronize the fuel and ignition sys tems The sensor produces a short 5 volt square wave pulse every two engine revolutions The signal wire from the CAM sensor is held up at 5 volts by a pull up resistor in the ECU The CAM sensor pulls this 5 volt level to ground until a small hole in the end of the camshaft passes the sensor at which time the...

Page 215: ...r 90 or 10 5 depend ing on the meter Go to Step 5 Replace Cam Sensor Go to Step 9 5 Wiring check Key OFF disconnect ECU C and C004 Measure resistance from C004 pin A to ECU C pin A4 C004 pin B to ECU C pin F1 C004 pin C to ECU B pin M2 Is resistance less than 5Ω 5Ω Go to Step 6 Repair the circuit as ne cessary Refer to Wire Harness Repair Go to Step 9 6 Key OFF disconnect ECU C and C004 Measure re...

Page 216: ... from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveabili ty After operating the engine within the test pa rameters of code check for any stored codes Does the engine operate normally with no stored codes System OK Go to On Board Diag nostics System Check Malfun ction Indi...

Page 217: ...217 ...

Page 218: ...Circuit Description 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 c...

Page 219: ...ve 500 RPM Does DTC 523821 reset Go to Step 4 Intermittent problem Go to Intermittent section 4 Clear DTC 523821 Key OFF Disconnect oil pressure switch connector C012 and isolate the connector from engine ground Start and run the engine Does DTC 523821 reset Go to Step 6 Go to Step 5 5 Replace oil pressure switch Is the replacement complete Go to Step 9 6 Ignition OFF Disconnect ECM harness connec...

Page 220: ...etc Using the DST clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and run to full operating temperature Observe the MIL Observe engine performance After operating the engine within the test pa rameters of DTC 523821check for any stored codes Does the engine operate normally with no stored codes System OK Go to OBD System Check ...

Page 221: ...221 ...

Page 222: ...ge somewhere in the system Voltage supply at the 5 volt reference is less than 4 8 volts or greater than 5 2 volts NOTE If the 5 volt supply is shorted to ground through wiring or a sensor this code may set Circuit Description The ECU has two externally available 5 volt regulated power supplies These power supplies are used as a power source and or a reference voltage for the various sensors and c...

Page 223: ...tep 4 Intermittent problem Go to Preliminary and Intermit tent Checks 4 Examine the connector of the sensor that causes the voltage to go out of range Is there any damage to the connector Repair as ne cessary Go to Step 8 Replace the sensor that causes the fault in the voltage Go to step last 5 Refer to the 5 volt supply table and check each supply circuit for a short to power or ground Are there ...

Page 224: ... from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveabili ty After operating the engine within the test pa rameters of code check for any stored codes Does the engine operate normally with no stored codes System OK Go to On Board Diag nostics System Check Malfun ction Indi...

Page 225: ...225 ...

Page 226: ...ge somewhere in the system Voltage supply at the 5 volt reference is less than 4 8 volts or greater than 5 2 volts NOTE If the 5 volt supply is shorted to ground through wiring or a sensor this code may set Circuit Description The ECU has two externally available 5 volt regulated power supplies These power supplies are used as a power source and or a reference voltage for the various sensors and c...

Page 227: ...sor Go to Step 4 Intermittent problem Go to Preliminary and Intermit tent Checks 4 Examine the connector of the sensor that causes the voltage to go out of range Is there any damage to the connector Repair as ne cessary Go to Step 8 Replace the sensor that causes the fault in the voltage Go to step last 5 Refer to the 5 volt supply table and check each supply circuit for a short to power or ground...

Page 228: ... from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and operate the vehicle to full operating temperature Observe the MIL Observe engine performance and driveabili ty After operating the engine within the test pa rameters of code check for any stored codes Does the engine operate normally with no stored codes System OK Go to On Board Diag nostics System Check Malfun ction Indi...

Page 229: ...229 ...

Page 230: ...n 9 volts MIL On during active fault Circuit Description 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 throt...

Page 231: ... wire harness connector ECU B Using a DVOM check for continuity between all electronic throttle connector pins and en gine ground Does the DVOM show continuity Repair the shorted to ground TPS circuit as ne cessary Refer to Wir ing Repairs Go to Step 5 5 Using a DVOM check for continuity between electronic throttle connector pin 1 and ECU B connector pin G3 Does the DVOM show continuity Go to Step...

Page 232: ...e connector pin 6 and ECU B connector pin G4 Does the DVOM show continuity Go to Step 11 Repair the shorted TPS circuit to ground as ne cessary Refer to Wiring Re pairs 11 Replace electronic throttle Is the replacement complete Go to Step 12 12 Remove all test equipment except the DST Connect any disconnected components fus es etc Using the DST clear DTC information from the ECM Turn the ignition ...

Page 233: ...information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and run to full operating temperature Observe the MIL Observe engine performance After operating the engine within the test pa rameters of DTC 524266 check for any stored codes Does the engine operate normally with no stored codes System OK Go to OBD System Check ...

Page 234: ...n 9 volts MIL On during active fault Circuit Description 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 throt...

Page 235: ...en gine ground Does the DVOM show continuity Repair the shorted to ground TPS circuit as ne cessary Refer to Wir ing Repairs Go to Step 5 5 Using a DVOM check for continuity between electronic throttle connector pin 1 and ECU B connector pin G3 Does the DVOM show continuity Go to Step 6 Repair the open circuit as necessary Refer to Wir ing Repairs 6 Using a DVOM check for continuity between electr...

Page 236: ... clear DTC information from the ECM Turn the ignition OFF and wait 30 seconds Start the engine and run to full operating temperature Observe the MIL Observe engine performance After operating the engine within the test pa rameters of DTC 524286 check for any stored codes Does the engine operate normally with no stored codes System OK Go to Step 13 13 Replace the ECM Is the replacement complete Go ...

Page 237: ...237 Servicing the Fuel System ...

Page 238: ...ctrical connectors in position 3 Connect the negative battery cable 4 Turn the ignition key to the ON position 5 Start the vehicle and check for proper opera tion of the electronic throttle body and the ECM by exercising the accelerator pedal with the vehicle in neutral II FUSE BOX MOUNTING BRACKET REMOVAL PROCEDURE 1 Disconnect the negative battery cable 2 Remove the four Screws Washers and Space...

Page 239: ...ender on the side of the engine 3 Remove electrical connection from Oil Pres sure Sender 4 Using a wrench hold the brass adapter to prevent from turning and turn the Switch counter clockwise and remove Do not re move the brass adapter from the engine block unless it is to be replaced INSTALLATION PROCEDURE 1 Apply Loctite 567 or equivalent high temp thread locker sealer to the threads on the Oil P...

Page 240: ...tor Cap 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 addi tional information 6 Connect Ignition Coi...

Page 241: ...and check for leaks at the inlet and outlet fittings using a commercial grade soapy solution or an electronic leak de tector If leaks are detected make repairs 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 VIII ENGINE COOLANT TEMPERATURE SENSOR ECT REMOVAL PROCEDURE 1 Disconnect the negat...

Page 242: ...ve Throttle Body electrical connector 4 Remove four Screws that secure the Throttle Body 5 Remove the Throttle Body and the Gasket INSTALLATION PROCEDURE 1 Inspect Throttle Body Gasket Replace if ne cessary 2 Place Throttle Body and Gasket on the Intake Manifold plenum align and secure with four Screws Torque to 7 9 ft lbs 9 5 12 2 Nm 3 Connect electrical connector 4 Reconnect negative battery cab...

Page 243: ... oil or heavy ends may build inside the secondary chamber of the Regulator These oil and heavy ends may be a result of poor fuel quality conta mination of the fuel or regional variation of the fuel make up A significant build up of oil can af fect the performance of the secondary diaphragm response The Recommended Maintenance Schedule found in this section recommends that the oil be drained period...

Page 244: ...k 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 ser viced fittings If leaks are detected make ...

Page 245: ...tridge to 16 to 24 N m 11 8 to 17 7 ft lbs 2 Install solenoid and nut onto cartridge Tigh ten nut to 7 85 N m 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 slowly to prevent activating the Excess Flow Check Valve 5 Slowly open the fuel valve on tank 6 Tur...

Page 246: ...etected make repairs 9 Check for MIL illumination XVI FUEL INJECTOR 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 connect ing it to the Injector Adapter The Fuel Injectors are held...

Page 247: ...he 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 re sult from the use of an inappropriate RTV sealer or silicone spray products Do not use silicone sprays or hoses which are assem ble...

Page 248: ...se the following conditions Rough or unstable idle Stalling or low idle speed Oil leaks Oil in the air cleaner Sludge in the engine A leaking PCV orifice or hose may cause the fol lowing problems Rough Idle Stalling High idle speed 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...

Page 249: ...x the inlet or outlet ends of the Hose when reinstalling INSTALLATION PROCEDURE 1 Slide Hose Clamps over each end of the Fuel Hose 2 Insert Port Fittings into each end of the Hose 3 Slide each Hose Clamp to a position approx imately from the end of the Hose and tighten 4 Lightly lubricate new O ring with Vaseline or petroleum jelly prior to installation Contamination of the HEGO sensor can re sult...

Page 250: ...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 5 Reinstall Hose Port into port and secure using a Retaining Pin 6 Reconnect negative battery cable 7 Open LPG tank valve IMPORTANT The fuel cylinder manual valve contains an Excess Flow Check Valve Open the manual valve slowly to prevent activat...

Page 251: ... kPa 3 psi 5 If the back pressure at either speed exceeds specification a restricted exhaust system is indicated 6 Inspect the entire exhaust system for a col lapsed pipe heat distress or possible internal catalytic converter failure 7 If there are no obvious reasons for the exces sive back pressure the catalytic converter is likely damaged and should be replaced 8 Check for MIL If a DTC code is f...

Page 252: ...ith new Screws Torque to 19 in lbs 2 2 Nm 2 Install the Rotor on the reluctor wheel and se cure with new Rotor Screws Torque to 18 in lbs 2 0 Nm 3 Install new Rotor Cap and secure with new Screws Torque to 21 in lbs 2 4 Nm 4 Connect the sensor harness connector 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...

Page 253: ...T The fuel cylinder manual valve contains an Excess Flow Check Valve Open the manual valve slowly to prevent activating the Excess Flow Check Valve 8 Turn Key to ON Check for leaks at the inlet and outlet fittings and the filter housing end connection using a soapy solution or an elec tronic leak detector If leaks are detected make repairs 9 Start engine and check for leaks once more XXXIV PCV REM...

Page 254: ...254 ...

Page 255: ...255 LPG Parts Diagram ...

Page 256: ...256 THROTTLE BODY ASSEMBLY ...

Page 257: ...Y ASSEMBLY Item Description Qty IMPCO Part Number 1 Screw Hex Sck Cap 4 S1 30295 0655 2 Washers Conical Spring 6mm 4 W1 31039 006 3 Throttle Body 1 A7 324 4 Gasket Throttle Body 2 A7 245 5 Bracket Fuel Rail Mount 1 B4 51980 001 ...

Page 258: ...258 FUEL RAIL INJECTORS ...

Page 259: ...e 1 A7 473 2 Screw Hex Flange M6 1 0 x 35 mm 2 P1 30559 3 Fuel Rail 3 0L 1 R8 51549 001 4 Pin Retaining 1 P1 30559 5 O Ring Inlet 4 A7 657 6 Spacer O ring 4 A7 656 7 Injector LPG CNG 4 A7 654 8 O ring Adapter 4 A7 655 9 Adapter Fuel Injector 4 A4 51981 001 10 O ring FKM 75 362 ID 4 GMN 033 ...

Page 260: ...260 REGULATOR ASSEMBLY ...

Page 261: ...sembled with all parts 1 A7 434 Filter Kit Includes 2 6 7 8 9 1 A7 170 Outlet Fitting Service Kit Includes 3 4 1 A7 172 5 Screw Kit Includes 3 screws 1 A7 176 Inlet Fitting w O Ring Includes 10 11 1 A7 171 12 Drain Plug O ring Kit Includes 12 O ring 1 A7 173 13 Lock Off Assembly 1 A7 175 ...

Page 262: ...262 HOSE ASSEMBLIES COOLANT VACUUM FUEL ...

Page 263: ...04 5 Hose 5 8 Fuel Oil 1 H1 19231 006 6 Clamp Ear Oetiker 2 C2 51552 05 113 7 Pin Retaining 1 P1 30559 8 Clamp Worm Drive 4 0130845 9 Clamp Oetiker 4 C1 51552 07 256 10 Hose 5 8 ID Fuel Oil 1 H1 19231 006 11 Bracket Vapor Filter 1 A10 167 12 Filter LPG Vapor 1 A8 367 13 Hose Formed Gate 1 H1 50599 001 14 Hose Formed Gate 1 15 Clamp Worm Drive 1 A10 169 16 Bolt M8 x 1 25 x 25 2 1510113 17 Nut Hex 2...

Page 264: ...264 THERMOSTAT HOUSING ...

Page 265: ...RMOSTAT HOUSING Item Description Qty Part Number GM Part Number 1 Bolt 2 90328100 09424320 2 Thermostat Housing 1 7142071 14096853 3 Gasket Thermostat Housing 1 7140310 10105135 4 Thermostat 1 7140340 10220957 ...

Page 266: ...266 ENGINE CONTROL MODULE ...

Page 267: ...267 ENGINE CONTROL MODULE Item Description Qty IMPCO Part Number 1 ECM Liugong 1 A11 173 ...

Page 268: ...268 SENSORS 4 1 3 6 5 2 7 ...

Page 269: ...mber GM Part Number 1 HEGO 1 S8 50328 001 2 Crank Sensor 1 S8 51822 001 12567712 3 Sensor TMAP 1 E1466001 4 Oil Pressure Switch 1 S10 50352 001 5 Adapter Oil Pressure Switch 1 7242360 6 Coolant Temp Switch 1 7144790 7 Adapter Coolant Switch 1 7176570 06 ...

Page 270: ...270 DISTRIBUTOR ...

Page 271: ...271 DISTRIBUTOR Item Description Qty Part Number GM Part Number 1 Distributor 1 93442429 93442429 2 Distributor Cap 1 89060454 89060454 3 Rotor 1 7241620 10467546 4 Module Sensor 1 7245370 10485432 ...

Page 272: ...272 FUSE BOX BRACKET ...

Page 273: ...m Description Qty Part Number 1 Screw Hex M4 x 16mm 4 S1 30295 0416 2 Washer Split Lock M4 4 W1 1988 003 3 Fuse Box Cover 1 C1 52520 001 4 Bracket ECM 1 B4 51789 001 5 Screw Hex Flange 2 90325088 6 Seal Fuse Box 1 S3 52522 001 ...

Page 274: ...274 IGNITION COIL ...

Page 275: ...275 IGNITION COIL Item Description Qty Part Number 1 Coil Ignition 1 7245530 ...

Page 276: ...276 MANIFOLDS ...

Page 277: ...300101 9 Screw Hex Flange M6 x 12mm 8 S1 30871 02 0612 10 Screw Hex Flange M6 1 0x x 16mm 3 S1 30871 02 0616 11 Screw Hex Flange M6 1 0 x 12mm 5 S1 50237 02 0620 12 Shield Heat GM 3 0L 2 Piece 1 7152160 13 Heat Shield RB Exhaust 1 G4 50067 001 14 Heat Shield Alternator 3 0L 1 G4 50068 001 15 TMAP Sensor 1 E1466001 16 Fitting 1 8 NPT 3 8 Hose Brass 1 2H 103B 17 Fitting 1 8 NPT 19 ID Hose 1 F4 4 18 ...

Page 278: ...278 WIRE HARNESS FUSES FUSE BOX COVER Fuse Box Layout 4 ...

Page 279: ...04Z 4 Wire Harness 4 Cyl 1 AW 50727 001 Auxiliary 10A Minifuse 1 914584 Littelfuse 297010 Power Fuse 20A Minifuse 1 7381270 Littelfuse 297020 Starter Fuse 20A Minifuse 1 7381270 Littelfuse 297020 VSW 10A Minifuse 1 914584 Littelfuse 297010 Starter Relay Starter Relay 1 885014 3011CCR1U0112VDC Power Relay Power Relay 1 885014 3011CCR1U0112VDC Shut Off Valve Relay Lock Off 1 885014 3011CCR1U0112VDC ...

Page 280: ...280 PCV VENT VALVE ...

Page 281: ...NT VALVE Item Description Qty Part Number GM Part Number 1 Vent Elbow 1 F4 51936 001 06487779 2 Grommet oil filter cap 1 G3 51937 001 14050440 3 PCV 1 V3 51806 001 06487779 4 Grommet PCV Valve 1 7120140 14001875 ...

Page 282: ...282 MISCELLANEOUS ENGINE ...

Page 283: ...ket Head Brass 1 P3 12 4 Fitting Pipe Thread Reducer 1 7176570 06 5 Oil Filter PF454 1 7110851 6 Plug 14 NPT 1 7242360 7 Switch Oil Pressure 1 S10 50352 001 8 Spark Plug R44LTS 4 E10 50075 9 Plug 14mm Fuel Rail Port 4 P3 50597 001 10 Fitting 1 2NPT 5 8 NIP Brass 1 F4 17920 11 Strap Lifting Eye 1 7010130 12 Screw Hex Flange 3 8 16 x 1 1 90325100 ...

Page 284: ...284 ALTERNATOR ...

Page 285: ...1 95300000 13 Spacer Alternator Brkt 1 7244570 14 Bracket Alt Lower 1 7244560 15 Bolt Hex 3 8 16 x 4 Grade 5 1 90305400 16 Bolt M8 1 25 Hx Head Grd 10 9 1 98333025 17 Washer Lock Med M8 Zn 1 93930000 18 Washer Flat Heavy 5 6 1 92200020 19 Pulley Water Pump 1 7144040 20 Pulley Crankshaf 1 7071620 21 3 8 24x2 bolt Hx Gr5 1 90315200 22 5 16 18 x Grade 5 8 90215075 23 3 8 16x3 1 2 Blt Sched Gr5 1 7144...

Page 286: ...286 STARTER ...

Page 287: ... 4 Nut Hex M8 x 1 25 Brass 1 97331000 5 Washer lock med M8 Zn 1 93930000 6 Starter Motor 1 7244520 7 Bracket Starter 2kW 3 0L 1 B4 52110 001 8 Nut Hex 10 24 1 95000000 9 Washer Lock 10 Med 1 93000000 10 Washer Flat 10 1 92000000 11 5 16 18 Bolt Hex Gr5 1 9205075 12 Washer Loc Med 5 16 1 93200000 13 Washer flat SAE 5 16 1 92200000 ...

Page 288: ...288 TOOL KIT ACCESSORIES 1 2 3 4 5 6 7 8 9 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 ...

Page 289: ...0 5 Fitting 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 Case Metal 14 25 x 9 x 4 25 1 C9 50724 001 10 Fitting 1 8 NPT 1 4Hs El Nylon 2 F4 8 11 Tool 20IPR Torx Plus Bit 1 T7 50172 12 Fitting UNF HS Vac Nip 1 F4 2 13 Gauge Test Fuel System 1 TG 31119 ...

Page 290: ...290 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 3 0L GM Engine Code BL3 7044670 ...

Page 291: ...291 ...

Page 292: ...292 3 0L UPPER ...

Page 293: ...il 12 10007818 13 Stud Vlv 8 03814692 14 Cap Vlv Sprg 8 10038209 15 Seal Vlv Stem Oil 8 10214034 16 Spring Vlv 8 94666172 17 Bolt Cyl Hd 10 10166832 18 Plug Cyl Hd Core Hole 2 03826506 19 Gasket Eng Cool Therm Hsg 1 10140501 20 Housing Eng Cool Therm 1 93442430 21 Bolt Eng Cool Therm Hsg 3 09424320 22 Lifter Vlv 8 05232720 23 Head Cyl Cmpl w Valves Springs Re tainers Seals 1 93442423 24 Insert Vlv...

Page 294: ...294 3 0L LOWER ...

Page 295: ...63 13 Bolt Cm Shaft 3 09442895 14 Bolt W Pmp 5 16 2 09440366 15 Key Cm Shft 2 00106751 16 Bolt CM Shaft 2 09442008 17 Washer CM Shf 1 10101744 18 Gear CM Shf 1 02771369 19 Plate Kit CM Shf 1 12508079 20 Ring CM Shf 1 00549631 21 Bearing CM Shf 4 14002525 22 Camshaft Eng 1 02770015 23 Valve Oil Filter 1 25013759 24 Pin Cyl HD 8 00585927 25 Fitting Oil Fltr 1 03853870 26 Bearing Kit Cr Shf 1 2 3 4 0...

Page 296: ...p 3 09424877 51 Reinforcement Eng Frt Cvr Incl w 31 1 NSS 52 Gasket Oil Pan 1 14096637 53 Bolt Eng Frt Cvr 12 09442895 54 Pump Oil 1 14091485 55 Nozzle Cm Shf Gr Lub 1 03875950 56 Bracket O Pmp 1 03970417 57 Crankshaft 1 93442002 58 Bolt Hex 1 4 20 x 3 4 1 09425113 59 Washer Flat 1 11609328 60 Nut O Pmp 1 09442946 61 Pin Oil Press Flf Vlv 1 12551790 62 Screen O Pmp Part of 54 1 02778192 63 Bolt Cr...

Page 297: ...85 Plug Eng Blk Core Hole AR 03826505 86 Plug Oil 1 NSS 87 Plug Eng Blk Oil 1 03835577 88 Tube Oil Lvl 1 93434708 89 Indicator Oil Lvl 1 14025224 90 Sealer Vlv Push Rod Cvr AR 12346286 91 Stud Vlv Push Rod Cvr 4 00352169 92 Nut Vlv Push Rod Cvr 4 00451399 93 Washer Vlv Push Rod Cvr 4 02436163 94 Ring Cr Shf Psn Sen Reluctor 1 NSS 95 Seal Cr Shf Psn Sen Conn 1 NSS 96 Sensor Cr Shf Posn 1 12567712 9...

Page 298: ...298 ...

Page 299: ...299 Labor Time Guide ...

Page 300: ...tices The times were calculated using an engine mounted on a stand TIME ALLOWANCES The labor times include the removal disassem bly cleaning re assembly installation and or adjustment of the affected component or assem bly Any cleaning time is limited to the installation or replacement of components such as mating surfaces and does not include clean ing other areas of the vehicle contaminated by f...

Page 301: ... is the process used to de termine the source of the problem and is the responsibility of both the technician and dealer ship management Symptom Diagnosis is complete when the cause of failure has been identified REPAIR DIAGNOSIS These are the checks tests and measurements required to identify the cause of a failure and or failed part Examples include Cleaning and inspection of all parts Use of te...

Page 302: ...is included in all labor time operations Additional Diagnostics is time that is necessary to complete a satisfactory diagnosis that beyond the normal time allowed This time must be identified as Additional Diag nostics and follow the same time recording and labor step documentation as Straight Time It is the responsibility of qualified dealership su pervisory personnel to assist technicians in bot...

Page 303: ...PLUGS SPARK REPLACE ALL J4227 0 7 WIRES SPARK PLUG REPLACE ALL J4207 0 3 COIL IGNITION REPLACEMENT J4340 0 6 BRACKET FUSE BOX REPLACE E3037 0 4 LPG FUEL CONTROL SYSTEM CHECK INCLUDES Connect scan tool or test equipment Check for trouble codes DTCs check HEGO operation disconnect scan tool or test equipment M1007 0 3 ELECTRONIC THROTTLE BODY REPLACEMENT M0075 0 8 THROTTLE BODY GASKET REPLACEMENT E3...

Page 304: ...REPLACEMENT J4590 0 5 ENGINE COOLANT TEMP SENSOR AND OR ADAPTER REPLACE J4591 0 6 CAMSHAFT SENSOR REPLACEMENT E3019 0 6 CRANK POSITION SENSOR REPLACEMENT J4592 0 7 TEMP MANIFOLD PRESSURE SENSOR TMAP REPLACEMENT F1015 0 7 FUEL TEMPERATURE PRESSURE SENSOR REPLACEMENT E3002 0 5 HEATED EXHAUST GAS OXYGEN SENSOR HEGO REPLACEMENT N1002 0 8 ...

Page 305: ...5 FUEL FILTER LOW PRESSURE VAPOR REPLACE E3042 0 3 BRACKET LOW PRESSURE VAPOR LPG FILTER REPLACE E3052 0 3 BRACKET REGULATOR MOUNTING REPLACEMENT E3009 0 5 FUEL INJECTOR ADAPTER AND OR FUEL RAIL REPLACE ADD Each Additional Fuel Injector ADD Fuel Injector Hose ADD Fuel Injector Adapter each E3044 1 0 0 2 0 1 0 1 FUEL RAIL BRACKET REPLACE E3046 0 3 LEAK CHECK LPG SYSTEM G0004 0 2 LPG FUEL SYSTEM PRE...

Page 306: ...ESCRIPTION OPERATION NUMBER TIME ALLOWED COOLANT HOSES REPLACE ALL INCLUDES Drain Fill Radiator T1001 0 7 COOLANT HOSE PORT FITTING REPLACE E3047 0 3 FUEL VAPOR HOSE REPLACE ALL INCLUDES Replacement of Vapor Hose Port Fittings E3048 0 4 FUEL VAPOR HOSE PORT FITTING REPLACE E3049 0 2 VACUUM LINE REPLACE ONE ADD Additional Line Replace Allowances Diagnosis Time 0 1 T1002 0 4 0 1 PCV INSPECT OR REPLA...

Page 307: ... DESCRIPTION OPERATION NUMBER TIME ALLOWED WATER PUMP AND OR GASKET REPLACE J3480 0 7 STARTER REPLACEMENT J4560 0 6 ALTERNATOR REPLACEMENT J4570 0 5 DRIVE BELT REPLACEMENT J4571 0 5 THERMOSTAT AND OR GASKET REPLACEMENT J4580 0 4 FLYWHEEL HARMONIC BALANCER REPLACEMENT J0720 0 5 ...

Page 308: ... HEAD GASKET REPLACEMENT Includes R R intake manifold rocker covers s and compression test J0508 2 3 CYLINDER HEAD REPLACEMENT Includes R R intake manifold rocker cover s and compression test J0518 3 0 VALVE RECONDITION OR REPLACEMENT ADD Each additional cylinder ADD To recondition all valves ADD To ream and fit guides for oversize stems J0528 2 9 0 4 0 9 0 2 VALVE SPRING CAP AND OR SEALS REPLACEM...

Page 309: ...CEMENT J0850 6 0 OIL PAN AND OR GASKET REPLACEMENT Includes Fluid replacement J1000 2 2 PUMP ENGINE OIL REPLACEMENT Includes R R engine oil pan and fluid replacement J1020 2 5 SEAL REAR MAIN BEARING REPLACEMENT Includes R R engine oil pan and fluid replace lower seal and repack upper seal J1120 2 8 BEARING CRANKSHAFT MAIN REPLACE ONE Includes R R engine oil pan and fluid and use of plastic type ga...

Page 310: ...CEMENT Includes R R all necessary components and use of plastic type gauge ADD Replace rings only Each piston NOT to exceed ALL All pistons ADD To replace connecting rods only Each rod NOT to exceed ALL All rods ADD To replace pistons only Each piston NOT to exceed ALL All pistons J1308 3 3 0 4 2 2 0 3 1 2 0 4 2 4 PLUG EXPANSION REPLACEMENT Note Use appropriate labor operation s for removal of nec...

Page 311: ...l components fluids and accessories ADD To recondition all valves and guides J1800 9 0 2 6 ENGINE PARTIAL REPLACEMENT Includes R R all components fluids and accessories ADD To recondition all valves and guides J1820 7 2 2 6 ENGINE ASSEMBLY REPLACEMENT Includes R R all components fluids and accessories J1880 3 5 ENGINE MOUNTS FRONT REPLACEMENT J1506 0 3 ...

Page 312: ...IME ALLOWED ADDITIONAL DIAGNOSTIC TIME Policy B Subject to review by IMPCO Technical Support G0001 Policy B 0 5 FASTENER OR FITTING TIGHTENING G0003 0 1 DRIVE TESTS G0006 0 2 SUBLET TIME Policy S Requires Prior Approval By IMPCO Technical Support G0007 Policy S 0 0 ...

Page 313: ...on identifying the technician s 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 pro vided OEM RESPONSIBILITIES Your request for review must include a detailed step by step description of your labor procedure in the space provide...

Page 314: ...ist all compo nents numbers type of fasteners and any Special Service Tools or procedures that are required Use the Labor Time Study form and include it with the Request for Review sheet on page 18 When complete send both forms to IMPCO Technologies 3030 South Susan Street Santa Ana CA 92704 Attn Technical Service Labor Time Review ...

Page 315: ..._____ TECHNICIAN INFORMATION Technician s Name Are you certified in this area of repair Yes No How many times have you performed this repair Once Twice How many Is the IMPCO Service Manual Supplement accurate Yes No Describe the inaccuracy Please include any additional inaccuracies and or suggestions on a separate sheet We welcome your input Have you attended an IMPCO Technical Training Class for ...

Page 316: ... TIME STUDY FORM Step Labor Description Watch Time Min Sec 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 Attach additional sheets if necessary Total Repair Time minutes seconds ...

Page 317: ...317 Definitions ...

Page 318: ...rmation 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 Crankshaft Position Sensor CMP Camshaft Position Sensor Conductor A material normally metallic that permits easy passage of electricity Contaminants Impurities or foreign material present in fuel Contr...

Page 319: ... specific 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 pressure relief device installed in the liquid LPG hose on a LPG fuel system IAT Intake Air Temperature Ideal Mixture The air fuel ratio at which the best compromise of engine performance to exhaust emi...

Page 320: ...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 increase the oxygen content and therefore reduce exhaust emissions Ozone A radical oxygen module O3 that is found in the upper atmosphere and filters out ultraviolet radiation from the sun Ground level ozone is formed by NOX during the for...

Page 321: ...on 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 USB Universal Serial Bus A plug or interface sup plied on most personal computers Vaporization A process in which liquid changes states into gas Venturi Air Valve Vacuum VAVV An amplified air valve vac...

Page 322: ...322 ...

Page 323: ...323 Appendix ...

Page 324: ...2 13 000 58 66 8 4 9 6 12 000 61 69 8 8 10 0 11 000 64 72 9 3 10 4 10 000 66 74 9 6 10 7 9 000 69 77 10 0 11 2 8 000 71 79 10 3 11 4 7 000 74 82 10 7 11 9 6 000 77 85 11 2 12 3 5 000 80 88 11 6 12 8 4 000 83 91 12 0 13 2 3 000 87 95 12 6 13 8 2 000 90 98 13 0 14 2 1 000 94 102 13 6 14 8 0 96 104 13 9 15 0 1 000 101 105 14 6 15 2 ...

Page 325: ...325 Ignition System Specifications Firing Order 1 6 5 4 3 2 Spark Plug Type R44LTS AC Plug Spark Plug Gap 035 in 0 889 mm Spark Plug Torque 11 lb ft 15 N m Spark Plug Wire Resistance 1000 Ohms per ft ...

Page 326: ...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 5 7280 32 0 9420 23 5 12300 14 10 16180 5 15 21450 4 20 28680 22 30 52700 40 40 100700 ...

Page 327: ...327 DTC SPN FMI Chart ...

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