Maintenance

ELECTRONIC ENGINE
CONTROL
TROUBLESHOOTING AND REPAIR
GM 3.0L ENGINE
GP/GLP/GDP2.00-3.00RF/TF
(GP/GLP/GDP040-060RG/TG/ZG) [A875];
GC/GLC040-065RG/TG/ZG [E187]
GM 4.3L ENGINE
GDP60-70CA (GP/GLP/GDP135-155CA) [A878];
GLC60-70CA (GC/GLC/GDC135-155CA) [A879];
GP/GLP/GDP070-110LG/MG [B813];
GC/GLC070-120LG/MG [B818]

PART NO. 524153918 2200 YRM 782

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Electronic Engine Control Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Troubleshooting Procedure ............................................................................................................................. 1
How This Section Is Arranged......................................................................................................................... 1
Where Do I Start? ........................................................................................................................................... 1
Visual/Physical Inspection............................................................................................................................... 1
Knowledge/Tools Required ............................................................................................................................. 1
Damage From Static Discharge (Static Electricity) ......................................................................................... 1
Troubleshooting Information ............................................................................................................................ 2
Malfunction Indicator Lamp (MIL) ............................................................................................................... 2
Reading Diagnostic Trouble Codes (DTC).................................................................................................. 2
Clearing Diagnostic Trouble Codes (DTCs) ................................................................................................ 6
ECM Diagnostic Codes Available.................................................................................................................... 7
Diagnostic Mode ......................................................................................................................................... 7
Field Service Mode ..................................................................................................................................... 7
ECM Learning Ability .................................................................................................................................. 7
SCAN Tool Information.................................................................................................................................... 8
On-Board Diagnostic (OBD) System Check ................................................................................................... 9
Test Description .......................................................................................................................................... 9
Troubleshooting Charts ....................................................................................................................................... 11
General ........................................................................................................................................................... 11
Tools and Test Equipment........................................................................................................................... 11
Troubleshooting Chart Description Summary ................................................................................................. 12
A-1 - No Malfunction Indicator Lamp ................................................................................................................... 12
Circuit Description ........................................................................................................................................... 12
Test Description............................................................................................................................................... 13
Other Troubleshooting Checks ........................................................................................................................ 13
A-2 - No Scan Data, No DTC 12, Malfunction Indicator Lamp ON...................................................................... 15
Circuit Description ........................................................................................................................................... 15
Test Description............................................................................................................................................... 15
A-3 - Starter Rotates Engine, Engine Will Not Run ............................................................................................. 17
Circuit Description ........................................................................................................................................... 17
Test Description............................................................................................................................................... 17
Other Troubleshooting Checks ........................................................................................................................ 17
A-4 - Fuel Injector Circuit..................................................................................................................................... 19
Test Description............................................................................................................................................... 19
A-5 - Fuel Pump Relay Circuit ............................................................................................................................. 21
Circuit Description ........................................................................................................................................... 21
Test Description............................................................................................................................................... 21
Other Troubleshooting Checks ........................................................................................................................ 21
A-6 - Fuel System Troubleshooting ..................................................................................................................... 23
Circuit Description ........................................................................................................................................... 23
Test Description............................................................................................................................................... 23
Other Troubleshooting Checks ........................................................................................................................ 23
Test Description............................................................................................................................................... 25
Fuel Pressure Check....................................................................................................................................... 27
A-7 - Ignition System Troubleshooting................................................................................................................. 27
Test Description............................................................................................................................................... 28
DTC 14 Engine Coolant Temperature Sensor Circuit (Low Temperature Indicated) ........................................... 31
Circuit Description ........................................................................................................................................... 31
Test Description............................................................................................................................................... 31
Other Troubleshooting Checks ........................................................................................................................ 31

©2003 Yale Materials Handling Corp. i

Table of Contents Electronic Engine Control

TABLE OF CONTENTS (Continued)

DTC 15 Engine Coolant Temperature Sensor Circuit (High Temperature Indicated) .......................................... 33
Circuit Description ........................................................................................................................................... 33
Test Description............................................................................................................................................... 33
Other Troubleshooting Checks ........................................................................................................................ 33
DTC 21 Throttle Position Sensor Circuit (Signal Voltage High) ........................................................................... 35
Circuit Description ........................................................................................................................................... 35
Test Description............................................................................................................................................... 35
Other Troubleshooting Checks ........................................................................................................................ 35
DTC 22 Throttle Position Sensor Circuit (Signal Voltage Low) ............................................................................ 37
Circuit Description ........................................................................................................................................... 37
Test Description............................................................................................................................................... 37
Other Troubleshooting Checks ........................................................................................................................ 37
DTC 31 Engine Governor Circuit......................................................................................................................... 39
Circuit Description ........................................................................................................................................... 39
Test Description............................................................................................................................................... 39
Other Troubleshooting Checks ........................................................................................................................ 39
DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage High - Low Vacuum) ...................... 41
Circuit Description ........................................................................................................................................... 41
Test Description............................................................................................................................................... 41
Other Troubleshooting Checks ........................................................................................................................ 41
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage Low - High Vacuum) ...................... 43
Circuit Description ........................................................................................................................................... 43
Test Description............................................................................................................................................... 43
Other Troubleshooting Checks ........................................................................................................................ 43
DTC 41 Electronic Spark Timing (EST) - Open EST Circuit ............................................................................... 45
Circuit Description ........................................................................................................................................... 45
Test Description............................................................................................................................................... 45
Other Troubleshooting Checks ........................................................................................................................ 45
DTC 42 EST - Grounded EST Circuit, Open or Grounded Bypass Circuit.......................................................... 47
Circuit Description ........................................................................................................................................... 47
Test Description............................................................................................................................................... 48
Other Troubleshooting Checks ........................................................................................................................ 48
DTC 51 ECM Failure ........................................................................................................................................... 50
Circuit Description ........................................................................................................................................... 50
Other Troubleshooting Checks ........................................................................................................................ 50
Troubleshooting, Poor Operation ......................................................................................................................... 51
General ........................................................................................................................................................... 51
Make a Careful Visual Check .......................................................................................................................... 51
FAULT: Codes or Performance That Is Not Regular........................................................................................ 51
FAULT: Loss of Diagnostic Trouble Code (DTC) Memory ............................................................................... 51
FAULT: Engine Quits While Driving ................................................................................................................. 51
Additional Checks ....................................................................................................................................... 51
FAULT: Engine Is Difficult to Start ................................................................................................................... 51
FAULT: Variation in Engine Power When Throttle Is Held Steady................................................................... 52
FAULT: Decreased Engine Power ................................................................................................................... 52
FAULT: Detonation .......................................................................................................................................... 53
FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes ........................................... 53
FAULT: One or More Cylinders Do Not Operate Correctly - Engine Does Not Idle Correctly ......................... 54
FAULT: Rough Idle or Engine Stalls During Idle.............................................................................................. 54
FAULT: Fuel Usage Too High .......................................................................................................................... 54
FAULT: Dieseling ............................................................................................................................................. 55

ii
Electronic Engine Control Table of Contents

TABLE OF CONTENTS (Continued)

FAULT: Backfire............................................................................................................................................... 55
System Test Charts ............................................................................................................................................. 55
General ........................................................................................................................................................... 55
Engine Coolant Temperature (ECT) Sensor Test ............................................................................................ 55
Throttle Position (TP) Sensor Check ............................................................................................................... 56
Minimum Idle Speed ....................................................................................................................................... 56
Adjustment.................................................................................................................................................. 57
B-1 - Idle Air Control (IAC) System Check........................................................................................................... 58
Circuit Description ........................................................................................................................................... 58
Other Troubleshooting Checks ........................................................................................................................ 58
B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test ............................................................................. 60
Circuit Description ........................................................................................................................................... 60
Test Description............................................................................................................................................... 60
B-3 - Check Governor System............................................................................................................................. 62
Governor System Not Operating Correctly...................................................................................................... 62
Check Function of Governor System .............................................................................................................. 62
Check PCV System......................................................................................................................................... 63
Fuel System Components Repair........................................................................................................................ 63
General ........................................................................................................................................................... 63
Fuel Pressure Relief Procedure ...................................................................................................................... 63
Fuel Pump Replacement................................................................................................................................. 63
Throttle Body Injection Unit (TBI) .................................................................................................................... 64
Remove....................................................................................................................................................... 64
Clean and Inspect ....................................................................................................................................... 65
Install .......................................................................................................................................................... 65
Fuel Meter Body.............................................................................................................................................. 65
Remove....................................................................................................................................................... 65
Install .......................................................................................................................................................... 68
Fuel Injector .................................................................................................................................................... 68
Remove....................................................................................................................................................... 68
Install .......................................................................................................................................................... 69
Pressure Regulator ......................................................................................................................................... 69
Remove....................................................................................................................................................... 69
Inspect ........................................................................................................................................................ 69
Install .......................................................................................................................................................... 69
Throttle Position Sensor (TPS)........................................................................................................................ 70
Remove....................................................................................................................................................... 70
Install .......................................................................................................................................................... 70
Idle Air Control (IAC) Valve ............................................................................................................................. 70
Remove....................................................................................................................................................... 70
Clean and Inspect ....................................................................................................................................... 70
Install .......................................................................................................................................................... 71
Governor System 3.0L Engine Repair................................................................................................................. 71
Governor Module, Replace ............................................................................................................................. 71
Governor Motor, Replace ................................................................................................................................ 71
Throttle Cables, Install and Adjust................................................................................................................... 71
Foot Directional Control Pedal, Check ............................................................................................................ 72
Governor System 4.3L Engine Repair................................................................................................................. 73
Governor Throttle Drive Assembly .................................................................................................................. 73
Remove....................................................................................................................................................... 73
Inspect ........................................................................................................................................................ 74

iii
Table of Contents Electronic Engine Control

TABLE OF CONTENTS (Continued)

Install .......................................................................................................................................................... 74
Governor Drive Motor...................................................................................................................................... 74
Remove....................................................................................................................................................... 74
Clean and Lubricate.................................................................................................................................... 74
Install .......................................................................................................................................................... 75
Inspect ........................................................................................................................................................ 76
Ignition System Components Repair ................................................................................................................... 76
ECM Replacement .......................................................................................................................................... 76
Function Check ............................................................................................................................................... 76
Distributor........................................................................................................................................................ 76
Remove....................................................................................................................................................... 76
Disassemble ............................................................................................................................................... 76
Inspect ........................................................................................................................................................ 77
Assemble .................................................................................................................................................... 77
Install .......................................................................................................................................................... 77
Firing Order................................................................................................................................................. 78
Ignition Timing ............................................................................................................................................ 78
Ignition Module Repair......................................................................................................................................... 78
Test For Fault................................................................................................................................................... 78
Replace ........................................................................................................................................................... 79
Sensing Coil .................................................................................................................................................... 79
Test ............................................................................................................................................................. 79
Replace....................................................................................................................................................... 80
Ignition Coil ..................................................................................................................................................... 80
Test ............................................................................................................................................................. 80
Remove....................................................................................................................................................... 80
Install .......................................................................................................................................................... 81
Sensors Repair.................................................................................................................................................... 81
Engine Coolant Temperature (ECT) Sensor, Replace .................................................................................... 81
MAP Sensor, Replace ..................................................................................................................................... 81
PCV System Repair............................................................................................................................................. 82
Replace ........................................................................................................................................................... 82
Wiring .................................................................................................................................................................. 82
Connectors and Terminals .............................................................................................................................. 82
Procedures for Spark Plugs, Spark Plug Wires, and Boots ............................................................................ 85
Wiring Diagram ............................................................................................................................................... 85
Spark Plugs Troubleshooting............................................................................................................................... 90
Special Tools ....................................................................................................................................................... 91

This section is for the following models:

GM 3.0L EngineGP/GLP/GDP2.00-3.00RF/TF (GP/GLP/GDP040-

060RG/TG/ZG) [A875];
GC/GLC040-065RG/TG/ZG [E187]
GM 4.3L EngineGDP60-70CA (GP/GLP/GDP135-155CA) [A878];
GLC60-70CA (GC/GLC/GDC135-155CA) [A879];
GP/GLP/GDP070-110LG/MG [B813];
GC/GLC070-120LG/MG [B818]

iv
2200 YRM 782
General
This section contains troubleshooting and repair proce-
dures for parts of the electronic engine controls. Users
of this section must know components and operation
as described in the section Electronic Engine Control
Description and Operation 2200 YRM 781.
The electronic engine control system is made of many
parts. The main parts are the Throttle Body Injection
(TBI) unit and the Electronic Control Module (ECM).
See Figure 1. These parts and their sensors provide in-
formation about engine operation and the systems they
control. The ECM has the ability to perform some trou-
bleshooting of itself and of other parts of the system.
When a problem is found, the ECM turns ON the Mal-
function Indicator Lamp that is in the instrument cluster.
A Diagnostic Trouble Code (DTC) is kept in the memory
of the ECM.
1. ECM 3. J2 CONNECTOR
2. J1 CONNECTOR
Figure 1. ECM
TROUBLESHOOTING PROCEDURE
Before using this part of the manual, knowledge of
correct troubleshooting procedures is required. If cor-
rect troubleshooting procedures are not followed, as
described in this section, replacement of good parts
can result. Troubleshooting charts use a SCAN Tool
where possible. The SCAN Tool has the ability to save
time in troubleshooting and preventing replacement of
good parts.
HOW THIS SECTION IS ARRANGED
This section is in 5 parts that describe troubleshooting
and repair procedures. They are as follows:
General
Troubleshooting Charts
Troubleshooting, Poor Operation
General
System Test Charts
Repairs
WHERE DO I START?
There are 3 things to do to start troubleshooting. First
is to become familiar with the electronic engine control
system.
Second, always start your work with a good visual/phys-
ical inspection. See the following paragraph for more
explanation.
Third is the On-Board Diagnostic (OBD) System Check.
VISUAL/PHYSICAL INSPECTION
A careful visual and physical inspection must be done
as part of any diagnostic procedure. This can solve the
repair of a problem without further steps. Inspect all
vacuum hoses for correct routing, restrictions, cuts, or
bad connections. Be sure to inspect hoses that are dif-
ficult to see beneath the air filter. Inspect all wires in the
engine compartment for proper connections, damaged
spots, or contact with sharp edges or the exhaust man-
ifolds. This visual/physical inspection is very important.
It must be done carefully.
KNOWLEDGE/TOOLS REQUIRED
To use this manual most effectively, a general under-
standing of basic electrical circuits and circuit testing
tools is required. One should be familiar with wiring dia-
grams, the meaning of voltage, ohms, amps, basic the-
ories of electricity, and understand what happens in an
open or shorted wire. To perform troubleshooting pro-
cedures, use of a diagnostic SCAN Tool is required. A
tachometer, test lamp, ohmmeter, digital voltmeter with
10 megohms impedance, vacuum gauge, and jumper
wires are also required. Special tools that are required
for system service and the ones described above are
shown in the Special Tools section found in back of this
manual.
DAMAGE FROM STATIC DISCHARGE
(STATIC ELECTRICITY)
NOTE: To prevent damage by static electricity, DO NOT
touch the ECM connector pins.
Electronic components used in control systems use a
very low voltage, and can be easily damaged by static
discharge or static electricity. Less than 100 volts of
static electricity can cause damage to some electronic
1
General 2200 YRM 782

components. There are several ways for a person to problem goes away, the lamp will go out after 10 sec-
become statically charged. Most common methods of onds. In either condition a DTC will remain in the ECM.
charging are by friction and by induction. An example of
charging by friction is a person sliding across a car seat; When the lamp remains ON while the engine is running,
in which a charge of as much as 2 to 5,000 volts can or when there is a malfunction, On-Board Diagnostic
build up. Charging by induction occurs when a person (OBD) System Check must be done.
with well-insulated shoes stands near a highly charged
When a problem is not regular or constant, the Malfunc-
object and momentarily touches ground. Charges of
tion Indicator Lamp will turn ON for approximately 10
the same polarity are drained off, leaving the person
seconds and then turns OFF. However, the Diagnostic
highly charged with the opposite polarity. Static charges
Trouble Code (DTC) is kept in memory of the ECM un-
of either type can cause damage, therefore, it is impor-
til DTCs are cleared (see Clearing Diagnostic Trouble
tant to use care when handling and testing electronic
Codes (DTCs) in this section). A DTC that is not con-
components.
stant can reset. If it is a problem that is not constant, a
DTC Chart is not used. However you can use the Other
TROUBLESHOOTING INFORMATION
Troubleshooting Checks in the section for that DTC to
Troubleshooting charts and function checks in this help locate the problem.
section are designed to find a bad circuit or component
through logic based on the process of elimination. Reading Diagnostic Trouble Codes (DTC)
Charts are prepared with the requirement that the ve-
The Diagnostic Connector (see Figure 2) is used to
hicle functioned correctly at time of assembly and that
communicate with the ECM. The Diagnostic Connec-
there are no multiple failures. ECM does constant test-
tor is installed on the bracket near the valve cover. See
ing on certain control functions. ECM communicates
Figure 3 and Figure 4. It is used in the assembly plant
the source of a malfunction with Diagnostic Trouble
to receive information in checking that the engine is op-
Codes (DTC). DTCs are two-digit numbers that can
erating correctly before it leaves the plant. DTC(s) kept
range from 12 to 99. When a malfunction is found by
in the ECM’s memory can be read with a SCAN Tool
the ECM, a DTC is set and Malfunction Indicator Lamp
connected to the Diagnostic Connector.
is turned ON.

Malfunction Indicator Lamp (MIL)

This lamp is on the instrument cluster and has the fol-
lowing functions:

It lets the operator know that a problem has occurred

and that the vehicle must be taken in for service as soon
as possible. A. GROUND
B. FAULT ANALYSIS TERMINAL
It displays Diagnostic Trouble Codes (DTC’s) kept by C. NOT USED
D. NOT USED
the ECM which help the technician troubleshoot system E. CHECK ENGINE LIGHT
problems. F. +12 VOLTS
G. SERIAL DATA FOR SCAN TOOL TESTER
As a bulb and system check, the lamp will come ON H. NOT USED
with the ignition switch ON and the engine not running. J. NOT USED
When the engine is started, the lamp will turn OFF. K. NOT USED

If the lamp remains ON, the system has found a prob- Figure 2. Diagnostic Connector
lem. This problem is referred to as a current DTC. If the

2
2200 YRM 782 General

Figure 3. Electronic Engine Control Components Arrangement (GM 3.0L Engine)

3
General 2200 YRM 782

Legend for Figure 3

A. TOP VIEW B. SIDE VIEW
1. THROTTLE BODY INJECTION (TBI) UNIT 9. GOVERNOR MOTOR
2. FUEL INJECTOR 10. FUEL PUMP RELAY
3. FUEL INJECTOR FUSE 11. DIAGNOSTIC CONNECTOR
4. ECM FUSE (IGNITION) 12. FUEL PUMP FUSE
5. STARTER FUSE 13. ECM FUSE (B+)
6. ENGINE COOLANT TEMPERATURE (ECT) 14. MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR 15. OIL PRESSURE SWITCH
7. DISTRIBUTOR 16. IGNITION COIL
8. ELECTRONIC CONTROL MODULE (ECM)

4
2200 YRM 782 General

Figure 4. Electronic Engine Control Components Arrangement (GM 4.3L Engine)

5
General 2200 YRM 782

Legend for Figure 4

A. TOP VIEW B. VIEW FROM TRANSMISSION
1. ENGINE COOLANT TEMPERATURE SENSOR 10. FUEL PRESSURE TEST PORT
(ECT) 11. FUEL FILTER
2. FUEL PUMP FUSE 12. THROTTLE BODY INJECTOR
3. ECM FUSE (B+) 13. FUEL INJECTORS
4. THROTTLE POSITION SENSOR (TPS) 14. MANIFOLD ABSOLUTE PRESSURE (MAP)
5. ELECTRONIC CONTROL MODULE (ECM) SENSOR
6. IDLE AIR CONTROL (IAC) 15. FUEL PUMP RELAY
7. DIAGNOSTIC CONNECTOR 16. OIL PRESSURE SWITCH
8. IGNITION COIL 17. OIL PRESSURE SENDER
9. TYPE EST DISTRIBUTOR 18. TEMPERATURE GAUGE SENDER

When SCAN Tool is connected to the Diagnostic Con- correctly at this time. If DTC 12 is not indicated, a prob-
nector with key switch ON and engine OFF, the system lem is in the diagnostic system itself.
will enter the Diagnostic Mode. At this point, the Mal-
function Indicator Lamp will flash DTC 12 3 times con- Following the output of DTC 12, if additional codes are
secutively (see Figure 5). The following is the flash se- stored, the Malfunction Indicator Lamp will flash the
quence for DTC 12: DTC 3 times. If more than one DTC has been stored
• Long pause in the ECM’s memory, the DTC’s will be flashed start-
• Flash ing with the newest DTC set and finishing with the old-
• Pause est DTC set. Remember each DTC will be flashed 3
• Flash-flash times. When all DTCs have been flashed the sequence
• Long pause will start over again with DTC 12.
• Flash
• Pause Clearing Diagnostic Trouble Codes (DTCs)
• Flash-flash
Install the SCAN Tool according to the operator’s
• Long pause flash
manual for the tool. Select clear DTCs from the tools
• Pause
menu. This operation electronically clears all ECM
• Flash-flash
DTCs. Check for DTCs again to see that the DTCs are
DTC 12 (which means no crankshaft rpm signal) in- cleared.
dicates that the ECM’s diagnostic system is operating

1. LONG PAUSE 2. FLASH 3. PAUSE 4. FLASH-FLASH

Figure 5. Diagnostic Trouble Code 12 Example

6
2200 YRM 782 General

ECM DIAGNOSTIC CODES AVAILABLE

Table 1. ECM Diagnostic Codes Available

Turn On Malfunction
Code Description
Indicator Lamp
12 Indicates that Fault Monitor System is working correctly No
14 Engine Coolant Temperature Sensor Circuit - High Volts Yes
15 Engine Coolant Temperature Sensor Circuit - Low Volts Yes
21 Throttle Position Sensor - High Volts Yes
22 Throttle Position Sensor - Low Volts Yes
31 Governor Circuit Malfunction Yes
33 MAP Sensor Circuit - High Volts Yes
34 MAP Sensor Circuit - Low Volts Yes
41 Ignition Control (IC) System. Open EST Circuit Yes
42 Ignition Control (IC) System - Grounded EST Circuit or Open or Grounded Yes
Bypass Circuit.
51 ECM Internal Problem Yes

Diagnostic Mode If the SCAN Tool is connected to the Diagnostic Con-

CAUTION
To prevent ECM damage, the key must be OFF when
disconnecting or reconnecting ECM power.
When the SCAN Tool is connected to the Diagnostic
Connector with the key switch ON and the engine OFF,
the system will enter the Diagnostic Mode.
nector and turned ON with the engine running, system
will enter Field Service Mode. For the GM 3.0L en-
gine, this will cause the engine to run at approximately
1500 rpm and 8 before top dead center spark advance.
For GM 4.3L engine, the numbers are approximately
1000 rpm and 0 before top dead center spark advance.
While the system is in Field Service Mode, new trouble
codes can be kept in the ECM.

1. Display a DTC 12 by flashing the Malfunction Indi- ECM Learning Ability

cator Lamp (indicating the system is operating cor-
rectly).
2. Display any additional stored DTCs by flashing the
Malfunction Indicator lamp. Each DTC will flash 3
times, then DTC 12 will flash again.
3. The Idle Air Control (IAC) valve moves to its fully
extended position, blocking the idle air passage.
The ECM has a learning ability that lets it make cor-
rections for variations in the idle system to improve idle
performance. If the battery is disconnected for any rea-
son, the learning process resets and begins again. To
teach the vehicle, make sure that the engine is at op-
erating temperature. Drive the lift truck at part throttle,
with moderate acceleration, and idle until normal per-
formance returns.

Field Service Mode

NOTE: The ignition timing can be set with a timing light.

7
General 2200 YRM 782

SCAN TOOL INFORMATION

Table 2. SCAN Tool Information

Test under following conditions:

Idle speed, upper radiator hose hot, throttle closed, NEUTRAL, all accessories OFF
SCAN Position Units Displayed Values
Engine Speed rpm ±100 rpm from desired idle.
Idle Speed rpm ECM idle command (changes with temperature)
Coolant Temp. C/ F 85 to 100 C (180 to 212 F)
Ignition Volts volts 12.5 to 14.5 v
MAP Volts/kPa 1 to 2 volts (depends on Vac. and BARO press.),
30 to 40 kPa (4 to 6 psi)
BARO Volts/kPa 1 to 2 volts (depends on BARO pressure), 98 to
102 kPa (14 to 15 psi)
Throttle Position volts 0.45 to 1.25 v
Throttle Angle 0 to 100% 0
Governor TPS 0 to 100% 0
Desired Governor TPS 0 to 100% 0
Governor Enable Yes/No Yes
Governor rpm Control Active/Not Active Not Active
Governor rpm Mode High rpm/Normal Normal
Idle Air Control Counts/Steps Between 5 and 50
rpm Overspeed Yes/No No
Fuel Trim Steps N/A
Injector Pulse Width MSec 0.8 to 3.0 mSEC
Spark Advance No. of Degrees Varies
Base Timing N/A N/A
Knock Signal Yes/No No
Knock Retard No. of Degrees
Governor mph Control Active/Not Active Not Active
Vehicle Speed mph 0 mph
mph Overspeed Yes/No No
Low Oil Pressure Yes/No No
Power Steering Switch Normal/High Normal
Emergency Stop Active/Not Active Not Active
Lift Mode Active/Not Active Not Active
EEPROM ID number XXXX (varies with calibration) - 2201
Time From Start hrs., min., sec. 0:00:00 to 18:12:15

8
2200 YRM 782
ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK
On-Board Diagnostic (OBD) System Check is a trou-
bleshooting chart to find a problem caused by a mal-
function in the electronic engine control system. See
Figure 6. It must be the starting point for any trou-
bleshooting.
SCAN data shown in Table 2 can be used for com-
parison after doing troubleshooting checks and finding
On-Board Diagnostics working correctly with no trouble
codes shown. The data are an average of display val-
ues from normally operating vehicles and show a dis-
play of a normally operating system.
After visual/physical inspection, On-Board Diagnostic
(OBD) System Check is the starting point for all trou-
bleshooting procedures.
The correct procedure to find a problem is to follow 3
basic steps.
1. Are On-Board Diagnostics working? This is deter-
mined by doing the OBD System Check Since this
is the starting point for troubleshooting procedures,
always begin here.
If On-Board Diagnostics do not work, the OBD System
Check will not lead to a troubleshooting chart to fix the
problem. If On-Board Diagnostics are working correctly,
go to the next step.
General
2. Is there a Diagnostic Trouble Code? If there is a
DTC, go directly to the DTC chart for that number.
This will determine if the fault is still there. If there
is no DTC, proceed to Step 3.
3. SCAN Serial Data transmitted by the ECM. This in-
volves reading the information available on the Se-
rial Data Stream with one of the tools available for
that purpose. Information on these tools and the
meaning of the displays can be found in the opera-
tor’s manual of the tool. Readings for certain oper-
ating conditions can be found in Table 2.
Test Description
The numbers below are a reference to the bold numbers
in Figure 6.
1. Diagnostic Trouble Code (DTC) 12 means no rpm
reference pulses from the ignition module. This is
correct when engine is not running.
2. Checks the Serial Data Circuit (HZ) in Figure 8 and
ensures ECM is able to transmit Serial Data.
3. A SCAN Tool Parameter that is not within typical
ranges may help isolate the area which is causing
the problem.
9
General 2200 YRM 782

Figure 6. On-Board Diagnostic Check System

10
2200 YRM 782 Troubleshooting Charts

Troubleshooting Charts
GENERAL • If the engine compartment is cleaned with steam,
make sure that any water or steam is not sent
WARNING toward the ECM or its sensors. The heat and
steam can damage the electronic components
This troubleshooting requires the operation of the
and cause corrosion in the electrical connec-
engine for some tests. Make sure tests are done
tions.
carefully to prevent injury:
• Use only the tools and test equipment described
• Put the lift truck on a level surface. Lower the
in Tools and Test Equipment to prevent damage
carriage and forks and apply the parking brake.
to good components and to obtain correct test
Make sure the lift truck cannot move and cause an
results.
injury during the tests. Use blocks as necessary
• All voltage measurements must be made with a
to prevent movement of the lift truck.
digital voltmeter with a rating of 10 megohm input
• The fuel system and the engine must operate cor-
impedance.
rectly. Any problems or leaks in the fuel sys-
• When a test light is used in troubleshooting, the
tem and the engine must be repaired before doing
test light must have less than 0.3 amps (300 mil-
troubleshooting.
liamps) of maximum current flow. A test for a cor-
• The fan and the drive belts can remove fingers or
rect test light is shown in Figure 7.
cause other injuries. Be careful that your hands
and tools do not touch the moving fan or the drive The following troubleshooting charts are designed to
belts. give an efficient method of fault analysis on electronic
• The engine exhaust and other parts of the engine engine controls.
are hot. Do not touch a hot surface and cause a
burn. Tools and Test Equipment

CAUTION The following tools are necessary for troubleshooting

the system: (also, see Special Tools in back of section)
Electronic equipment can be damaged if trou-
• Ohmmeter
bleshooting and repairs are not done correctly.
• Digital voltmeter. Voltmeter must have a minimum
The following CAUTIONS must be followed when
input impedance of 10-megohms. (A digital voltmeter
doing troubleshooting or repairs on an engine with
and ohmmeter are normally included in a multi-meter
an ECM:
test instrument.
• Always disconnect the battery negative cable be-
• Tachometer with inductive trigger signal sensor.
fore disconnecting and removing any parts ex-
• Test light that has a low current draw as described in
cept as described in Troubleshooting.
Figure 7.
• Never start the engine unless the battery is cor-
• Vacuum pump with a gauge. This vacuum pump is
rectly connected.
held and operated with the hand. The gauge must be
• Never disconnect the battery from any equipment
able to indicate a gauge pressure (vacuum) of 34 kPa
when the engine is running.
(10 inHg). See Microprocessor Spark Timing Sys-
• Never disconnect the battery from the charging
tem - MSTS (for GM 4.3L engines, early control mod-
system when the engine is running.
ules) 2200 YRM 463, Microprocessor Spark Timing
• If the battery must be charged with a battery
System - MSTS (for GM 3.0L engines, early control
charger, ALWAYS disconnect the battery from the
modules) 2200 YRM 603, or Microprocessor Spark
electrical system.
Timing System - MSTS (for GM 3.0L and 4.3L en-
• Make sure that all electrical connections are clean
gines, later control modules) 2200 YRM 765 for a
and have good electrical contact.
Pressure Conversion Chart.
• Never connect or disconnect the wiring harness
• Spark tester. Spark tester is used to check the sec-
at the ECM when the key switch is ON.
ondary ignition. Spark tester is also called an ST125
• Always disconnect the battery and the ECM con-
and creates a 25 kilovolt load on secondary ignition
nectors if electric arc welding must be done on
components.
the vehicle.

11
A-1 - No Malfunction Indicator Lamp 2200 YRM 782

Legend for Figure 7

NOTE: IF THE AMMETER INDICATES LESS THAN

0.3 amps (300 milliamps), THE TEST LIGHT CAN BE
USED.

IF THE AMMETER INDICATES MORE THAN 0.3 amps

(300 milliamps), THE TEST LIGHT CANNOT BE USED
BECAUSE IT CAN CAUSE DAMAGE TO THE ELEC-
TRONIC COMPONENTS.
1. DC AMPS 3. BATTERY
2. TEST LIGHT

TROUBLESHOOTING CHART
DESCRIPTION SUMMARY
Table 3 provides a descriptive summary of the trou-
bleshooting charts that follow this section.

Figure 7. Current Flow Test for Test Light

Table 3. Troubleshooting Chart Description Summary

Chart Malfunction Indicator

Description
Number Lamp Status
A-1 A-1 - No Malfunction Indicator Lamp ON
A-2 A-2 - No Scan Data, No DTC 12, Malfunction Indicator Lamp ON ON
A-3 A-3 - Starter Rotates Engine, Engine Will Not Run OFF
A-4 A-4 - Fuel Injector Circuit OFF
A-5 A-5 - Fuel Pump Relay Circuit OFF
A-6 A-6 - Fuel System Troubleshooting OFF
A-7 A-7 - Ignition System Troubleshooting OFF

A-1 - No Malfunction Indicator Lamp

CIRCUIT DESCRIPTION
Malfunction Indicator Lamp will be ON when the ignition
is ON and engine is not running. Voltage from the igni-
tion switch is supplied to the light bulb. The Electronic
Control Module (ECM) will control the lamp and turn it
ON by connecting it to ground through circuits AZ and
GV. See Figure 8.

12
2200 YRM 782
Figure 8. Chart A-1 - No Malfunction Indicator Lamp
TEST DESCRIPTION
The numbers below are a reference to the bold numbers
in Figure 9.
1. This test gives a ground circuit for the Malfunction
Indicator Lamp circuit. If lamp works now, external
circuits are correct.
2. This tests circuits HD, HC, and JM for voltage.
3. Using a test light connected to Battery +, check
each of the system ground circuits to be sure there
is a good ground.
4. If a fuse is open, remember to locate any short cir-
cuits to ground or other high ampere causes on that
circuit.
A-1 - No Malfunction Indicator Lamp
OTHER TROUBLESHOOTING CHECKS
If engine runs correctly, check for the following:
• Fault in the light bulb.
• Circuits AZ and GV are open.
• 5 ampere circuit breaker in instrument cluster is bad.
This will cause no dash indicator lights, gauges, or
seat belt reminder in the 3.0L engine.
If engine cranks but will not run:
• ECM Battery + fuse/circuit HD is open.
• ECM ignition fuse/circuit JM is open.
• Poor connections to ECM.
13
A-1 - No Malfunction Indicator Lamp 2200 YRM 782

Figure 9. Chart A-1 - No Malfunction Indicator Lamp (GM 3.0L Engine Only)

14
2200 YRM 782 A-2 - No Scan Data, No DTC 12, Malfunction Indicator Lamp ON

A-2 - No Scan Data, No DTC 12, Malfunction Indicator Lamp ON

CIRCUIT DESCRIPTION
Malfunction Indicator Lamp (MIL) will be ON when igni-
tion is ON and engine is not running. Voltage from ig-
nition switch is supplied to the light bulb. ECM will con-
trol the light and turn it ON by connecting it to ground
through circuit AZ to the ECM. See Figure 10.
When SCAN Tool is connected and turned ON, the Mal-
function Light will flash a DTC 12, followed by any trou-
ble code(s) kept in memory. A steady light means a
short to ground in the light control circuit AZ, GV or an
open in circuit HS.

Figure 10. Chart A-2 - No Scan Data, No DTC 12, Malfunction Indicator Lamp ON

TEST DESCRIPTION
The numbers below are a reference to the bold numbers
in Figure 11.
1. If there is a problem with the ECM that causes a
SCAN Tool to not read data from the ECM, then
ECM will not flash a DTC 12.
• If DTC 12 does flash, be sure SCAN Tool is work-
ing correctly on another vehicle.
• If SCAN is working correctly and circuit HZ is
good, the ECM can be the cause for the NO
SCAN DATA symptom.
2. This step will check for an open diagnostic circuit
HS.
3. If the light turns OFF after the ECM connector J2 is
disconnected, then circuit AZ, GV is not shorted to
ground.
If 10 to 12 volts are present between A and B, check
SCAN Tool on a good truck. If, when used on a good
truck, the SCAN Tool does not cause Malfunction Indi-
cator Lamp to flash DTC 12, the SCAN Tool is faulty.

15
A-2 - No Scan Data, No DTC 12, Malfunction Indicator Lamp ON 2200 YRM 782

Figure 11. Chart A-2 - No Scan Data, No DTC 12, Malfunction Indicator Lamp ON

16
2200 YRM 782
A-3 - Starter Rotates Engine, Engine Will Not Run
CIRCUIT DESCRIPTION
Before using this chart, battery condition, engine crank-
ing speed, and fuel quantity must be checked to make
sure they are correct. See Figure 12.
Figure 12. Chart A-3 - Starter Rotates Engine, Engine Will Not Run
TEST DESCRIPTION
The numbers below are a reference to the bold numbers
in Figure 13.
1. A Malfunction Indicator Lamp ON is a test to deter-
mine if there is battery and ignition voltage at the
ECM.
• If no SCAN data is caused by an ECM problem,
Figure 11 will diagnose the ECM.
• If throttle or coolant sensors are not within these
ranges, the ECM can be using the wrong mode
for starting.
• SCAN Tool will display RPM during cranking if
pulses are received at the ECM.
2. If RPM was indicated during crank, the ignition
module is receiving a crank signal, but No Spark
at this test indicates the ignition module is not
triggering the coil.
3. While cranking engine, there must be no fuel spray
with the injector electrical connector disconnected.
Replace injector or seals if fuel sprays or drips.
A-3 - Starter Rotates Engine, Engine Will Not Run
4. Test light will flash, indicating the ECM is controlling
the injector.
5. Fuel spray from the injector indicates that fuel is
available. However, the engine can be getting too
much fuel. No fuel spray from injector indicates a
fault in the fuel system or no ECM control of injector.
OTHER TROUBLESHOOTING CHECKS
• Water or foreign material can cause a no start con-
dition during freezing weather. The engine can start
after approximately 5 minutes in a heated shop.
• A MAP sensor voltage reading between 0.5 to 3.0
volts can cause a no start condition. Disconnect the
MAP sensor. If the engine starts, replace the MAP
sensor. See MAP Sensor, Replace in Sensors Re-
pair.
• If fuel pump fuse is damaged, test current draw of
pump motor in tank. If more than 5 to 6 amps, correct
the circuit or replace the pump motor in the tank.
17
A-3 - Starter Rotates Engine, Engine Will Not Run 2200 YRM 782

Figure 13. Chart A-3 - Starter Rotates Engine, Engine Will Not Run

18
2200 YRM 782 A-4 - Fuel Injector Circuit

A-4 - Fuel Injector Circuit

This troubleshooting chart is used if Figure 13 indicates
a fuel injector problem. If both fuel injector circuits indi-
cate a problem, test one circuit at a time. See Figure 14.

Figure 14. Chart A-4 - Fuel Injector Circuit

TEST DESCRIPTION to the fuel injector circuit, momentarily illuminates,

the ECM and wires are correct.
The numbers below are a reference to bold numbers in
Figure 15. 2. This step checks for 12 volts to the fuel injector.
This test will also determine if there is a short circuit
1. This test will determine if the Ignition Module is gen- to a voltage source on the ECM side of the circuit.
erating a reference pulse and check the wires and
ECM for a fault. If a 12-VOLT TEST LIGHT is con- 3. This test checks for a good circuit to the ECM.
nected to 12 volts and then touched and removed
from circuit GY, a reference pulse is normally gen-
erated. If the fuel injector TEST LIGHT, connected

19
A-4 - Fuel Injector Circuit 2200 YRM 782

Figure 15. Chart A-4 - Fuel Injector Circuit

20
2200 YRM 782
A-5 - Fuel Pump Relay Circuit
CIRCUIT DESCRIPTION
When the ignition switch is turned ON, the ECM will ac-
tivate the fuel pump relay with a ground path and run the
fuel pump. The fuel pump relay will operate as long as
the engine is cranking or running if the ECM is receiv-
ing ignition reference pulses. The ECM will stop the fuel
pump relay signal 2 seconds after the ignition reference
pulses stop. This will also occur 2 seconds after the key
is ON and the engine not started. See Figure 16.
Figure 16. Chart A-5 - Fuel Pump Relay Circuit
TEST DESCRIPTION
The numbers below are a reference to bold numbers in
Figure 17.
1. Test light will connect to ground through relay to the
fuel pump.
2. If pump does not run, it can be damaged or worn.
3. After fuel pump relay is replaced, continue with the
Oil Pressure Switch Test, Step 4.
4. At this point, fuel pump relay is operating correctly.
Test parallel circuit through the oil pressure switch.
A-5 - Fuel Pump Relay Circuit
If the fuel pump relay or relay ground circuit from the
ECM fail, the fuel pump will receive an electrical current
through the circuit for the oil pressure switch when the
engine is running.
The fuel pump test terminal is near the relay in the en-
gine compartment. When the engine is stopped, the
pump can be turned ON by applying Battery + to the
test terminal.
5. If fuse was damaged, check circuit for too much
current usage (including fuel pump).
OTHER TROUBLESHOOTING CHECKS
A fuel pump relay that does not work can cause long
cranking times. Extended crank period is caused by
the time necessary for oil pressure to reach pressure
required to close the oil pressure switch and turn ON
the fuel pump.
21
A-5 - Fuel Pump Relay Circuit 2200 YRM 782

Figure 17. Chart A-5 - Fuel Pump Relay Circuit

22
2200 YRM 782
A-6 - Fuel System Troubleshooting
CIRCUIT DESCRIPTION
When ignition switch is turned ON, the ECM will acti-
vate the fuel pump relay with a ground path and run
the fuel pump. Fuel pump relay will operate as long
as the engine is cranking or running if the ECM is re-
ceiving ignition reference pulses. The ECM will stop
the fuel pump relay signal 2 seconds after the ignition
references pulses stop. This will also occur 2 seconds
after the key was ON and the engine not started. See
Figure 18.
Figure 18. Chart A-6 - Fuel System Troubleshooting
TEST DESCRIPTION
The numbers below are a reference to bold numbers in
Figure 19.
1. Check fuel pressure while pump is running. Pres-
sure will start to drop as soon as pump stops be-
cause of an internal relief in the pressure regulator.
2. If engine does not run, use Figure 13.
3. This test checks operation of the fuel pump check
valve. A check valve that leaks will cause fuel in
pressure line to drain back to the tank and cause
A-6 - Fuel System Troubleshooting
If the fuel pump relay or relay ground circuit from the
ECM fail, the fuel pump will receive electrical current
through the oil pressure switch circuit when engine is
running.
When engine is stopped, the fuel pump can be turned
ON by applying Battery + to fuel pump test terminal.
This terminal is located near the pump relay.
The fuel pump delivers fuel to the Throttle Body Injec-
tor (TBI) unit where system pressure is controlled to 72
±3 kPa (10.5 ±0.5 psi). Excess fuel is returned to the
fuel tank.
long start times. The amount of pressure is not
important as long as some pressure is maintained.
OTHER TROUBLESHOOTING CHECKS
Fuel system pressure that is incorrect can cause one of
the following symptoms:
• Cranks, but will not start.
• Starts, but will not continue to run.
• Long cranking times before engine starts.
• Rough idle or low idle speed.
• Engine miss, feels like ignition problem.
• High fuel usage, loss of power, poor performance.
23
A-6 - Fuel System Troubleshooting 2200 YRM 782

Figure 19. Chart A-6 - Fuel System Troubleshooting

24
2200 YRM 782 A-6 - Fuel System Troubleshooting

1. RETURN LINE 6. PUMP

2. FUEL SUPPLY SHUTOFF VALVE 7. FUEL FILTER
3. FUEL RETURN SHUTOFF VALVE 8. FUEL PRESSURE LINE
4. STRAINER 9. FUEL PRESSURE TEST PORT
5. FUEL TANK 10. FUEL PRESSURE GAUGE

Figure 20. Chart A-6 - Fuel System Troubleshooting

TEST DESCRIPTION
The numbers below are a reference to bold numbers in
Figure 21.
1. Fuel pressure less than 69 kPa (10 psi) can cause
several problems. It can cause hard starting in cold
conditions and poor performance. Low fuel pres-
sure can also allow engine to run at idle or low
speeds, but cause engine to run poorly or stall when
more fuel is required (such as accelerating or at
high speed).
2. Causing a restriction in fuel flow at the tank (as
shown), causes fuel pump to develop its maximum
pressure. With fuel pump running, pressure will in-
crease to more than 75 kPa (11 psi).
NOTE: Do not block the fuel return line completely (out-
let side of TBI assembly). Too much pressure can dam-
age the TBI pressure regulator.
3. This test determines if high fuel pressure is caused
by a restriction in the fuel return line, or a problem
with the pressure regulator.
4. If pressure is correct at idle, yet becomes lower as
engine is accelerated, repair restriction in fuel feed
line. If there is no restriction, replace fuel pump.
5. Wrong fuel pump (too much capacity) can also
cause high pressure.
6. Check that shutoff valves are open when finished.

25
A-6 - Fuel System Troubleshooting 2200 YRM 782

Figure 21. Chart A-6 - Fuel System Troubleshooting

26
2200 YRM 782 A-7 - Ignition System Troubleshooting

FUEL PRESSURE CHECK 3. Energize fuel pump.

4. Compare fuel pressure to specifications.

WARNING
A small amount of fuel may be released when con- 5. Disconnect power supply for the fuel pump.
necting the fuel pressure gauge. To prevent a fire
or personal injury, put a shop towel near the fuel 6. Disconnect fuel pressure gauge.
pressure port fitting before connecting the gauge.
7. Replace cap for the pressure gauge port.
Clean all fuel spillage. Put the towel in approved
container when connection is completed. 8. Turn the ignition switch ON and OFF twice, wait-
ing 10 seconds between cycles, and check for fuel
1. Clean any dirt or grease from the cap for the pres-
leaks.
sure gauge port, then remove it.

2. Connect fuel pressure gauge.

A-7 - Ignition System Troubleshooting

Figure 22. Chart A-7 - Ignition System Troubleshooting

27
A-7 - Ignition System Troubleshooting
TEST DESCRIPTION
The numbers below are a reference to bold numbers in
Figure 23.
NOTE: If a tachometer has been connected to the
TACH CONN., disconnect it before doing this test.
1. Check a minimum of 2 spark plug wires to make
sure that 1 spark plug wire does not have an open
circuit (Spark Tester ST-125).
2. If spark occurs when EST connector is discon-
nected, output from the sensing coil is too low for
EST operation.
3. A spark indicates that the fault is in the distributor
cap or the rotor.
4. The normal voltage at C and + terminals is battery
voltage. A low voltage can indicate:
a. An open circuit or a high resistance circuit from
distributor to ignition coil or
b. An open circuit in the primary winding of the
ignition coil.
If voltage at C is less than battery voltage, and there are
10 volts or more at +, there is an open circuit from C to
the ignition coil or an open circuit in the primary winding
of the ignition coil.
28
2200 YRM 782
5. Use the TEST LIGHT to check for a short circuit in
the EST module or in circuit from the ignition coil to
the EST module. Check for approximately 12 volts
between the TACH CONN. and ground.
If voltage is low (approximately 1 to 6 volts), there can
be a fault in the ignition coil. This condition can cause
a failure in the ignition coil from too much heat. If there
is an open circuit in the primary winding of the ignition
coil, a low voltage can leak through the EST module
from the B+ to the TACH CONN. terminal.
6. EST module normally goes ON when 1.5 to 8 volts
is applied to terminal P. When EST module is ON,
voltage between TACH CONN. and ground will nor-
mally decrease to 7 to 9 volts. This test checks
if sensing coil or EST module has a fault. When
1.5 to 8 volts is momentarily applied to terminal P,
this voltage acts as a trigger voltage that replaces
voltage from sensing coil. The procedure shows
a TEST LIGHT, but any low voltage, low current
source can be used as a trigger voltage.
7. When momentary trigger voltage is removed, a
spark is normally generated through the ignition
coil. If no spark occurs, replace ignition coil. If a
spark occurs, check sensing coil and rotating timer
core.
2200 YRM 782 A-7 - Ignition System Troubleshooting

Figure 23. Chart A-7 - Ignition System Troubleshooting (Sheet 1 of 2)

29
A-7 - Ignition System Troubleshooting 2200 YRM 782

Figure 23. Chart A-7 - Ignition System Troubleshooting (Sheet 2 of 2)

30
2200 YRM 782 DTC 14 Engine Coolant Temperature Sensor Circuit (Low Temperature Indicated)

DTC 14 Engine Coolant Temperature Sensor Circuit

(Low Temperature Indicated)
CIRCUIT DESCRIPTION As engine warms up, sensor resistance decreases and
the voltage drops. The ECM reads this voltage as a
The Engine Coolant Temperature (ECT) sensor uses temperature.
a thermistor to control signal voltage to the ECM. The
ECM applies a reference voltage on circuit GQ to the
sensor. When engine is cold, sensor (thermistor) resis-
tance is high. The ECM will then sense a high signal
voltage. See Figure 24.

Figure 24. DTC 14 Engine Coolant Temperature Sensor Circuit (Low Temperature Indicated)

TEST DESCRIPTION OTHER TROUBLESHOOTING CHECKS

The numbers below are a reference to bold numbers in
Figure 25.
1. Checks to see if DTC 14 was set as result of current
failure or intermittent condition.
• DTC 14 will set if:
Signal voltage indicates a coolant temperature
below 30 C ( 22 F) after engine runs for 120
seconds.
2. This test causes the conditions for a DTC 14. If
the ECM sees a circuit to ground (low voltage) and
displays a low temperature, the ECM and wiring are
correct.
• After engine is started, the temperature will increase
steadily to about 80 C (180 F), then become stable
when the thermostat opens.
• If engine has been allowed to cool to an ambient tem-
perature (overnight), coolant reading on the SCAN
Tool will be that ambient temperature.
• DTC 14 will occur if circuit GQ, GR, or HU is open.
• If circuit GR is open, DTC 33 and DTC 14 can both
set.
• Use chart in Figure 25 to test the accuracy of the
sensor.
• If DTC 14 is not constant, see Troubleshooting, Poor
Operation.

3. This test will determine if there is wiring problems

or a damaged ECM. If circuit GR is open, there can
also be a DTC 33 stored.

31
DTC 14 Engine Coolant Temperature Sensor Circuit (Low Temperature Indicated) 2200 YRM 782

Figure 25. DTC 14 Engine Coolant Temperature Sensor Circuit (Low Temperature Indicated)

32
2200 YRM 782 DTC 15 Engine Coolant Temperature Sensor Circuit (High Temperature Indicated)

DTC 15 Engine Coolant Temperature Sensor Circuit

(High Temperature Indicated)
CIRCUIT DESCRIPTION

Figure 26. DTC 15 Engine Coolant Temperature Sensor Circuit (High Temperature Indicated)

The Engine Coolant Temperature (ECT) sensor uses OTHER TROUBLESHOOTING CHECKS
a thermistor to control signal voltage to the ECM. The
ECM applies a reference voltage on circuit GQ to the • After engine is started, temperature will increase
sensor. When engine is cold, sensor (thermistor) resis- to approximately 80 C (180 F), then become stable
tance is high. The ECM will then sense a high signal when thermostat opens.
voltage. See Figure 26. • If engine has been allowed to cool to an ambient
temperature (overnight), the coolant reading on the
As engine warms up, sensor resistance decreases and SCAN Tool will be that ambient temperature.
voltage drops. The ECM reads this voltage as a tem- • A DTC 15 occurs if circuit GQ has a short circuit to
perature. ground.
• Use the chart in Table 4 to test the accuracy of the
TEST DESCRIPTION sensor.
• If DTC 15 is not constant, see Troubleshooting, Poor
The numbers below are a reference to bold numbers in Operation.
Figure 27.
Table 4. ECT Sensor - Temperature vs Resistance
1. Checks to see if DTC 15 was set as a result of
current failure or intermittent condition. C F Ohms
• DTC 15 will set if:
Signal voltage indicates a coolant temperature 100 212 177
above 135 C (275 F) for 3 seconds. 70 158 467
2. This test causes the conditions for a DTC 15. If 40 104 1459
the ECM sees a circuit to ground (high voltage) and
20 68 3520
displays a high temperature, the ECM and wiring
are correct. 5 41 7280

3. If SCAN Tool shows a temperature below 30 C 10 14 16,180

( 22 F), replace sensor. 20 4 28,680
40 40 100,700

33
DTC 15 Engine Coolant Temperature Sensor Circuit (High Temperature Indicated) 2200 YRM 782

Figure 27. DTC 15 Engine Coolant Temperature Sensor Circuit (High Temperature Indicated)

34
2200 YRM 782 DTC 21 Throttle Position Sensor Circuit (Signal Voltage High)

DTC 21 Throttle Position Sensor Circuit (Signal Voltage High)

CIRCUIT DESCRIPTION Signal voltage will vary from less than 1.25 volts at idle
to approximately 4.5 volts at Wide Open Throttle (WOT).
The Throttle Position (TP) Sensor makes a voltage sig- See Figure 28.
nal that changes with the position of the throttle plate.

Figure 28. DTC 21 Throttle Position Sensor Circuit (Signal Voltage High)

TEST DESCRIPTION 3. This test will determine if there is a damaged TP

The numbers below are a reference to bold numbers in
Figure 29.
1. Checks to see if DTC 21 was caused by current
failure or a condition that is not constant.
• DTC 21 will set if:
Signal voltage above 3.9 volts,
MAP reading below 65 kPa (9.4 psi)
RPM less than 1750,
All these conditions exist for 5 seconds,
• OR
TP volts above 4.8 volts at any time.
2. This test causes the conditions for a DTC 21. If
the ECM sees the open circuit (low voltage) and
displays a low voltage, the ECM and circuit GU are
correct.
Sensor, damaged ECM, or an open circuit HV.
OTHER TROUBLESHOOTING CHECKS
• A SCAN Tool displays throttle position in volts. Closed
throttle voltage will be less than 1.25 volts. TP Sensor
voltage will increase at a steady rate as throttle moves
to Wide Open Throttle (WOT).
• Check that circuit does not have a short and a voltage
higher than 5.0 volts by testing it with a voltmeter to
ground.
• A DTC 21 will occur if circuit HV is open, or circuit GU
has a short to voltage or circuit GT.
• If DTC 21 is not constant, see Troubleshooting, Poor
Operation.

35
DTC 21 Throttle Position Sensor Circuit (Signal Voltage High) 2200 YRM 782

Figure 29. DTC 21 Throttle Position Sensor Circuit (Signal Voltage High)

36
2200 YRM 782 DTC 22 Throttle Position Sensor Circuit (Signal Voltage Low)

DTC 22 Throttle Position Sensor Circuit (Signal Voltage Low)

CIRCUIT DESCRIPTION Signal voltage will vary from less than 1.25 volts at idle
to about 4.5 volts at Wide Open Throttle (WOT). See
The Throttle Position (TP) Sensor makes a voltage sig- Figure 30.
nal that changes with the position of the throttle plate.

Figure 30. DTC 22 Throttle Position Sensor Circuit (Signal Voltage Low)

TEST DESCRIPTION 3. This test will determine if there is a damaged TP

The numbers below are a reference to bold numbers in
Figure 31.
1. Checks to see if DTC 22 was caused by a current
failure or a condition that is not constant.
• DTC 22 will set if:
Signal voltage below 0.2 volts (200mV),
Engine is running.
2. This test causes the conditions for a DTC 22. If the
ECM see the jumper in the circuit (high voltage) and
displays over 4.0 volts, the ECM and circuits GU/GT
are correct.
Sensor, damaged ECM, or an open circuit HV.
OTHER TROUBLESHOOTING CHECKS
• A SCAN Tool displays throttle position in volts. Closed
throttle voltage will be less than 1.25 volts. TP Sensor
voltage will increase at a steady rate as throttle is
move to Wide Open Throttle (WOT).
• A DTC 22 will occur if circuit GT or GU is open or
connected to ground.
• If DTC 22 is not constant, see Troubleshooting, Poor
Operation.

37
DTC 22 Throttle Position Sensor Circuit (Signal Voltage Low) 2200 YRM 782

Figure 31. DTC 22 Throttle Position Sensor Circuit (Signal Voltage Low)

38
2200 YRM 782
DTC 31 Engine Governor Circuit
CIRCUIT DESCRIPTION
The ECM sends a controlled signal pulse to the gov-
ernor control module (circuit JR) to drive the governor
motor. See Figure 32.
Depending on the need of the engine for the governor,
the module translates the ECM data into the correct
value of D.C. current (circuits JP and JQ) to the mo-
tor. This current causes the motor to limit engine speed
Figure 32. DTC 31 Engine Governor Circuit
TEST DESCRIPTION
The numbers below are a reference to bold numbers in
Figure 33.
DTC 31 will set if the ECM is commanding near 100%
authority.
1. This check determines if the governor control mod-
ule has a voltage supply to operate.
CAUTION
DO NOT hold current to the motor for longer than
30 seconds, as the motor can be damaged.
DTC 31 Engine Governor Circuit
by loosening the throttle cable. The system is capable
of reducing the throttle back to near idle position.
A DTC 31 will find a damaged ECM, governor module,
motor, linkage, or wiring. If DTC 31 is set, the ECM will
limit engine RPMs by momentarily reducing fuel (at a
slightly higher RPMs than governor calibration).
2. Applying Battery + to motor will not let the throttle
plate open.
3. This test requires complete governor control to de-
termine if ECM or governor system has a fault.
Throttle plate must not open during this test.
OTHER TROUBLESHOOTING CHECKS
A SCAN Tool displays governor TPS. Watch this value
as engine rpm increases beyond the governor limits.
This test will allow you to see the ECM’s control try to
limit engine speed.
39
DTC 31 Engine Governor Circuit 2200 YRM 782

Figure 33. DTC 31 Engine Governor Circuit

40
2200 YRM 782 DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage High - Low Vacuum)
DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit
(Signal Voltage High - Low Vacuum)
CIRCUIT DESCRIPTION
The Manifold Absolute Pressure (MAP) sensor re-
sponds to changes in manifold pressure (vacuum).
The ECM receives this information as a signal voltage
that will vary from about 1 to 1.5 volts at closed throttle
Figure 34. DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage High - Low Vacuum)
TEST DESCRIPTION
The numbers below are a reference to bold numbers in
Figure 35.
1. This step will determine if DTC 33 is caused by a
current failure or a condition that is not constant.
• A DTC 33 will set if:
MAP signal is more than 90 kPa (27 inHg) (low
manifold vacuum),
TP Sensor less than 5%,
These conditions exist longer than 10 seconds.
2. This step causes the conditions for a DTC 33. If
the ECM sees the change, ECM and circuits HA
and HW are good.
3. See System Test Charts for complete test of MAP
sensor.
idle, to 4 to 4.5 volts at Wide Open Throttle (low vac-
uum). If the MAP sensor fails, the ECM will use a fixed
MAP value and use the Throttle Position (TP) Sensor
to control fuel delivery. See Figure 34.
OTHER TROUBLESHOOTING CHECKS
• With ignition ON and engine stopped, manifold pres-
sure is equal to atmospheric pressure and signal volt-
age will be high. This information is used by the ECM
as an indication of vehicle altitude and is referred to
as BARO. Comparison of this BARO reading with a
known good vehicle with the same type of sensor is
a good way to check accuracy of a sensor. Correct
readings will be within 0.4 volts of each other.
• A DTC 33 occurs if either circuit HW is open, or if
circuit GR has a short to voltage or to circuit HA.
• If HW is open, DTC 33 and DTC 14 will set.
• If DTC 33 is not constant, see Troubleshooting, Poor
Operation.
41
DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage High - Low Vacuum) 2200 YRM 782

Figure 35. DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage High - Low Vacuum)

42
2200 YRM 782 DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage Low - High Vacuum)
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit
(Signal Voltage Low - High Vacuum)
CIRCUIT DESCRIPTION
The Manifold Absolute Pressure (MAP) sensor re-
sponds to changes in manifold pressure (vacuum).
The ECM receives this information as a signal voltage
that will change from approximately 1.0 to 1.5 volts
Figure 36. DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage Low - High Vacuum)
TEST DESCRIPTION
The numbers below are a reference to bold numbers in
Figure 37.
1. This step will determine if DTC 34 is the result of a
current failure or an intermittent condition.
• A DTC 34 will set if:
MAP signal is less than 14 kPa (4 inHg) (high
manifold vacuum),
RPM less than 1200 or TP Sensor more than
15%.
AND
These conditions exist longer than 0.2 seconds.
2. This step causes the conditions for a DTC 34. If
the ECM sees the change, ECM and circuits HA
and HW are good.
3. SCAN Tool does not display 12 volts. What is im-
portant is that the ECM sees that voltage is more
at closed throttle idle, to 4 to 4.5 volts at Wide Open
Throttle (low vacuum). If the MAP sensor fails, the
ECM will substitute a fixed MAP value and use the
Throttle Position (TP) Sensor to control fuel delivery.
See Figure 36.
than 4.0 volts. This would indicate that the ECM
and circuit HA are good.
OTHER TROUBLESHOOTING CHECKS
• With the ignition ON and engine stopped, manifold
pressure is equal to atmospheric pressure and sig-
nal voltage will be high. This information is used by
the ECM as an indication of vehicle altitude and is
referred to as BARO. Comparison of this BARO read-
ing with a known good vehicle with the same type of
sensor is a good way to check accuracy of a sensor.
Correct readings will be within 0.4 volts of each other.
• A DTC 34 occurs if either circuit GR or HA is open or
has a short circuit to ground.
• If GR or HA has a short circuit to ground, both DTC
34 and DTC 22 can set.
• If DTC 34 is not constant, see Troubleshooting, Poor
Operation.
43
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage Low - High Vacuum) 2200 YRM 782

Figure 37. DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage Low - High Vacuum)

44
2200 YRM 782 DTC 41 Electronic Spark Timing (EST) - Open EST Circuit

DTC 41 Electronic Spark Timing (EST) - Open EST Circuit

CIRCUIT DESCRIPTION
A DTC 41 is indicated if there is an open circuit in the
Electronic Spark Timing Signal (EST). See Figure 38.
When the system is running on the ignition module,
there is no voltage on the bypass wire because the ig-
nition module sends the Electronic Spark Timing Signal
(EST) to ground. If the ECM senses a voltage on the
EST wire, a Code 41 will be set and the electronic con-
trol system will not go into the EST mode of operation.
When engine is being started and approximately 400
rpm is sensed, bypass voltage is applied. The EST will
no longer be grounded in the ignition module and EST
voltage will normally have a variation during operation.
If the bypass wire is open or grounded, the ignition mod-
ule will not change to EST mode and a Code 42 will be
indicated.
If the EST wire has a short circuit to ground, there will
not be an EST signal and a Code 42 will be indicated.

Figure 38. DTC 41 Electronic Spark Timing (EST) - Open EST Circuit

TEST DESCRIPTION
The numbers below are a reference to bold numbers in
Figure 39.
1. A Code 41 is indicated if there is an open circuit in
the Electronic Spark Timing Signal (EST). This test
checks that the Code 42 is a real fault.
2. This test checks that the ground path through the
ignition module is correct. A short circuit in circuit
GW to ground will also indicate less than 500 ohms
and a Code 42 will be indicated.
OTHER TROUBLESHOOTING CHECKS
The SCAN Tool cannot check for a Code 41 fault.
If the Code 42 is not constant or not regular and a Code
is indicated, see the section Troubleshooting, Poor Op-
eration. Also see Figure 23.

45
DTC 41 Electronic Spark Timing (EST) - Open EST Circuit 2200 YRM 782

Figure 39. DTC 41 Electronic Spark Timing (EST) - Open EST Circuit

46
2200 YRM 782 DTC 42 EST - Grounded EST Circuit, Open or Grounded Bypass Circuit

DTC 42 EST - Grounded EST Circuit, Open or Grounded

Bypass Circuit
CIRCUIT DESCRIPTION
DTC 42 is indicated if there is a grounded circuit in
the Electronic Spark Timing signal (EST) or open or
grounded bypass circuit. See Figure 40.
When system is running on ignition module, there is no
voltage on the bypass wire because the ignition mod-
ule sends the Electronic Spark Timing signal (EST) to
ground. If ECM senses a voltage on EST wire, a Code
41 will be set and the electronic control system will not
go into the EST mode of operation.
When engine is being started and approximately 400
rpm is sensed, bypass voltage is applied. The EST will
no longer be grounded in the ignition module and EST
voltage will normally have a variation during operation.
If bypass wire is open or grounded, ignition module will
not change to EST mode and a Code 42 will be indi-
cated.
If EST wire has a short circuit to ground, there will not
be an EST signal and a Code 42 will be indicated.

Figure 40. DTC 42 Electronic Spark Timing (EST) - Grounded EST Circuit, Open or Grounded Bypass Circuit

47
DTC 42 EST - Grounded EST Circuit, Open or Grounded Bypass Circuit 2200 YRM 782

TEST DESCRIPTION 3. If the module did not make the switch in Step 2, this
step makes the following checks:
The numbers below are a reference to bold numbers in
Figure 41. a. Circuit GW has a short circuit to ground.

1. Code 42 is indicated if there is a grounded circuit in b. Bypass circuit GZ is open.

the electronic spark timing signal (EST) or open or
grounded bypass circuit. This test checks that the c. Ignition module has a fault or bad connection.
Code 42 is a real fault.
4. This test checks that Code 42 is from a fault in the
2. When TEST LIGHT voltage touches circuit GZ, ECM and not a fault in circuit GW or GZ.
the module correctly causes the ohmmeter to
over-range if the ohmmeter is in the 1000 to 2000 OTHER TROUBLESHOOTING CHECKS
ohms position.
The SCAN Tool cannot check for a Code 42 fault.
When selector switch on the ohmmeter is changed to
If Code 42 is not constant or not regular and a Code is
the 10,000 to 20,000 ohms position, the ohmmeter cor-
indicated, see the section Troubleshooting, Poor Oper-
rectly indicates more than 5000 ohms. The important
ation. Also see Figure 23.
part of this test is to check if the module makes the
switch.

48
2200 YRM 782 DTC 42 EST - Grounded EST Circuit, Open or Grounded Bypass Circuit

Figure 41. DTC 42 Electronic Spark Timing (EST) - Grounded EST Circuit, Open or Grounded Bypass Circuit

49
DTC 51 ECM Failure 2200 YRM 782

DTC 51 ECM Failure

CIRCUIT DESCRIPTION
The Electronic Control Module (ECM) does an internal
check. This check, if it fails, will set a DTC 51. The in-
ternal program calibration causes a DTC 51. See Fig-
ure 42.

OTHER TROUBLESHOOTING CHECKS

• The SCAN tool cannot help find a DTC 51 problem.
• If DTC 51 is not constant, see Troubleshooting, Poor
Operation.

NOTE: CHECK THAT ALL CONNECTIONS AT ECM

ARE CORRECT.
CLEAR THE MEMORY AND CHECK AGAIN FOR DTC
51. IF DTC 51 APPEARS AGAIN, REPLACE ECM.

Figure 42. ECM Failure

50
2200 YRM 782
Troubleshooting, Poor Operation
NOTE: Before using the following information, make
sure you have done the On-Board Diagnostic (OBD)
System Check and found that:
1. The ECM and Malfunction Indicator Lamp are op-
erating correctly.
2. There are no Diagnostic Trouble Codes (DTC) or
there is a DTC but no Malfunction Indicator Lamp.
GENERAL
Make sure you have done the On-Board Diagnostic
(OBD) System Check before this Troubleshooting sec-
tion is used. Make sure problem is correctly described.
Check indicated items in this Troubleshooting section
under described problem. If starter will crank engine
but engine will not start, see A-3 - Starter Rotates
Engine, Engine Will Not Run.
MAKE A CAREFUL VISUAL CHECK
This check is very important because some problems
can be corrected without doing a fault analysis. Check
the following items:
• Ground connections for the ECM are clean and tight
• Vacuum hoses for correct connections or damaged
hoses
• Vacuum leaks at the mount for the TBI and the intake
manifold
• Condition of the ignition wires for cracks, bad connec-
tions, and indications of electric arcs
• Wires and connectors for damage and bad connec-
tions
FAULT: CODES OR PERFORMANCE THAT
IS NOT REGULAR
NOTE: DO NOT use the Diagnostic Trouble Code
(DTC) charts for problems that are not constant. Fault
must be present to locate problem. If a fault is not
constant, use of DTC charts can cause replacement of
good parts.
Definition: A problem that does not cause Malfunction
Indicator Lamp to illuminate and a code is not kept in
the ECM.
Check:
• Wires and connectors for damage and bad connec-
tions.
• Operation of lift truck with a SCAN Tool connected.
SCAN Tool will normally indicate a trouble code.
Troubleshooting, Poor Operation
• Electrical noise caused by a relay, solenoid, or switch.
This problem will occur when faulty component is op-
erated.
• Installation of lights, radios, or other electrical equip-
ment by operator that causes the problem.
• Sensor wires are too close to high voltage ignition
system wires. Wire for circuit HX from ECM to Ignition
Control Module (ICM) must be a good connection.
• Ignition secondary has a short to ground.
• Circuit AZ Malfunction Indicator Lamp or circuit HS
(diagnostic test terminal) has a short circuit to ground.
FAULT: LOSS OF DIAGNOSTIC TROUBLE
CODE (DTC) MEMORY
To check, disconnect Throttle Position (TP) sensor and
run engine at idle speed until Malfunction Indicator
Lamp comes ON. DTC 21 will be kept in memory when
ignition is turned OFF for at least 10 seconds. If not,
the ECM is bad.
FAULT: ENGINE QUITS WHILE DRIVING
Check for a failure of the injector driver in ECM. If injec-
tor driver fails, replace the ECM.
Additional Checks
If problem has not been found, see System Test Charts.
FAULT: ENGINE IS DIFFICULT TO START
Definition: The starter cranks the engine correctly, but
the engine is difficult to start, or the engine stops imme-
diately after it starts.
Check:
Make a CAREFUL VISUAL CHECK as described in
Make a Careful Visual Check. Make sure the opera-
tor is using the correct starting procedure.
SENSORS
• Engine Coolant Temperature (ECT) sensor. Using a
SCAN Tool, compare coolant temperature with ambi-
ent temperature when engine is cold. If coolant tem-
perature reading is 5 degrees greater than or less
than ambient air temperature on a cold engine, check
resistance in the ECT sensor circuit or sensor itself.
Compare ECT resistance value to charts in DTC 14
and DTC 15.
• MAP sensor.
51
Troubleshooting, Poor Operation
• Throttle Position (TP) sensor for binding or a high TP
voltage with throttle closed (will read between 0.33 to
1.33 volts).
FUEL SYSTEM
• Fuel pump relay operation - pump must turn ON for 2
seconds when ignition is turned ON. Use A-5 - Fuel
Pump Relay Circuit.
• Fuel pressure, use A-6 - Fuel System Troubleshoot-
ing.
• Dirty fuel.
• Injector driver circuit. Disconnect injector harness
connector at injector. Connect 12-volt test light be-
tween harness terminals of injector connector and
check light while cranking. If test light fails to blink
at connector, it is a bad injector circuit harness, con-
nector, or terminal.
• Injector resistance. Measure resistance of injector.
Nominal resistance of injector is 1.6 ohms or more at
20 C (68 F). Resistance will increase at higher tem-
peratures.
• A bad check valve for fuel pump will allow fuel in lines
to drain back to the tank after engine is stopped. To
check for this condition, perform A-6 - Fuel System
Troubleshooting.
IGNITION SYSTEM
• Correct ignition voltage output with spark tester.
• Spark plugs: dirty, cracks, wear, wrong gap, and
burned electrodes.
• Moisture, dust, cracks, burns.
• Wires or cables are damaged or have a short.
• Connections at Ignition Module are loose.
• Bad ECM and ignition grounds.
• Engine misses or quits under load or at idle. See
System Test Charts.
• Circuit GW (Electronic Spark Timing) for short to
ground.
• Idle Air Control (IAC) operation.
FAULT: VARIATION IN ENGINE POWER
WHEN THROTTLE IS HELD STEADY
Definition: Engine power variation under steady throt-
tle, feels like vehicle speeds up and slows down with no
change in accelerator pedal position.
Check:
Make a CAREFUL VISUAL CHECK as described in
Make a Careful Visual Check.
• ECM grounds are clean, tight, and in their proper lo-
cation.
• Vacuum lines for restrictions or leaks.
52
2200 YRM 782
• Alternator output voltage. Repair if less than 9 or
more than 16 volts.
• Governor cables.
SENSORS
• Manifold Absolute Pressure (MAP) sensor. MAP sen-
sor must change quickly at different throttle positions.
Check MAP sensor vacuum line for restrictions. The
ECM will respond to any MAP signal and can change
amount of fuel sent to engine, causing operating prob-
lems. Also use System Test Charts to test MAP sen-
sor.
IGNITION SYSTEM
• For correct ignition voltage output using spark tester.
• Spark plugs. Remove spark plugs, check for wet
plugs, cracks, wear, wrong gap, burned or dirty elec-
trodes or insulators. Repair or replace as necessary.
Also, check spark plug cables.
FUEL SYSTEM
To check if condition is caused by a rich or lean sys-
tem, test vehicle under same conditions that symptom
occurs as described by the customer.
• Fuel pressure while condition exists. Use A-6 - Fuel
System Troubleshooting.
• In-line fuel filter. Replace, if dirty.
• Fuel injector.
FAULT: DECREASED ENGINE POWER
Definition: Engine delivers less than expected power.
Little or no increase in speed when accelerator pedal is
pushed down part way.
Check:
Make a CAREFUL VISUAL CHECK as described in
Make a Careful Visual Check.
• Remove air filter and check for dirt or other restric-
tions. Replace as necessary.
• ECM grounds are clean, tight, and in their correct lo-
cations. See Wiring section for ECM wiring diagrams.
• Alternator output voltage. Repair if less than 9 or
more than 16 volts.
• Exhaust system for restriction or damage.
ENGINE
• Engine valve timing and compression.
• Engine for correct or worn camshaft.
IGNITION SYSTEM
• For correct operation of Electronic Spark Timing
(EST).
• Secondary voltage.
2200 YRM 782
FUEL SYSTEM
• Restriction in fuel filter.
• Dirty fuel.
• Fuel pressure, use A-6 - Fuel System Troubleshoot-
ing.
• Low fuel pressure after a cold start or during accel-
eration. If fuel pressure drops below 62 kPa (9 psi),
there can be a bad fuel pump or restriction in fuel sys-
tem.
GOVERNOR SYSTEM
• Throttle adjustment.
• Governor motor.
FAULT: DETONATION
Definition: Engine makes sharp metallic knocking
sounds that change when throttle position is changed.
This condition is normally worse during acceleration.
Air and fuel mixture is exploding in the cylinder instead
of burning evenly.
Check:
Make a CAREFUL VISUAL CHECK as described in
Make a Careful Visual Check.
If SCAN Tool readings are normal (see On-Board Di-
agnostic (OBD) System Check) and there are no en-
gine mechanical faults, fill fuel tank with a good grade
of gasoline that has a minimum octane rating of 87 to
89 and check vehicle performance.
IGNITION SYSTEM
• Spark plugs for correct heat range.
• Ignition wires and cables for shorts or damaged insu-
lation.
ENGINE
• For oil in combustion chamber.
• Valve oil seals for leaks
• Combustion chambers for excessive carbon build up.
Remove carbon with top engine cleaner using instruc-
tions on the can.
• Combustion chamber pressure by doing a compres-
sion test.
• Basic engine parts such as cam, head, pistons that
are not correct.
COOLING SYSTEM
• Problems from engine running too hot:
– Low engine coolant level.
Troubleshooting, Poor Operation
– Loose water pump belt.
– Restriction in airflow to radiator, or restriction in wa-
ter flow through radiator. Correct coolant solution.
FUEL SYSTEM
To check if the condition is caused by a rich or lean sys-
tem, test the vehicle under same conditions that symp-
tom occurs as described by the customer.
• Fuel pressure while condition exists. Use A-6 - Fuel
System Troubleshooting.
FAULT: ENGINE MOMENTARILY DOES
NOT INCREASE POWER WHEN THROTTLE
CHANGES
Definition: Engine momentarily does not increase
power when throttle is opened further. Engine can stop
when throttle is opened rapidly from idle.
Make a CAREFUL VISUAL CHECK as described in
Make a Careful Visual Check.
Check:
• Engine thermostat operates correctly and at the cor-
rect heat range.
• Alternator output voltage. Repair if less than 9 or
more than 16 volts.
SENSORS
• Throttle Position (TP) sensor. Check TP sensor for
correct operation. Voltage will increase evenly as
throttle is moved toward Wide Open Throttle (WOT).
• MAP sensor output.
IGNITION SYSTEM
• Dirty spark plugs or damaged secondary cables.
• Ignition system connection, circuit HX.
FUEL SYSTEM
• Fuel pressure, use A-6 - Fuel System Troubleshoot-
ing.
• Dirty fuel.
• Low fuel pressure after a cold start or during accel-
eration. If fuel pressure drops below 62 kPa (9 psi),
there can be a bad fuel pump or restriction in fuel sys-
tem.
GOVERNOR SYSTEM
• Throttle cables.
• Governor motor.
53
Troubleshooting, Poor Operation
FAULT: ONE OR MORE CYLINDERS DO
NOT OPERATE CORRECTLY - ENGINE
DOES NOT IDLE CORRECTLY
Definition: Operation of one cylinder is not regular and
problem increases when engine load increases. Prob-
lem normally does not occur above 1500 rpm. Engine
has a rough idle or has a large variation in idle speed.
Make a CAREFUL VISUAL CHECK as described in
Make a Careful Visual Check.
IGNITION SYSTEM
• Start engine, let engine become steady, then discon-
nect Idle Air Control (IAC) motor. Remove one spark
plug cable at a time, using pliers with insulation. Be
sure to connect the cable that was removed to ground
while testing.
• If there is a decrease in rpm on all cylinders (equal
to within 50 rpm), go to FAULT: Rough Idle or Engine
Stalls During Idle. Connect IAC valve.
• If there is no decrease in rpm on one or more cylin-
ders, check for spark on cylinder(s) using an oscillo-
scope or spark tester. Check one spark plug cable at
a time. If no spark, see System Test Charts. If there is
a spark, remove spark plug(s) in these cylinders and
check for:
• Cracks in the insulator, wrong gap, burned elec-
trodes, or wear.
• Spark plug cables by connecting ohmmeter to ends
of each cable in question. If meter reads over 30,000
ohms, replace cable(s).
ADDITIONAL CHECKS
An engine that misses can be caused by Electro Mag-
netic Inference (EMI) on the reference circuit. EMI can
be found by monitoring engine rpm with a SCAN Tool.
A sudden increase in rpm with little change in actual
engine rpm change, indicates EMI is present. If prob-
lem exists, check routing of secondary wires and check
ground circuit.
Check intake and exhaust manifold passage for restric-
tions.
ENGINE
• Do a cylinder compression check. If compression is
low, repair as necessary.
• Remove rocker cover. Check for bent push rods, worn
rocker arms, broken valve springs, worn camshaft
lobes, and valve timing. Repair as necessary.
FUEL SYSTEM
• Dirty fuel filter or low fuel pressure. Use A-6 - Fuel
System Troubleshooting.
54
2200 YRM 782
• Dirty fuel.
FAULT: ROUGH IDLE OR ENGINE STALLS
DURING IDLE
Definition: Engine has a rough idle speed or has a
large variation in idle speed. Engine stops running dur-
ing idle.
Make a CAREFUL VISUAL CHECK as described in
Make a Careful Visual Check.
Check:
• For vacuum leaks.
• ECM ground connections are clean. See ECM wiring
diagrams.
• For broken engine mounts.
• Alternator output voltage. Repair if less than 9 or
more than 16 volts.
IGNITION SYSTEM
• For correct ignition voltage output using spark tester
(ST-125) or equivalent.
• Spark plugs. Remove spark plugs, check for wet or
dirty plugs, cracks, wear, wrong gap, damaged elec-
trodes or insulators. Replace as necessary. Also,
check spark plug wires.
• Spark plug wires by connecting an ohmmeter to ends
of each cable in question. If meter reads over 30,000
ohms, replace cable(s).
ENGINE
• Do a cylinder compression check. See GM Engines
4-153, 4-181, 3.0L, 6-250 600 YRM 1020, GM En-
gines 4.3L V6, 5.7L V8 600 YRM 104, or GM En-
gines 4.3L V6 600 YRM 590.
• For correct camshaft or weak valve springs.
OTHER CHECKS
• MAP sensor output.
• Throttle linkage for smooth operation.
• IAC operation.
• PCV valve for correct operation.
FAULT: FUEL USAGE TOO HIGH
Definition: Fuel use is higher than expected or has in-
creased during later operation make a CAREFUL VI-
SUAL CHECK as described in Make a Careful Visual
Check.
Check:
• Vacuum hoses for damage, restriction, or correct con-
nections.
• Check operator’s methods of operation. Are tires at
correct pressure? Are loads more than capacity?
2200 YRM 782
• Check air filter for dirt or other restriction.
• Check for fuel leaks.
IGNITION SYSTEM
• Spark plugs. Remove spark plugs, check for wet or
dirty plugs, cracks, wear, wrong gap, damaged elec-
trodes or insulators. Replace as necessary. Also,
check spark plug wires.
COOLING SYSTEM
• Engine coolant level.
• Engine thermostat for a fault (always open) or for
wrong heat range. See GM Engines 4-153, 4-181,
3.0L, 6-250 600 YRM 1020, GM Engines 4.3L V6,
5.7L V8 600 YRM 104, or GM Engines 4.3L V6 600
YRM 590.
ENGINE
• Compression. See GM Engines 4-153, 4-181, 3.0L,
6-250 600 YRM 1020, GM Engines 4.3L V6, 5.7L
V8 600 YRM 104, or GM Engines 4.3L V6 600 YRM
590.
OTHER CHECKS
• For exhaust system restriction.
• Air intake system and crankcase for air leaks.
FAULT: DIESELING
Definition: Engine continues to run after ignition switch
is turned OFF but runs very roughly. If engine runs
smoothly, check ignition switch.
Make a CAREFUL VISUAL CHECK as described in
Make a Careful Visual Check.
System Test Charts
GENERAL
This part of the section has the following:
• Components tests
• Circuit tests
• Function tests and adjustments
For location of components, complete engine electronic
wiring diagrams, and ECM wiring harness connector
terminal end views, see Wiring in this section.
System Test Charts
Check:
• Fuel injector and TBI for fuel leaks. Use A-6 - Fuel
System Troubleshooting.
FAULT: BACKFIRE
Definition: Fuel explodes in intake manifold or in ex-
haust system, making loud noise.
Make a CAREFUL VISUAL CHECK as described in
Make a Careful Visual Check.
Check:
IGNITION SYSTEM
• Correct output from ignition coil with spark tester.
• Spark plugs. Remove spark plugs, check for wet or
dirty plugs, cracks, wear, wrong gap, damaged elec-
trodes or insulators. Replace as necessary. Also,
check spark plug wires.
• Spark plug wires for damage and correct installation.
Inspect ignition coil assembly.
• Do fuel system tests. Use A-6 - Fuel System Trou-
bleshooting.
ENGINE
• Compression - Look for valves that stick or leak.
• Valve timing. See GM Engines 4-153, 4-181, 3.0L,
6-250 600 YRM 1020, GM Engines 4.3L V6, 5.7L
V8 600 YRM 104, or GM Engines 4.3L V6 600 YRM
590.
• Intake and exhaust manifold passages for restric-
tions.
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR TEST
The ECT, using the following procedure, can be tested
at different temperatures. A volt/ohmmeter, a ther-
mometer, engine coolant, and something to heat the
coolant will be needed for the test.
• Heat coolant to one of the temperatures shown in Ta-
ble 5.
• Position ECT sensor (sensing end) into heated
coolant.
• Wait about 60 seconds to allow coolant to heat sen-
sor.
• Test sensor resistance and compare reading to those
in Table 5.
55
System Test Charts 2200 YRM 782

• Sensors with a reading within 10% of specifications

shown in Table 5 can be used.

Table 5. ECT Sensor - Temperature vs Resistance

C F Ohms
100 212 177
90 194 214
80 176 332
70 158 467
60 140 667
50 122 943
45 113 1188
40 104 1459
Figure 43. Good TP Sensor Reading
35 95 1802
30 86 2238
25 77 2796
20 68 3520
15 59 4450
10 50 4670
5 41 7280
0 32 9420
5 23 12,300
10 14 16,180
15 5 21,450
20 4 28,680
30 22 52,700
40 40 100,700 Figure 44. Damaged TP Sensor Reading

MINIMUM IDLE SPEED

THROTTLE POSITION (TP) SENSOR
CHECK
Using a SCAN Tool, watch the TP sensor percent and
voltage. The reading will increase evenly as throttle
plate is opened. See Figure 43. The reading must not
be lower than previous reading as throttle plate opens
up. A reading that goes lower or higher, then lower as
plate is opened, indicates a damaged sensor that must
be replaced. See Figure 44.
• Minimum idle speed (minimum air setting) set only
when installing a replacement throttle body.
• The idle stop screw is used to hold minimum idle
speed of engine. On original equipment throttle bod-
ies, it is adjusted at the factory, then covered with a
plug.

56
2200 YRM 782 System Test Charts

Adjustment 11. Connect IAC valve electrical connector.

NOTE: The minimum idle speed adjustment is impor- 12. Reset IAC valve pintle position:
tant for correct system operation. A minimum idle speed
that is too high can cause IAC valve pintle to constantly a. Start and run engine over 2000 rpm.
touch the bottom of its seat and cause valve failure. If
b. Select Field Service Mode.
minimum idle speed is too low, vehicle can be hard to
start in cold weather or can cause a stall during idle. c. Run engine at 2000 rpm for approximately 10
seconds.
1. Put a block on both sides of the drive tires and apply
parking brake. d. Exit Field Service Mode.
2. Put transmission in NEUTRAL. Start and run en- e. Allow engine to return to idle.
gine until it reaches normal operating temperature.
f. Turn ignition switch OFF.
3. Turn ignition key OFF.
g. Wait 10 seconds, start engine, let idle.
4. Connect a SCAN Tool to Diagnostic Connector.
h. Check for correct idle. (IAC at 5-40 Counts.)
5. Turn ignition key to ON position.
i. Disconnect SCAN Tool.
6. Select Field Service Mode on the SCAN Tool. This
will cause IAC valve pintle to extend, closing the j. Remove blocks from drive tires.
air passage in the throttle body. Wait 45 seconds,
disconnect IAC valve connector, then exit Field Ser-
vice Mode.

7. Start and run engine. It may be necessary to hold

throttle open slightly to run engine.

8. Select Engine RPM on the SCAN Tool, and read

engine speed.

NOTE:
• Engine must be at normal operating temperature.
• All accessories must be OFF.
• Make sure throttle and governor cables do not hold
throttle open.
• Correct idle speed is 800 ±25 rpm (for engines that
have more than 10 hours operating time.)

9. Remove plug as shown in Figure 45. Adjust mini-

mum idle speed if necessary. 1. PLUG 2. IDLE STOP SCREW

10. Turn ignition switch OFF. Figure 45. Idle Speed Adjustment

57
B-1 - Idle Air Control (IAC) System Check
B-1 - Idle Air Control (IAC) System Check
CIRCUIT DESCRIPTION
The ECM controls engine idle speed with the IAC valve.
To increase idle speed, the ECM retracts the IAC valve
pintle away from its seat, allowing more air to bypass
the throttle bore. To decrease idle speed, IAC valve
Figure 46. Chart B-1 - Idle Air Control (IAC) System Check
OTHER TROUBLESHOOTING CHECKS
• A slow, unstable, or fast idle speed can be caused by
a problem other than the IAC system. Out of control
range IAC SCAN Tool counts will be above 50 if idle
is too low, and zero counts if idle is too high. Make
the following checks to repair a problem that is not in
the IAC system:
• Vacuum Leak (High Idle) - If idle is too high, stop en-
gine. Fully extend (low) IAC with tester. Start engine.
If idle speed is above 800 RPM, fix vacuum leak in-
cluding PCV system. Also check for smooth move-
ment of throttle plate or linkage.
• PCV Valve - If a high idle condition exists (800 to
1000 RPM), check for vacuum leaks and correct PCV
valve operation. All throttle bodies are preset at the
factory and do not need adjustment. A missing PCV
valve or grommet or a valve that sticks can cause this
condition.
58
2200 YRM 782
pintle extends toward its seat, reducing bypass airflow.
A SCAN Tool will read the ECM commands to the IAC
valve in counts. Higher counts indicate more air bypass
(higher idle). Lower counts indicate less air is allowed
to bypass (lower idle). See Figure 46 and Figure 47.
• System Too Lean (High Air/Fuel Ratio) - Idle speed
can be too high or too low. Engine speed can vary
up and down and disconnecting IAC valve does not
help. Check for low fuel pressure, water in fuel, or a
dirty injector.
• System Too Rich (Low Air/Fuel Ratio) - Idle speed
will be too low. SCAN Tool IAC counts will usually be
above 50. System is rich and can cause black smoke
in exhaust. Check for high fuel pressure or an injector
that leaks or sticks.
• Throttle Body - Remove IAC valve and inspect bore
for dirt.
• IAC Valve Electrical Connections - Check IAC valve
connections for correct contact.
• See Troubleshooting, Poor Operation.
• If problems are fixed by disconnecting the IAC,
carefully check connections, IAC valve terminal re-
sistance, or replace IAC.
2200 YRM 782 B-1 - Idle Air Control (IAC) System Check

Figure 47. Chart B-1 - Idle Air Control (IAC) System Check

59
B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test 2200 YRM 782

B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test

CIRCUIT DESCRIPTION
The Manifold Absolute Pressure (MAP) sensor mea-
sures the changes in the intake manifold pressure that
come from engine load (intake manifold vacuum) and
rpm changes. See Figure 48. The MAP sensor con-
verts these changes into a voltage output. The ECM
sends a 5-volt reference voltage to the MAP sensor. As
the manifold pressure changes, the output voltage of
the sensor also changes. By monitoring sensor output
voltage, the ECM knows manifold pressure. A lower
pressure (low voltage) output voltage will be about 1 to
2 volts at idle, while higher pressure (high voltage) out-
put voltage will be about 4 to 4.8 at Wide Open Throt-
tle (WOT). The MAP sensor is also used, under certain
conditions, to measure barometric pressure, allowing
the ECM to make adjustments for altitude changes. The
ECM uses the MAP sensor to control fuel delivery and
ignition timing.

Figure 48. Chart B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test

TEST DESCRIPTION vehicle in Step 1. When applying vacuum to sen-

The numbers below are a reference to the bold numbers
in Figure 49.
1. Using a SCAN Tool, take MAP sensor voltage read-
ing of a known good vehicle. When comparing
SCAN readings to a known good vehicle, it is im-
portant to compare vehicles that use a MAP sen-
sor having the same color insert and same number.
See Figure 49.
2. Apply 34 kPa (10 inHg) vacuum to the MAP sensor
to cause voltage readings of 1.5 to 2.1 volts less
than voltage reading gathered from known good
sor, change in voltage must be quick. Slow voltage
change indicates a bad sensor.
3. Check vacuum source to sensor for leaking or re-
striction. Be sure that no other vacuum devices are
connected to the MAP vacuum source.
NOTE: Make sure the electrical connector remains se-
curely fastened.
4. Remove sensor from intake manifold and twist sen-
sor, by hand only, to check for intermittent connec-
tion. Output changes greater than 0.10 volt indicate
a bad sensor or connection. If bad, replace sensor.

60
2200 YRM 782 B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test

Figure 49. Chart B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test

61
B-3 - Check Governor System 2200 YRM 782

B-3 - Check Governor System

GOVERNOR SYSTEM NOT OPERATING 2. Accelerate engine to maximum throttle.
CORRECTLY
3. Observe engine speed.
A governor system that does not operate correctly can
4. Did engine accelerate smoothly, and to the normal
cause any of the following:
limit?
• Engine rpm more than limit of governor
• Engine power variation (surge) If system appears to function incorrectly, compare RPM
• Engine backfire readings from a SCAN Tool with readings from a sec-
• Low engine power ondary tachometer attached to a spark plug wire. They
• No acceleration (low engine rpm) must be very close or the same.
CHECK FUNCTION OF GOVERNOR If they are different, check for Electro Magnetic Infer-
SYSTEM ence (EMI). Inspect for spark plug wires too close to
the distributor primary wires, or charging system wires.
Normal testing for governor will include the following
(see Figure 50): If readings are close or the same, see chart for DTC 31
for more testing. It is possible that the system will not
1. Start engine, keep transmission in NEUTRAL. set DTC 31. In this case the DTC 31 chart can be used.

Figure 50. Chart B-3 Check Governor System

62
2200 YRM 782 Fuel System Components Repair

CHECK PCV SYSTEM With this system, fumes are sent into the air filter and
into the engine intake manifold.
CAUTION
An engine that is operated without any crankcase
ventilation can be damaged. Therefore, it is impor-
tant to replace the PCV valve at intervals shown in
the Periodic Maintenance section.

A restriction in PCV valve or hose can cause:

• Rough idle, slow idle speed, oil leaks, or oil in the air
cleaner.

A PCV valve or hose that leaks can cause:

• Rough idle, high idle speed, or engine stalls.
1. CHECK VALVE NEEDLE
If engine has a rough idle, check for a restriction in PCV
valve or hose. See Figure 51. Replace parts as de- Figure 51. PCV Valve
scribed in PCV System Repair.

Fuel System Components Repair

GENERAL
NOTE: The following is general information to be used
when working on fuel system:
• Always use new O-rings on fuel line fittings.
• All steel tubing on fuel system must be replaced with
original equipment parts.
• All fuel hoses must be replaced with original equip-
ment parts.
• Do not replace any steel fuel tubing with fuel hose.
Do not replace any steel fuel tubing with copper or
aluminum tubing.
• Some parts of Throttle Body Injector (TBI) can be
cleaned in a cleaner such as Yale Carburetor Cleaner
or its equivalent. DO NOT clean the following parts:
Throttle Position Sensor (TPS), IAC valve, fuel injec-
tors, cover for fuel meter body, ball bearings, or gov-
ernor assembly.
FUEL PRESSURE RELIEF PROCEDURE
1. Disconnect negative battery terminal to avoid fuel
leakage if an accidental attempt is made to start
engine.
2. Loosen fuel filler cap to relieve tank vapor pressure.
3. The internal relief in TBI unit relieves fuel pump
pressure when engine is OFF. Therefore, no addi-
tional pressure relief procedure is required.
FUEL PUMP REPLACEMENT
WARNING
To reduce the risk of fire and personal injury, do not
operate the fuel pump outside of the fuel tank. The
pump can make sparks and cause an explosion.

1. Disconnect negative cable at battery.

WARNING
To reduce the risk of fire and personal injury, relieve
the fuel system pressure before servicing fuel sys-
tem components.
After relieving system pressure, a small amount of fuel
may be released when servicing fuel lines or connec-
tions. To reduce the chance of personal injury, cover
fuel line fittings with a shop towel before disconnecting
to catch any fuel that may leak out. Place towel in an
approved container when disconnect is completed.
2. Loosen fuel filler cap to release pressure in fuel
tank. See Figure 52.
3. Disconnect fuel lines at access plate on fuel tank.
Disconnect wiring harness from TBI.
4. Remove capscrews holding access plate to fuel
tank. Remove access plate, fuel pump, and send-
ing unit, if attached.
5. Inspect fittings and fuel lines that are inside fuel
tank for damage. Inspect screen for damage.

63
Fuel System Components Repair 2200 YRM 782

6. Install fuel pump and fittings on access plate. Install Legend for Figure 52
float assembly.
1. WIRING HARNESS
7. Use a new seal ring and install access plate on tank. 2. COVER
3. SHUTOFF VALVE
Tighten capscrews for access plate. 4. OUTLET FUEL LINE
5. ACCESS PLATE
8. Connect fuel lines to fittings. Connect wire connec- 6. SEAL RING
tors. 7. CAPSCREW
8. WASHER
9. O-RING
10. SENDING UNIT (NOT ON ALL UNITS)
11. RETURN FUEL LINE AND FUEL PUMP
SUPPORT
12. CLAMP
13. FLEXIBLE COUPLING
14. FUEL PUMP AND MOTOR
15. SCREEN

THROTTLE BODY INJECTION UNIT (TBI)

Remove
NOTE: See Parts Manual for repair kits for components
of the Throttle Body Injection (TBI) unit. To make sure
the replacement part has the correct part number, see
Figure 53. The TBI is made of many separate com-
ponents. See Figure 54 and Figure 55. The TBI can
be replaced as a complete unit or parts of the TBI can
be replaced while the TBI is installed on engine. Re-
placement of individual components is described in the
following procedures.

1. Disconnect negative cable at battery.

2. Loosen fuel filler cap to release pressure in fuel

tank.

3. Disconnect and remove parts that connect TBI to

air filter.

4. Disconnect wires to IAC valve, TPS, governor mo-

tor, and fuel injector. Remove wiring harness grom-
met for fuel injector.

5. Disconnect throttle cable at throttle crank.

6. Disconnect vacuum hoses.

7. Disconnect fuel pressure and fuel return lines at

TBI. Hold fittings in TBI to keep them from turning
when fuel lines are disconnected.

8. Remove fasteners that hold TBI to manifold. Re-

move TBI. Cover opening in manifold to prevent dirt
from entering engine.
Figure 52. Fuel Pump Arrangement

64
2200 YRM 782
1. DAY OF YEAR 4. SHIFT
2. YEAR IDENTIFICATION
3. ASSEMBLY PLANT 5. SOURCE CODE
CODE
Figure 53. TBI Identification
Clean and Inspect
See the cleaning instructions in the NOTE under Gen-
eral at the beginning of this section. Clean gasket from
manifold and TBI. Be careful to prevent damaging ma-
chined surfaces and check all machined surfaces for
damage. Check manifold for loose parts.
Install
1. Use a new gasket and install TBI on manifold.
Tighten fasteners for TBI to 25 N•m (18 lbf ft).
2. Use new O-rings and washers on fuel lines. Con-
nect fuel pressure and fuel return lines. Tighten fuel
line nuts to 27 N•m (20 lbf ft).
3. Connect vacuum hoses.
4. Connect throttle cable at throttle cam. Check ad-
justment of throttle cables as described in Governor
System 3.0L Engine Repair and Governor System
4.3L Engine Repair.
5. Install wiring harness grommet for fuel injector.
Connect wires to IAC valve, TPS, and fuel injector.
Fuel System Components Repair
6. Connect negative cable at battery.
7. Turn key switch ON (do not start the engine) and
check for fuel leaks.
8. Use a new gasket and connect air filter to TBI.
9. Set position of pintle valve of IAC as follows:
a. Depress throttle pedal a small amount.
b. Start and run engine for 3 seconds.
c. Turn key switch OFF for 10 seconds.
d. Start engine and check for correct idle opera-
tion.
FUEL METER BODY
Remove
1. Disconnect negative cable at battery.
2. Loosen fuel filler cap to release pressure in fuel
tank. See Figure 54 and Figure 55.
3. Disconnect and remove parts that connect air filter
to TBI.
4. Disconnect electrical connector at fuel injector. Re-
move grommet and wires from body.
5. Disconnect fuel lines at fuel meter body. Hold fit-
tings in fuel meter body to keep them from turning
when fuel lines are disconnected.
6. For 4.3L engine, remove fuel line fitting from inlet
port in fuel meter body.
7. Remove screws that hold fuel meter body to throttle
body.
a. For 3.0L engine, remove fasteners that hold TBI
to manifold.
b. For 4.3L engine, remove fuel meter body and
gasket.
8. Clean gasket surfaces on fuel meter body and throt-
tle body.
65
Fuel System Components Repair 2200 YRM 782

1. FUEL INJECTOR 5. THROTTLE BODY

2. FUEL METER BODY 6. THROTTLE POSITION SENSOR
3. INLET FUEL FITTING 7. IDLE AIR CONTROL VALVE
4. FUEL RETURN PORT 8. FUEL PRESSURE REGULATOR

Figure 54. Throttle Body Injection (TBI) Unit for 3.0 Liter Engine

66
2200 YRM 782 Fuel System Components Repair

Figure 55. Assembly View of Throttle Body Injection (TBI) Unit for 4.3 Liter Engine

67
Fuel System Components Repair 2200 YRM 782

Legend for Figure 55

1. FUEL INJECTOR 7. INLET FUEL FITTING
2. FUEL PRESSURE REGULATOR 8. FUEL RETURN FITTING
3. THROTTLE POSITION SENSOR 9. GASKET (TBI TO MANIFOLD)
4. IDLE AIR CONTROL VALVE 10. O-RING
5. GOVERNOR MOTOR AND THROTTLE DRIVE 11. GASKET
ASSEMBLY 12. FUEL METER BODY
6. VACUUM PORTS

Install 5. Remove screws and retainer for fuel injector.

1. Use new gasket and install fuel meter body on throt- 6. To remove fuel injector, use a screwdriver as shown
tle body. See Figure 54 and Figure 55. in Figure 57. Remove and discard O-rings on fuel
injector.
2. Use thread locking adhesive (Loctite® 262) on
screws for fuel meter body. Install screws and
tighten them to 4.0 N•m (35 lbf in).

3. Use a new gasket and install TBI on manifold.

Tighten fasteners for TBI to 25 N•m (18 lbf ft).

4. Use new gasket and install fuel line fittings. Tighten

fittings to 40 N•m (30 lbf ft).

5. Use new O-rings and washers on fuel lines. Con-

nect fuel pressure and fuel return lines. Tighten fuel
line fittings to 27 N•m (238 lbf in).
1. FUEL INJECTOR (TOP VIEW)
6. Install wiring harness grommet for fuel injectors. 2. PART NUMBER
Connect wires at fuel injector. 3. MONTH, 1 TO 9 (JAN. TO SEPT.)
O, N, D (OCT., NOV., DEC.)
7. Connect negative cable at battery. Turn key switch 4. DAY
to START position (do not start engine). Ignition On 5. YEAR
function will cycle the fuel pump for a few seconds, 6. BUILD DATE CODE
7. • = INDICATES HIGH DYNAMIC RANGE
pressurizing the fuel system. Visually inspect fuel
system (fittings, fuel pump, and fuel lines) for leaks. Figure 56. Fuel Injector Identification
8. Use new gasket and connect air filter to TBI.

FUEL INJECTOR
Remove
NOTE: The fuel injector must be replaced as a complete
unit. To make sure the replacement part has the correct
part number, see Figure 56.

1. Disconnect negative cable at battery.

1. FUEL INJECTOR 3. FULCRUM
2. Loosen fuel filler cap to release pressure in fuel 2. SCREWDRIVER 4. FUEL METER
tank. BODY

3. Disconnect and remove parts that connect air filter Figure 57. Fuel Injector Removal
to TBI.

4. Disconnect electrical connector at fuel injector.

68
2200 YRM 782 Fuel System Components Repair

Install 5. Use a new gasket and connect air filter to TBI.

1. Lubricate new O-rings with engine oil. See Fig- PRESSURE REGULATOR
ure 58. Install lower (small) O-ring so it is against
fuel filter. Install upper (large) O-ring on fuel injec- Remove
tor.
1. Disconnect negative cable at battery.

2. Loosen fuel filler cap to release pressure in fuel

tank. See Figure 59.

1. COVER 4. SPRING
2. SCREW 5. DIAPHRAGM
3. SPRING SEAT 6. FUEL METER
BODY

Figure 59. Pressure Regulator

3. Disconnect and remove parts that connect air filter

to TBI.

4. Hold pressure regulator to compress spring. Re-

1. FUEL INJECTOR 5. SCREW move screws holding pressure regulator to fuel me-
2. UPPER O-RING 6. COVER/RETAINER
3. LOWER O-RING 7. FUEL VAPOR ter body. Remove pressure regulator assembly.
4. FUEL METER BLOCK Remove diaphragm.
BODY
Inspect
Figure 58. Fuel Injector Installation (4.3L Engine
Shown) Inspect valve seat in fuel meter body for damage. Re-
place fuel meter body if there is any damage.
2. Install fuel injector into bore of fuel meter body.
Push fuel injector until it is against its seat. Turn Install
fuel injector so that electrical connector is toward
notch. 1. Install a new diaphragm. See Figure 59. Make sure
diaphragm fits in groove of fuel meter body.
3. Use thread locking adhesive (Loctite 262) on
screws for retainer. Install retainer and screws. 2. Install seat for spring and spring in cover, then in-
Tighten screws to 3.0 N•m (27 lbf in). stall cover. Use thread locking adhesive (Loctite
262) on screws for cover. Install screws and tighten
4. Connect negative cable at battery. Turn key switch to 2.4 N•m (21 lbf in).
to START position (do not start engine). Ignition On
function will cycle the fuel pump for a few seconds, 3. Connect negative cable at battery. Turn key switch
pressurizing the fuel system. Visually inspect fuel to START position (do not start engine). Ignition On
system (fittings, fuel pump, and fuel lines) for leaks. function will cycle the fuel pump for a few seconds,

69
Fuel System Components Repair 2200 YRM 782

pressurizing the fuel system. Visually inspect fuel IDLE AIR CONTROL (IAC) VALVE
system (fittings, fuel pump, and fuel lines) for leaks.
Remove
4. Use a new gasket and connect air filter to TBI.

THROTTLE POSITION SENSOR (TPS) CAUTION

If the IAC valve has been in service, DO NOT push
Remove or pull on pintle. Moving pintle can damage internal
parts of IAC valve.
1. Disconnect and remove parts that connect TBI to
air filter. See Figure 60. 1. Disconnect and remove parts that connect TBI to
air filter. See Figure 61.

A. DISTANCE OF PINTLE EXTENSION

B. DIAMETER OF PINTLE
1. SCREW 3. O-RING
2. IAC VALVE BODY 4. PINTLE
1. THROTTLE BODY ASSEMBLY Figure 61. Idle Air Control Valve
2. THROTTLE POSITION SENSOR
3. SCREW
4. THROTTLE SHAFT 2. Disconnect electrical connector from IAC valve.

Figure 60. Throttle Position Sensor (TPS) 3. Remove screws for IAC valve and valve.

2. Disconnect electrical connector from TPS. Clean and Inspect

3. Remove screws for TPS and remove TPS.
Install
1. With throttle valve closed, install TPS on throttle
shaft. See Figure 60. Rotate TPS to align screw
holes. Use thread locking adhesive (Loctite 262)
on screws. Install screws and tighten to 2.0 N•m
(18 lbf in).
NOTE: If IAC valve must be replaced, make sure re-
placement part has correct part number and that the
shape and diameter of pintle is made for this applica-
tion.
See cleaning instructions in NOTE under General at
beginning of this section. Use a carburetor cleaner to
clean carbon from valve seat for pintle, air passage, and
surface for O-ring. Inspect O-ring for damage.

2. Connect electrical connector to TPS. Use a new

gasket and connect air filter to TBI.

70
2200 YRM 782 Governor System 3.0L Engine Repair

Install 4. Use a new gasket and connect air filter to TBI.

NOTE: When installing a new IAC valve, measure dis- 5. Do the following procedures to reset position of pin-
tance between tip of pintle and flange (dimension A in tle:
Figure 61.) If distance is more than 28 mm (1.1 in.), use
your finger to slowly retract pintle. This procedure will a. Depress throttle pedal a small amount.
not damage a NEW IAC valve. DO NOT do this proce-
b. Start and run engine for 5 seconds.
dure if IAC valve has been in service.
c. Turn key switch to OFF for 10 seconds.
1. Lubricate O-ring for IAC valve with engine oil and
install it on valve. d. Start engine and check for correct idle opera-
tion.
2. Install IAC valve on throttle body. Tighten screws to
3.0 N•m (27 lbf in).

3. Connect electrical connector to IAC valve.

Governor System 3.0L Engine Repair

GOVERNOR MODULE, REPLACE 3. Disconnect throttle cables at TBI and throttle pedal.
Disconnect cables at governor.
NOTE: The governor module is installed on inside of
cowl, under plastic panel. 4. Remove governor assembly from bracket.

1. Disconnect negative battery cable. 5. Install governor assembly on bracket.

2. Loosen panel under instrument panel (pull panel 6. Install and adjust throttle cables as described in
rearward). Throttle Cables, Install and Adjust.

3. Disconnect electrical connector. Remove mounting 7. Connect electrical connector at governor.

screws and remove module.
8. Connect negative battery cable.
4. Inspect electrical connectors and terminals for
damage. THROTTLE CABLES, INSTALL AND
ADJUST
5. Install governor module with screws. Connect con-
nector at module. 1. Connect throttle cables to governor actuator as
shown in Figure 62. Only the 2 pulleys closest
6. Install panel on cowl. to governor motor are used. Install lockwashers
7. Connect negative battery cable. and flat washers on cable housings. Slide each
cable housing to end of slot. Each cable will align
GOVERNOR MOTOR, REPLACE with a groove in a pulley. The pulley closest to
governor motor is for cable that goes to TBI unit.
1. Disconnect negative battery cable. Install cable ends into pulley, making sure cables
fit in grooves. Check for free operation of cables
2. Remove cover from governor assembly. on pulleys. Tighten nuts on cable housings to 18
to 20 N•m (12 to 15 lbf ft).

71
Governor System 3.0L Engine Repair 2200 YRM 782

6. Adjust pedal return stop (see Figure 63) to ensure

there is no tension on throttle cable at idle posi-
tion. When pedal return stop is in correct position,
tighten capscrew that holds stop to bracket.

FOOT DIRECTIONAL CONTROL PEDAL,

CHECK
Slowly move Foot Directional Control pedal pad
from FORWARD to REVERSE and REVERSE to
FORWARD. See Figure 63. There must be some
movement of pedal pad before pedal frame moves and
throttle opens.

1. GOVERNOR 4. ACTUATOR
MOTOR ASSEMBLY
2. COVER 5. CABLE TO
3. CABLE TO TBI ACCELERATOR
UNIT PEDAL

Figure 62. Throttle Cables

2. Connect cable to pedal as shown in Figure 63.

3. Push on throttle pedal and hold it against floor

plate. Adjust cable housing at pedal bracket until
pulleys in governor actuator are rotated fully clock-
wise against internal stop (as seen from front of
lift truck). Adjust cable housing only enough so
cable is not loose. There also must be no tension
in cable. When adjustment is correct, tighten both
jam nuts at pedal bracket.

4. Connect cylinder cable anchor on other cable to 1. PEDAL PAD 5. CAPSCREW

lever on TBI unit. Install cable housing in bracket 2. PEDAL FRAME 6. CRANK
that is fastened to TBI adapter. Adjust cable hous- 3. PEDAL RETURN 7. GAS
ing at bracket to get full throttle at TBI. Tighten jam STOP
4. LINK
nuts at bracket when adjustment is correct.
Figure 63. Foot Directional Control Pedal
5. Install cover on governor assembly.

72
2200 YRM 782 Governor System 4.3L Engine Repair

Governor System 4.3L Engine Repair

GOVERNOR THROTTLE DRIVE
ASSEMBLY
Remove
1. Disconnect and remove parts connecting TBI to air
filter. See Figure 64, Figure 65, and Figure 66.

2. Disconnect electrical connector at drive motor.

CAUTION
The spring for the throttle lever has tension. Hold
throttle valves closed, then rotate cam for throttle
lever clockwise. Rotate cam until ball joint for throt-
tle cable is in 11 o’clock position. See Figure 66. 1. THROTTLE DRIVE ASSEMBLY
This procedure will prevent damage to throttle drive 2. SCREW
assembly.
Figure 64. Governor Throttle Drive Assembly
3. Remove screws that hold throttle drive assembly to
throttle body. Remove throttle drive assembly.

Figure 65. Governor Motor and Throttle Drive Assembly

73
Governor System 4.3L Engine Repair 2200 YRM 782

Legend for Figure 65

1. THROTTLE DRIVE ASSEMBLY COVER PLATE 5. GOVERNOR MOTOR LEVER
2. DC GOVERNOR MOTOR 6. SHAFT TO THROTTLE PLATES
3. THROTTLE DRIVE CAM 7. THROTTLE DRIVE ASSEMBLY HOUSING
4. THROTTLE DRIVE LEVER

Inspect This procedure will prevent damage to throttle drive

assembly.
Check for worn or damaged parts.
2. Disconnect spring from motor lever so that motor
Install lever will be free when drive motor is removed. See
Figure 67.
1. Hold throttle valves closed. Rotate throttle drive
cam until ball joint for throttle cable is in 11 o’clock
position. See Figure 66.

1. HOLD THROTTLE VALVES CLOSED 1. THROTTLE DRIVE ASSEMBLY COVER PLATE

2. CAM FOR THROTTLE LEVER AT 11 O’CLOCK 2. MOTOR DRIVE LEVER
POSITION 3. SHOCK ABSORBER
4. DISCONNECT SPRING TO REMOVE MOTOR
Figure 66. Align Governor Throttle Drive 5. WIND SPRING AND CONNECT TO ENGAGE
MOTOR DRIVE LEVER
2. Put throttle drive assembly in position. Use a thread
locking adhesive (Loctite® 262) on screws and in- Figure 67. Governor Drive Motor Arrangement
stall screws for throttle drive assembly. Tighten
them to 4.5 N•m (40 lbf in). Check that cam for throt- 3. Remove 4 screws that hold drive motor to cover
tle valves and throttle valves rotate freely. plate. Remove screw under throttle lever cam last.
Move throttle lever cam clockwise from drive motor
3. Connect electrical connector at drive motor. to prevent release of spring tension. See Figure 68.
4. Use a new gasket and connect air filter to TBI. 4. Remove drive motor.

GOVERNOR DRIVE MOTOR 5. Remove shock absorber(s) only if it is damaged.

See Figure 70.
Remove
Clean and Lubricate
1. Remove governor motor and throttle drive assem-
bly (see Figure 67). Some parts of the governor throttle drive need to be
lubricated with a special grease (Mobil No. 28 or equiv-
alent). Clean and lubricate these parts only if new parts
CAUTION are used or there is no grease on parts. Lubricate parts
The spring for the throttle lever has tension. Hold as shown in Figure 69.
throttle valves closed, then rotate cam for throttle
lever clockwise. Rotate cam until ball joint for throt-
tle cable is in 11 o’clock position. See Figure 66.

74
2200 YRM 782 Governor System 4.3L Engine Repair

Legend for Figure 68

1. THROTTLE LEVER CAM
2. SCREW
3. DRIVE MOTOR

Figure 68. Governor Throttle Drive Assembly

1. LEVER AND BEARING ASSEMBLY 5. COVER PLATE

2. THROTTLE TO MOTOR LINK 6. LUBRICATION POINTS
3. SHOCK ABSORBER 7. THROTTLE DRIVE CAM
4. THROTTLE DRIVE LEVER

Figure 69. Lubricate Governor

Install
1. If replaced, install shock absorber parts as shown
in Figure 70.

2. Align motor lever with cover plate. See Figure 67.

Put straight end of spring in detent area in cover
plate. Put motor drive lever against shock absorber.

3. Wind spring for motor drive lever to engage motor 1. SUPPORT PIN 4. RETAINER RING
drive lever as shown in Figure 67. 2. SHOCK (HERE ONLY)
ABSORBER 5. LEVER AND
4. Rotate cam until ball joint for throttle cable is in 11 3. COVER PLATE BEARING
o’clock position. See Figure 66 and Figure 68. ASSEMBLY

Figure 70. Shock Absorber

75
Ignition System Components Repair
5. Use a thread locking adhesive (Loctite® 262) on
screws and install screws for governor drive motor.
Tighten screws to 3.2 N•m (28 lbf in).
Ignition System Components Repair
ECM REPLACEMENT
1. Disconnect negative battery cable.
2. Disconnect connectors from ECM.
3. Remove capscrews that hold ECM to mount plate
on frame.
NOTE: To prevent Electrostatic Discharge damage to
ECM, DO NOT TOUCH connector pins of ECM.
4. Install ECM in position and install capscrews. Con-
nect connectors to ECM.
5. Connect negative battery cable.
FUNCTION CHECK
1. Turn ignition key ON.
2. Connect SCAN Tool to Diagnostic Connector and
check for DTC 12. Check that no other DTCs are
present. This indicates that ECM functions cor-
rectly.
Let DTC 12 flash 4 times in a row to check that no other
DTCs are present. This indicates that ECM functions
correctly.
DISTRIBUTOR
Remove
CAUTION
Carefully lift and release lock tabs on connectors
to distributor. Lock tabs can be easily broken if too
much force is applied with screwdriver or other tool.
Never permit TACH CONN. terminal to touch
ground. Ignition module or ignition coil can be
damaged.
1. Disconnect battery negative (ground) cable.
2. If removal of spark plug wires are not required for
repairs, leave them connected to distributor cap.
76
2200 YRM 782
Inspect
Check that motor drive lever rotates freely. Make sure
spring returns drive lever to position against shock ab-
sorber.
Remove 2 capscrews that fasten distributor cap to
distributor. Move distributor cap away from work
area.
3. Disconnect distributor 4-terminal connector.
4. Disconnect ignition coil connector.
5. Remove bolt and clamp that hold distributor in en-
gine. Make a note of positions of rotor to distrib-
utor housing and distributor to engine. Slowly pull
distributor from engine until rotor just stops turning
counterclockwise and make a note of position of ro-
tor. This position must be used when distributor is
installed again.
Disassemble
1. Remove rotor. See Figure 71. Make a match mark
on gear and shaft so they can be assembled in the
same position.
2. Use a punch to remove roll pin from shaft.
3. Remove gear.
4. Remove shaft with timer core from housing.
5. Remove retainer from housing. Use a screwdriver
as a prybar.
6. Disconnect sensing coil from ignition module.
CAUTION
Carefully lift and release lock tab on connector to
sensing coil. Lock tab can be easily broken if too
much force is applied with screwdriver or other tool.
7. Use a screwdriver to lift lock tab. Remove sensing
coil.
8. Remove 2 screws that hold ignition module in hous-
ing. Remove ignition module.
2200 YRM 782 Ignition System Components Repair

1. Apply silicon grease to bottom of ignition module.

See Figure 71. Install ignition module into housing
and tighten 2 screws.

2. Install sensing coil. Tab on bottom of sensing coil

fits into anchor hole in housing.

3. Connect sensing coil to ignition module. Make sure

lock tab on connector is fastened.

4. Install retainer.

5. Install shaft assembly into housing.

6. Install seal on housing. Install gear on end of shaft.

7. Align marks on gear and shaft. Install roll pin. Turn

shaft assembly and make sure teeth of timer core
on shaft assembly do not touch pole piece.

8. Install rotor on shaft.

Install
1. Put rotor and distributor in same position as it was
removed from engine.

If engine has been rotated after distributor was re-

moved, the following procedure must be used be-
fore distributor is installed again:
1. CAP 7. SEAL
2. ROTOR 8. HOUSING a. Remove No. 1 spark plug.
3. SHAFT/TIMER 9. MODULE
CORE 10. ALIGNMENT PIN b. Put a finger over No. 1 spark plug hole and
4. RETAINER 11. POLE PIECE slowly rotate engine until pressure is felt on
5. PIN 12. COIL compression stroke.
6. DRIVE GEAR
c. Align timing mark on crankshaft pulley to 0
Figure 71. Distributor (3.0L Shown) (TDC) on engine timing indicator.

Inspect d. Turn distributor rotor to point near position on

Inspect shaft for a loose fit between shaft and its bush-
ing in housing. If bushing or shaft is worn so that shaft
moves from side to side in bushing, replace shaft or
housing.
Inspect housing for cracks or damage.
distributor cap for No. 1 spark plug lead.
e. Install distributor in engine. Rotor and shaft will
rotate a few degrees when gear on distributor
shaft engages drive gear on engine cam. Tim-
ing is correct if rotor points at position on dis-
tributor cap for No. 1 spark plug lead.

Assemble 2. Install clamp and bolt. Tighten bolt with your hand.

NOTE: Yale Part No. 504069721 is a silicon bearing
grease used between electronic components and their
heat sinks. A small container of silicon grease is en-
closed in package with a new ignition module.
3. Install distributor 4-terminal connector.
4. Install ignition coil connector.
5. Install distributor cap and 2 capscrews. If spark
plug wires were removed, install them in correct
sequence.

77
Ignition Module Repair
6. Connect battery negative cable.
7. Start engine and check engine timing. See Distrib-
utor, Ignition Timing below for more information on
Ignition Timing.
8. Tighten bolt for distributor clamp to 43 N•m
(25 lbf ft).
Firing Order
The Firing Order for the GM 3.0L engine is 1-3-4-2.
The Firing Order for the GM 4.3L engine is 1-6-5-4-3-2.
See Figure 72.
Figure 72. Firing Order for GM 4.3L V-6
Ignition Module Repair
TEST FOR FAULT
NOTE: The ignition module can be checked in the dis-
tributor. A test light and 3 jumper wires are needed to
perform the tests. The battery in the vehicle must be
fully charged so that starter rotates engine at normal
speed.
1. Disconnect 4-terminal connector from distributor.
See Figure 73. Use 2 jumper wires between dis-
tributor and 4-terminal connector to connect the fol-
lowing circuits:
REFERENCE Circuit GY
GROUND Circuit HX
2. Connect test light to a 12-volt positive source. Start
engine. Touch probe of test light to pin B in 4-termi-
nal connector on distributor. When 12 volts are ap-
plied through test light to pin B (BYPASS), ignition
module changes to EST mode. EST connection
(pin D) is open and engine will normally stop. This
step checks BYPASS operation of ignition module.
78
2200 YRM 782
Ignition Timing
1. Start and run engine until it is at normal operating
temperature. Turn key switch OFF.
2. Connect SCAN Tool to Diagnostic Connector con-
nector.
3. Connect a timing light to No. 1 spark plug wire.
WARNING
Do not touch moving parts (fan, belt, shafts, pul-
leys).
4. Start engine and check initial timing. Correct setting
for initial timing set point is 8 BTDC on 3.0L engine
and 0 BTDC on 4.3L engine.
5. If timing is not correct, loosen clamp that holds dis-
tributor housing. Rotate housing right or left to get
correct timing. Tighten clamp when timing is cor-
rect.
6. Disconnect timing light. Disconnect SCAN Tool.
Put cover on Diagnostic Connector.
3. Use a jumper to connect pin D (EST) to pin C (REF-
ERENCE) at distributor. Apply 12 volts through test
light to pin B (BYPASS) as described in Step 2.
Start engine. If engine starts, this step checks that
EST circuit in ignition module is good.
4. Remove test light from pin B (BYPASS) while en-
gine is running. If engine stops, this check shows
that ignition module internally changes EST circuit
to ground. Since there is a jumper wire between pin
D (EST) to pin C (REFERENCE), the REFERENCE
signal is also sent to ground and engine stops.
5. If any tests described in Step 2, Step 3, or Step 4
do not work as indicated, check wiring harness for
a short circuit or an open circuit. If wiring harness
is good, replace ignition module.
6. When tests are complete, connect system for nor-
mal operation.
2200 YRM 782
Figure 73. Ignition Module Test
REPLACE
1. Remove distributor cap and rotor. See Figure 71.
2. Remove 2 screws that hold ignition module in dis-
tributor.
3. Lift ignition module and disconnect connections.
Make a note of connections so that they can be
correctly connected again. Remove ignition mod-
ule from distributor.
NOTE: Do not remove silicon grease from ignition mod-
ule or distributor if same ignition module will be installed
again. If a new ignition module is installed, a small con-
tainer of silicon grease is in package. Clean old sili-
con grease and apply a new layer of silicon grease to
both ignition module and distributor housing. This sili-
con grease is necessary for cooling ignition module.
4. Connect connectors in distributor to ignition mod-
ule. Make sure connectors are the same as when
they were removed.
5. Install ignition module in distributor.
6. Install 2 screws that fasten ignition module in dis-
tributor.
Ignition Module Repair
7. Install distributor cap and rotor.
SENSING COIL
Test
NOTE: Also see A-7 - Ignition System Troubleshooting.
This test checks the resistance of the sensing coil for the
ignition module. The distributor can stay on the engine
for this test.
Do the following procedure to check the sensing coil:
• Connect an ohmmeter to either sensing coil connec-
tion and housing as shown in Step 1 of Figure 74. If
reading is not infinity (∞), replace sensing coil.
• Connect an ohmmeter to both connectors of sensing
coil as shown in Step 2 of Figure 74. Move connec-
tors at sensing coil and at connector to find any open
circuits that are not constant. Ohmmeter will correctly
indicate 500 to 1500 ohms. If indication is not con-
stant or is not within resistance range, replace sens-
ing coil.
79
Ignition Module Repair 2200 YRM 782

A. CLEAN METAL FOR GOOD GROUND

CONNECTION

Figure 75. Test Ignition Coil

3. Connect an ohmmeter as shown in Step 2 of Fig-

ure 75. Use low scale. Indication will be very low or
1. SENSING COIL 2. OHMMETER approximately zero. If indication is not low, replace
CONNECTIONS 3. IGNITION MODULE
ignition coil.
Figure 74. Test the Sensing Coil
4. Connect an ohmmeter as shown in Step 3 of Fig-
ure 75. Use high scale. Reading must not be infinity
Replace (∞). If reading is infinity, replace ignition coil.
Remove and disassemble distributor as described in re-
5. Connect distributor lead and wiring to ignition coil.
pairs for Distributor.
Remove
IGNITION COIL
1. Turn key switch to OFF. Apply parking brake.
Test
2. Disconnect negative battery cable.
NOTE: Also see A-7 - Ignition System Troubleshooting.
3. Put tags for identification on connectors and discon-
This procedure tests for open circuits and short circuits nect them from coil.
in ignition coil. Ignition coil can stay on engine for this
test.
CAUTION
1. Disconnect distributor wire and control wires from Do not damage high voltage wires (spark plug
ignition coil. wires) during removal. Hold wire by boot near end
of wire. Rotate boot before pulling it and connec-
2. Connect an ohmmeter as shown in Step 1 of Fig- tion from terminal.
ure 75. Use high scale. Correct indication is infinity
(∞). If a short circuit is indicated, replace ignition 4. Remove high voltage wire.
coil.

80
2200 YRM 782 Sensors Repair

5. Remove nuts (or capscrews) that fasten bracket for Install

ignition coil to engine.
1. Install original bracket on replacement coil using
6. Remove ignition coil and bracket assembly from en- screws (supplied with replacement coil). See Fig-
gine. ure 75.

7. Use a drill and punch to remove two rivets that fas- 2. Install ignition coil assembly on engine with nuts (or
ten bracket to coil. capscrews).

3. Install control wire connectors and high voltage wire

on ignition coil.

4. Connect negative (ground) battery cable.

Sensors Repair
ENGINE COOLANT TEMPERATURE (ECT) 3. Inspect electrical connectors and terminals for
SENSOR, REPLACE damage.

4. Install sensor on bracket.

WARNING
The coolant can be very hot. Use caution to prevent 5. Connect electrical connector. Connect vacuum
personal injury. hose from MAP sensor to fitting at TBI unit.

1. Disconnect battery negative cable. Disconnect

connector at ECT sensor. See Figure 76.

2. Use a wrench and carefully loosen ECT from

coolant manifold.

3. Use a liquid sealant on threads and install ECT in

its hole in coolant manifold. Tighten ECT carefully
to 30 N•m (22 lbf ft).

4. Connect connector at ECT. Connect battery nega-

1. TEMPERATURE SENSOR
tive cable. 2. ELECTRICAL CONNECTOR
3. LOCK TAB
5. Fill radiator with coolant as required.
Figure 76. Engine Coolant Temperature Sensor
MAP SENSOR, REPLACE (ECT)
1. Disconnect negative battery cable. Disconnect
electrical connector.

2. Remove mounting screws and disconnect vacuum

hose.

81
Wiring 2200 YRM 782

PCV System Repair

REPLACE
1. Remove PCV valve from rocker arm cover. See
Figure 77.

2. Run engine at idle speed.

3. Put your thumb over end of PCV valve to check

for vacuum. If there is no vacuum at PCV valve,
check for restrictions in hoses, manifold port, or
PCV valve. Replace damaged parts.

4. Turn engine OFF and remove valve. Shake valve

and listen for movement of needle inside valve. If
valve does not move, replace valve. Connect hose 1. PCV VALVE 3. VALVE COVER
between PCV valve and fitting on intake manifold. 2. GROMMET

Figure 77. PCV System

Wiring
NOTE: The most common fault that occurs in an elec-
tronic engine control system is caused by a bad con-
nection in the wiring. Work carefully and make sure that
connectors are not damaged during troubleshooting.
The ECM wiring harness electrically connects the ECM
to solenoids, switches, and sensors in the engine com-
partment. A wiring harness must be replaced with a
wire harness that has the same part number. If a repair
(wire splice) must be made to a wiring harness, replace-
ment wire must have a high temperature insulation.
The signal wires in the electronic control system have
a low voltage and low current. All wire splices must be
high quality so that a fault is not made in the circuit by
the wire splice. Use solder on the wire splices when
possible.
Some connectors are made as a one-piece unit. A dam-
aged, one-piece connector must be replaced with a wire
splice into the wiring harness. Some connectors can be
replaced or a terminal within the connectors can be re-
placed. These connectors are described in Connectors
and Terminals.
CONNECTORS AND TERMINALS
Be careful when using a probe to check voltages on ter-
minals in a connector. It is easy to cause a short circuit
between 2 terminals with opposite voltages. Electronic
components can be easily damaged by a short circuit.
Always use a jumper between connectors when check-
ing circuits. Never damage insulation or a seal on a
connector when making a check or doing troubleshoot-
ing. The Connector Test Adapter Kit has a variation of
adapters and connectors that can be used when trou-
bleshooting a circuit.
When troubleshooting, open circuits are often difficult
to see because of dirt, corrosion, or a terminal that is
not in alignment in its socket. When troubleshooting
for an open circuit, always check for loose connections
and a terminal that can have corrosion. A fault that is
not regular nor constant can also be caused by a loose
connection or a terminal that has corrosion.
If a connector must be repaired, be sure to replace it
with the correct connector type. Some of the smaller
connectors can look similar, but have a different con-
struction.
Micro-Pack® Connector is shown in Figure 78. This
connector is normally used to connect the wire harness
to the ECM.

82
2200 YRM 782 Wiring

NOTE: Not all Metri-Pack connectors have a seal.

Do the following procedures to remove and install a ter-

minal:

1. Open any secondary locks that hold wires and

seals in their positions. Slide seals along wires
from ends of connector.

2. Hold wire and use it to push terminal to its forward

position in connector body. Hold terminal in this
position.

3. Find lock tab for terminal in connector channel.

Push a removal tool (pick) of correct size into con-
nector channel. See Figure 78 and Figure 80.

1. WIRE 4. YALE TOOL KIT

2. TERMINAL OTC P/N 7733
3. LOCK TAB

Figure 78. Micro-Pack Connector

Metri-Pack® Connectors, shown in Figure 79, come in

several sizes and types that are used on the wire har-
ness. These connectors are made by Packard Electric 1. PICK 3. TERMINAL
Company. The typical connectors used on lift trucks 2. LOCK TAB 4. CONNECTOR
are No. 56, No. 150, No. 280, No. 480, and No. 630. BODY
Some of these connectors are push-to-seat and others
Figure 80. Metri-Pack Pull-to-Seat Connector
are pull-to-seat. Make sure connector is correctly iden-
tified before it is changed. Terminals can be damaged 4. Use removal tool to move lock tab and release ter-
if they are removed or installed wrong. minal from its seat.

Push-To-Seat - Gently pull wire to remove terminal

from back of connector. See Figure 80.

Pull-To-Seat - Gently push wire to remove terminal

through front of connector. See Figure 81.

CAUTION
Work carefully and do not use enough force to dam-
age terminal or connector.

5. Inspect terminal and connector for damage. Make

repairs as necessary. See Figure 82.
1. PICK 3. TERMINAL 6. If terminal will be used again, make sure lock tab
2. LOCK TAB 4. CONNECTOR
BODY is correctly bent so that terminal will be locked in
connector again.
Figure 79. Metri-Pack Push-to-Seat Connector

83
Wiring 2200 YRM 782

Legend for Figure 82

NOTE: THE GREATER THE DISTANCE D, A FAULT

CAN OCCUR IN THE CONNECTION.
A. D = 0
B. D = GREATER THAN 0
1. CONTACT TAB

7. Push terminal into connector channel. Make sure

that lock tab correctly locks terminal in position.

8. Push seals into their position and install any sec-

ondary locks.

Weather-Pack® Connectors all have a rubber seal at

rear end of connector. All Weather-Pack Connectors
have a round barrel shape around the terminal. This
connector is used in the engine compartment to pro-
tect against moisture and dirt which can cause corro-
sion and a fault in the voltage signal. These connectors
normally have the low voltage and current used by the
electronic control system. The repair of this type of con-
nector is shown in Figure 83 and Figure 84.
1. FEMALE TERMINAL Use a remover tool (J28742BT8234-A from Tool Kit
2. LOCK TAB
3. PICK TOOL (J35689/BT8446-A) OTC P/N 7733) to remove pin and sleeve terminals.
4. CONNECTOR BODY These terminals can easily be damaged during re-
5. SEAL moval if correct tool is not used. Terminal must then be
replaced. When making repairs on these connectors,
Figure 81. Metri-Pack Series 150 Pull-to-Seat make sure that terminals are all in their seats correctly
Terminal Removal and sealing rings are installed. These connectors must
be correctly installed and in good condition so that
electronic engine control operates correctly.

Figure 82. Metri-Pack Series Terminal Inspection Figure 83. Weather-Pack Terminal and Connector

84
2200 YRM 782 Wiring

Legend for Figure 83 PROCEDURES FOR SPARK PLUGS,

A. PUSH-TO-SEAT TERMINAL, MALE SPARK PLUG WIRES, AND BOOTS
1. TERMINAL 4. SEAL NOTE: Use a silicon grease on inside of spark plug
2. LOCK TAB 5. REMOVAL TOOL boots to make a better weather seal and make spark
3. WIRE 6. CONNECTOR plug boot easier to remove. The following silicon
BODY greases are approved for use:

General Electric® GE627

Packard® PM776

Wacker® Silicones G47

NOTE: The condition of spark plugs removed from en-

gine can show engine operating problems. See Spark
Plugs Troubleshooting.

1. Do not damage spark plug wires during removal.

Hold wire by boot near end of wire. Rotate boot a
half-turn before pulling it and connection from spark
plug. Do not use pliers or other tools that can dam-
age boot. Do not pull wires to disconnect spark plug
wires. Pull boot, or use a tool made for this purpose.

2. Do NOT put a hole in boot or insulation of spark plug

wire. Do NOT try to insert a wire between boot and
connector of spark plug wire.

3. Make sure spark plug wires are installed in same

locations using clips. Spark plug wires can be dam-
aged or cause poor engine operation if they are not
correctly installed.

4. Special care must be used when spark plug boots

are installed. Make sure that metal terminal within
boot is fully connected to spark plug terminal. Make
sure that boot has not moved on wire. If there is
boot to wire movement, boot can appear to be fully
installed when it is not.

5. Make sure to install insulator in shield at boot of all

spark plug wires.

Figure 84. Weather-Pack Terminal Repair
WIRING DIAGRAM
The wiring diagram for the electronic control module is
shown in Figure 85. The wiring diagram is followed by
tables of pinouts for the ECM connectors J1 and J2.
See Table 6 and Table 7.

85
Wiring 2200 YRM 782

Figure 85. Wiring Connections (Sheet 1 of 2)

86
2200 YRM 782 Wiring

Figure 85. Wiring Connections (Sheet 2 of 2)

87
Wiring 2200 YRM 782

Table 6. ECM Connector J1 Identification

Pin No. Ckt No. Function To Pin Pin No. Ckt Function To Pin
No.
1 JBA Fuel Injector B 17 Not Used
2 Not Used 18 Not Used
3 HX Distributor, Reference Low A 19 Not Used
4 HQ Ground 20 JX Ground
5 HL Ground 21 Not Used
6 Not Used 22 JR Governor Module B
7 Not Used 23 JA Fuel Pump Relay 85
8 Not Used 24 GZ Distributor, Bypass circuit C
9 AZ Service Engine Soon Light 25 Not Used
10 GW Distributor, EST Signal D 26 Not Used
11 HJ Idle Air Control B, HI B 27 HK Idle Air Control B, LO A
12 JT Idle Air Control A, LO C 28 HG Idle Air Control A, HI D
13 Not Used 29 Not Used
14 Not Used 30 Not Used
15 Not Used 31 Not Used
16 Not Used 32 HZ Diagnostic Connector G

88
2200 YRM 782 Wiring

Table 7. ECM Connector J2 Identification

Ckt
Pin No. Ckt No. Function To Pin Pin No. Function To Pin
No.
1 HD Diagnostic Connector F 17 Not Used
ECM B+ Fuse A
2 Not Used 18 HW Coolant Temperature Sensor A
HU MAP Sensor A
3 HV Throttle Position Sensor B 19 GR MAP Sensor C
4 GT Throttle Position Sensor A 20 JX Not Used
5 Not Used 21 Not Used
6 Not Used 22 HS Diagnostic Connector B
7 Not Used 23 Not Used
8 Not Used 24 Not Used
9 Not Used 25 Not Used
10 GY Distributor, Reference D 26 GU Throttle Position Sensor C
11 GQ Coolant Temperature Sensor B 27 HA MAP Sensor B
12 Not Used C 28 Not Used
13 Not Used 29 Not Used
14 Not Used 30 Not Used
15 Not Used 31 Not Used
16 Not Used 32 JM ECM Fuse B
GE Governor Controller (GM 3.0L) A
BCC Ignition Coil B

89
Spark Plugs Troubleshooting 2200 YRM 782

Spark Plugs Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Brown to gray or tan deposits Normal wear. Clean the spark plugs, set the elec-
and some electrode wear. trode clearance, and install.

Dry, black carbon deposits. Poor ignition output. Check distributor to coil connections.

Wet, oily deposits with mini- Break-in of new or recently overhauled Clean and install spark plugs.
mum electrode wear. engine.

Clearances too large between valve See Engine section for your engine.
stem and valve guide.

Worn seals on inlet valves. Replace seals.

Red, brown, yellow, and white By-products of combustion. Clean spark plugs, set electrode clear-
colored coatings on insulator. ance, and install.
Engine operation is not con-
stant during difficult operating
conditions.

Heavily deposits on part of Valve seals have leaks if condition is Check seals. Replace if necessary.
plug that goes into cham- found in only 1 or 2 cylinders. Clean, set electrode clearance, and in-
ber and on side facing intake stall spark plugs.
valve.

Yellow glaze coating on insu- Melted by-products of combustion. Avoid sudden acceleration with full
lator of spark plug. throttle after long periods of low speed
driving. Replace spark plugs.

Insulator tips are burned or Overheating. Check cooling system.

electrodes worn. Lean air-fuel mixture.
Check heat range of spark plugs for too
hot.
Check ignition timing.
Check torque value of spark plugs to
make sure they are correctly installed.

Spark plugs have broken or Heat shock from sudden rise in tip tem- Replace spark plugs. Set electrode
cracked insulator tips. perature under severe operating con- clearance to correct value.
ditions. Electrode clearance not cor-
rect.

90
2200 YRM 782 Special Tools

Special Tools
SCAN Tool
Reads problem codes from the ECM memory. Used to
analyze and troubleshoot components and the ECM
operation of the electronic engine control system.
SCAN Tool will also record data stream information
when the engine is operating. This procedure will
record information that is not regular nor constant or
that only occurs during some conditions.
Available from:
Rinda Technologies Inc.
4563 North Elston Ave.
Chicago, IL 60630
Spark Tester
Used to check secondary ignition voltage. Also called
an ST125.

OTC Part No. 3320 Tester for Idle Air Control and Idle Speed Control
The TBI units do not have external adjustments for
idle speed nor idle air control. This tester is required
to set the idle air control and the idle speed control
electronically.
OTC Part No. 3053 Signal Test Lights for Idle Air Control and Idle
Speed Control
Signal test lights that can be used with the Tester for
Idle Air Control and Idle Speed Control Part No. 3320.
Vacuum Pump, Hand Operated
Use gauge to check engine manifold vacuum and to
test vacuum sensors, valves, and solenoids.

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Special Tools 2200 YRM 782

Digital Multimeter
Voltmeter - A minimum impedance of 10 megohms is
required so that the electronic circuit being measured
is accurate.
Ammeter - Can be used to measure current flow in
electronic circuits.
Ohmmeter - Some Ommeters will automatically change
ranges. Other Ohmmeters have range switches.
Many of the multimeters available will also operate as a
tachometer, distributor dwell, and a diode tester.

Tachometer
Use a tachometer with an inductive trigger sensor to
check the engine speed.

Test Light (Without Internal Battery)

Used to check for open circuits, short circuits, and for
signal voltages in a circuit.

Adjustment Wrench for Minimum Idle Speed

Used to adjust the throttle stop screw on the TBI unit.

Injector Harness Test Light

A specially designed light used to visually indicate
injector electrical pulses from the ECM.

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 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 782 3/03 (5/02)(2/02) Printed in U.S.A.