Maintenance

ELECTRONIC ENGINE
CONTROL
GM 3.0L
TROUBLESHOOTING AND REPAIR
GP/GLP/GDP2.00-3.00RF/TF
(GP/GLP/GDP040-060RG/TG/ZG) [A875];
GC/GLC040-065RG/TG/ZG [E187]

PART NO. 524158885 2200 YRM 611

 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
Where Do I Start? ........................................................................................................................................... 1
Visual/Physical Inspection............................................................................................................................... 1
Knowledge/Tools Required ............................................................................................................................. 1
Damage From Static Discharge (Static Electricity) ......................................................................................... 1
Troubleshooting Information ............................................................................................................................ 1
Malfunction Indicator Lamp (MIL).................................................................................................................... 2
Reading Diagnostic Trouble Codes (DTCs) .................................................................................................... 2
Clearing Diagnostic Trouble Codes (DTC’s) ................................................................................................... 3
Diagnostic Mode ............................................................................................................................................. 3
Field Service Mode ......................................................................................................................................... 3
ECM Learning Ability....................................................................................................................................... 4
On-Board Diagnostic (OBD) System Check ................................................................................................... 4
Troubleshooting Charts ................................................................................................................................... 7
Tools and Test Equipment ............................................................................................................................... 7
A-1 - No Malfunction Indicator Lamp ................................................................................................................... 8
Circuit Description ........................................................................................................................................... 8
Test Description............................................................................................................................................... 8
Other Troubleshooting Checks ........................................................................................................................ 8
A-2 - No SCAN Data, No DTC 12, Malfunction Indicator Lamp On..................................................................... 11
Circuit Description ........................................................................................................................................... 11
Test Description............................................................................................................................................... 11
A-3 - Starter Rotates the Engine, Engine Will Not Run ....................................................................................... 13
Circuit Description ........................................................................................................................................... 13
Test Description............................................................................................................................................... 13
Other Troubleshooting Checks ........................................................................................................................ 14
A-4 - Fuel Injector Circuit..................................................................................................................................... 16
Circuit Description ........................................................................................................................................... 16
Test Description............................................................................................................................................... 16
A-5 - Fuel Pump Relay Circuit ............................................................................................................................. 18
Circuit Description ........................................................................................................................................... 18
Test Description............................................................................................................................................... 18
Other Troubleshooting Checks ........................................................................................................................ 18
A-7 - Fuel System Troubleshooting ..................................................................................................................... 20
Circuit Description ........................................................................................................................................... 20
Test Description............................................................................................................................................... 21
Other Troubleshooting Checks ........................................................................................................................ 21
Test Description............................................................................................................................................... 21
Fuel Pressure Check....................................................................................................................................... 24
A-8 Ignition System Troubleshooting ................................................................................................................... 25
Test Description............................................................................................................................................... 25
DTC 14 - Engine Coolant Temperature Sensor Circuit (High Temperature Indicated) ........................................ 29
Circuit Description ........................................................................................................................................... 29
Test Description............................................................................................................................................... 29
Other Troubleshooting Checks ........................................................................................................................ 29
DTC 15 - Engine Coolant Temperature Sensor Circuit (Low Temperature Indicated) ......................................... 31
Circuit Description ........................................................................................................................................... 31
Test Description............................................................................................................................................... 31
Other Troubleshooting Checks ........................................................................................................................ 31
DTC 21 - Throttle Position Sensor Circuit (Signal Voltage High)......................................................................... 33

©2003 Yale Materials Handling Corp. i

Table of Contents Electronic Engine Control

TABLE OF CONTENTS (Continued)

Circuit Description ........................................................................................................................................... 33
Test Description............................................................................................................................................... 33
Other Troubleshooting Checks ........................................................................................................................ 33
DTC 22 - Throttle Position Sensor Circuit (Signal Voltage Low).......................................................................... 35
Circuit Description ........................................................................................................................................... 35
Test Description............................................................................................................................................... 35
Other Troubleshooting Checks ........................................................................................................................ 35
DTC 31 - Engine Governor Circuit....................................................................................................................... 37
Circuit Description ........................................................................................................................................... 37
Test Description............................................................................................................................................... 37
Other Troubleshooting Checks ........................................................................................................................ 37
DTC 33 - Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage High - Low Vacuum) .................... 39
Circuit Description ........................................................................................................................................... 39
Test Description............................................................................................................................................... 39
Other Troubleshooting Checks ........................................................................................................................ 39
DTC 34 - Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage Low - High Vacuum) .................... 41
Circuit Description ........................................................................................................................................... 41
Test Description............................................................................................................................................... 41
Other Troubleshooting Checks ........................................................................................................................ 41
DTC 42 - Electronic Spark Timing (EST) ............................................................................................................ 43
Circuit Description ........................................................................................................................................... 43
Test Description............................................................................................................................................... 44
Other Troubleshooting Checks ........................................................................................................................ 44
DTC 51 - ECM Failure ......................................................................................................................................... 46
Circuit Description ........................................................................................................................................... 46
Other Troubleshooting Checks ........................................................................................................................ 46
Troubleshooting, Poor Operation ......................................................................................................................... 46
General ........................................................................................................................................................... 46
Make a Careful Visual Check...................................................................................................................... 46
FAULT: Codes or Performance That is Not Regular ................................................................................... 46
Definition:................................................................................................................................................ 46
Check: .................................................................................................................................................... 47
FAULT: Loss Of Diagnostic Trouble Code (DTC) Memory .............................................................................. 47
FAULT: Engine Quits While Driving ................................................................................................................. 47
Additional Checks ....................................................................................................................................... 47
FAULT: Engine Is Difficult To Start .................................................................................................................. 47
Definition: .................................................................................................................................................... 47
Check:......................................................................................................................................................... 47
FAULT: Variation In Engine Power When The Throttle Is Held Steady ........................................................... 48
Definition: .................................................................................................................................................... 48
Check:......................................................................................................................................................... 48
FAULT: Decreased Engine Power ................................................................................................................... 48
Definition: .................................................................................................................................................... 48
Check:......................................................................................................................................................... 48
FAULT: Detonation .......................................................................................................................................... 48
Definition: .................................................................................................................................................... 48
Check:......................................................................................................................................................... 48
FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes ........................................... 49
Definition: .................................................................................................................................................... 49
Check:......................................................................................................................................................... 49
FAULT: One Or More Cylinders Do Not Operate Correctly. The Engine Does Not Idle Correctly. .................. 49

ii
Electronic Engine Control Table of Contents

TABLE OF CONTENTS (Continued)

Definition: .................................................................................................................................................... 49
Check:......................................................................................................................................................... 49
FAULT: Rough Idle Or Engine Stalls During Idle ............................................................................................. 50
Definition: .................................................................................................................................................... 50
Checks: ....................................................................................................................................................... 50
FAULT: Fuel Usage Too High .......................................................................................................................... 50
Definition: .................................................................................................................................................... 50
Check:......................................................................................................................................................... 50
FAULT: Dieseling ............................................................................................................................................. 50
Definition: .................................................................................................................................................... 50
Checks: ....................................................................................................................................................... 51
FAULT: Backfire............................................................................................................................................... 51
Definition: .................................................................................................................................................... 51
Check:......................................................................................................................................................... 51
Engine Coolant Temperature (ECT) Sensor Test ................................................................................................ 51
Throttle Position (TP) Sensor Check ................................................................................................................... 52
Minimum Idle Speed Adjustment......................................................................................................................... 53
Adjust .............................................................................................................................................................. 53
C-1 - Idle Air Control (IAC) System Check .......................................................................................................... 54
Circuit Description ........................................................................................................................................... 54
Other Troubleshooting Checks ........................................................................................................................ 54
C-2 - Manifold Absolute Pressure (MAP) Sensor Output Test............................................................................. 56
Circuit Description ........................................................................................................................................... 56
Test Description:.............................................................................................................................................. 56
PCV System Check ............................................................................................................................................. 58
Governor System Check ..................................................................................................................................... 58
Governor System Not Operating Correctly...................................................................................................... 58
Governor System Function, Check ................................................................................................................. 59
Fuel System Components Repair........................................................................................................................ 59
General ........................................................................................................................................................... 59
Fuel Pressure Relief Procedure ...................................................................................................................... 59
Fuel Pump, Replace........................................................................................................................................ 59
TBI Unit ........................................................................................................................................................... 60
Remove....................................................................................................................................................... 60
Clean and Inspect ....................................................................................................................................... 61
Install .......................................................................................................................................................... 61
Fuel Meter Body.............................................................................................................................................. 62
Remove....................................................................................................................................................... 62
Install .......................................................................................................................................................... 62
Fuel Injector .................................................................................................................................................... 63
Remove....................................................................................................................................................... 63
Install .......................................................................................................................................................... 63
Pressure Regulator ......................................................................................................................................... 64
Remove....................................................................................................................................................... 64
Inspect ........................................................................................................................................................ 64
Install .......................................................................................................................................................... 64
Throttle Position Sensor (TPS)........................................................................................................................ 64
Remove....................................................................................................................................................... 64
Install .......................................................................................................................................................... 64
Idle Air Control (IAC) Valve ............................................................................................................................. 65
Remove....................................................................................................................................................... 65

iii
Table of Contents Electronic Engine Control

TABLE OF CONTENTS (Continued)

Clean and Inspect ....................................................................................................................................... 65
Install .......................................................................................................................................................... 65
Throttle Body................................................................................................................................................... 66
Remove and Disassemble .......................................................................................................................... 66
Inspect ........................................................................................................................................................ 66
Assemble and Install................................................................................................................................... 66
Oil Pressure Switch, Replace.......................................................................................................................... 66
Governor System Repair ..................................................................................................................................... 68
Governor Module, Replace ............................................................................................................................. 68
Governor Motor, Replace ................................................................................................................................ 68
Throttle Cables, Install and Adjust................................................................................................................... 69
Foot Directional Control Pedal, Check ............................................................................................................ 70
Ignition System Components Repair ................................................................................................................... 70
ECM, Replace ................................................................................................................................................. 70
Function, Check .............................................................................................................................................. 70
Distributor........................................................................................................................................................ 70
Remove....................................................................................................................................................... 70
Disassemble ............................................................................................................................................... 71
Inspect ........................................................................................................................................................ 71
Assemble .................................................................................................................................................... 71
Install .......................................................................................................................................................... 72
Ignition Timing ............................................................................................................................................ 72
Ignition Module Repair......................................................................................................................................... 72
Test For a Fault................................................................................................................................................ 72
Ignition Module, Replace................................................................................................................................. 73
Sensing Coil .................................................................................................................................................... 74
Test ............................................................................................................................................................. 74
Replace....................................................................................................................................................... 74
Ignition Coil ..................................................................................................................................................... 74
Test ............................................................................................................................................................. 74
Remove....................................................................................................................................................... 75
Install .......................................................................................................................................................... 75
Sensors Repair.................................................................................................................................................... 75
Engine Coolant Temperature (ECT) Sensor, Replace .................................................................................... 75
MAP Sensor Replacement.............................................................................................................................. 75
PCV System Repair............................................................................................................................................. 76
Replace ........................................................................................................................................................... 76
Wiring Repair....................................................................................................................................................... 76
Connectors and Terminals .............................................................................................................................. 76
Procedures for Spark Plugs, Spark Plug Wires, and Boots ............................................................................ 79
Spark Plug Troubleshooting................................................................................................................................. 80
Wiring Diagrams .................................................................................................................................................. 81
Special Tools ....................................................................................................................................................... 86

This section is for the following models:

GP/GLP/GDP2.00-3.00RF/TF (GP/GLP/GDP040-060RG/TG/ZG) [A875];

GC/GLC040-065RG/TG/ZG [E187]

iv
2200 YRM 611
General
This section has the troubleshooting and repair proce-
dures for the parts of the electronic engine controls.
Users of this section must know the components and
operation as described in the section Electronic En-
gine Control - Description and Operation 2200 YRM
612.
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).
These parts and their sensors give information about
engine operation and the systems it controls. The ECM
has the ability to perform some troubleshooting of itself
and of other parts of the system. When a problem is
found, the ECM turns on the Malfunction Indicator lamp
in the instrument cluster. A Diagnostic Trouble Code
(DTC) is kept in the memory of the ECM.
TROUBLESHOOTING PROCEDURE
Before using this part of the manual, you need to know
the information and the correct troubleshooting proce-
dures. If the correct troubleshooting procedures are not
followed as described in this section, it can result in re-
placement of good parts. Troubleshooting charts use
a SCAN Tool where possible. The SCAN Tool has the
ability to save time in troubleshooting and preventing
the replacement of good parts.
WHERE DO I START?
There are three things to do to start troubleshooting.
The first is to become familiar with the electronic engine
control system.
Secondly, always start your work with a good visual/
physical inspection. See the following section for more
explanation.
The last item on the "Where Do I Start" list 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 cause
the repair of a problem without further steps. Inspect all
vacuum hoses for correct routing, restrictions, cuts and
bad connections. Be sure to inspect hoses that are dif-
ficult to see beneath the air filter. Inspect all the wires in
the engine compartment for proper connections, dam-
aged spots, or contact with sharp edges or the exhaust
manifolds. This visual/physical inspection is very impor-
tant. It must be done carefully.
General
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 di-
agrams, the meaning of voltage, ohms, amps, and the
basic theories of electricity, and understand what hap-
pens in an open or shorted wire. To perform the trou-
bleshooting procedures, the 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 at the end of this section.
DAMAGE FROM STATIC DISCHARGE
(STATIC ELECTRICITY)
CAUTION
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
components. There are several ways for a person to be-
come statically charged. The most common methods of
charging are by friction and by induction. An example of
charging by friction is a person sliding across a car seat,
in which a charge of as much as 2 to 5,000 volts can
build up. Charging by induction occurs when a person
with well-insulated shoes stands near a highly charged
object and momentarily touches ground. Charges of
the same polarity are drained off, leaving the person
highly charged with the opposite polarity. Static charges
of either type can cause damage, therefore, it is impor-
tant to use care when handling and testing electronic
components.
TROUBLESHOOTING INFORMATION
The troubleshooting charts and function checks in this
section are designed to find a bad circuit or component
through logic based on the process of elimination. The
charts are prepared with the requirement that the ve-
hicle functioned correctly at the time of assembly and
that there are no multiple failures. See Figure 1. The
ECM does constant testing on certain control functions.
The ECM communicates the source of a malfunction
with Diagnostic Trouble Codes (DTC). The DTCs are
two-digit numbers that can range from 12 to 99. When
1
General
a malfunction is found by the ECM, a DTC is set and
the Malfunction Indicator lamp is turned on.
Figure 1. ECM
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 for service as soon
as possible.
It displays Diagnostic Trouble Codes (DTCs) kept by
the ECM which help the technician troubleshoot system
problems.
As a bulb and system check, the lamp will come on
with the ignition switch ON and the engine not running.
When the engine is started, the lamp will turn off.
If the lamp remains on, the system has found a prob-
lem. This problem is referred to as a "current" DTC. If
the problem goes away, the lamp will go out after 10
seconds. In either condition, a DTC will remain in the
ECM.
When the lamp remains on while the engine is running,
or when there is a malfunction, the On-Board Diagnos-
tic (OBD) System Check must be done.
When a problem is not regular or constant, the Malfunc-
tion Indicator lamp will turn on for approximately 10 sec-
onds and then will go off. However, the DTC will be kept
in the memory of the ECM until the DTCs are cleared
(see DTC clearing in this section). A DTC that is not
constant can reset. If it is a problem that is not con-
stant, a DTC chart is not used. However, you can use
the "Other Troubleshooting Checks" on the page facing
2
2200 YRM 611
the troubleshooting chart for that DTC to help locate the
problem.
READING DIAGNOSTIC TROUBLE CODES
(DTCS)
The Diagnostic Link Connector (DLC) is used to com-
municate with the ECM. See Figure 2. The DLC is in-
stalled on the bracket on top of the valve cover. It is used
in the assembly plant to receive information in checking
that the engine is operating correctly before it leaves
the plant. The DTC(s) kept in the ECM’s memory can
be read with a SCAN Tool connected to the DLC.
1. DIAGNOSTIC LINK CONNECTOR
Figure 2. Diagnostic Link Connector
When the SCAN Tool is connected to the DLC with the
key switch ON and the engine OFF, the system will en-
ter the Diagnostic Mode. At this point, the Malfunction
Indicator lamp will flash "DTC 12" three times consec-
utively (see Figure 3). The following is the flash se-
quence for "12": long pause, flash, pause, flash-flash,
long pause, flash, pause, flash-flash, long pause, flash,
pause, flash-flash. DTC 12 (which means no crankshaft
rpm signal) indicates that the ECM’s diagnostic system
is operating correctly at this time. If DTC 12 is not indi-
cated, a problem is in the diagnostic system itself.
Following the output of DTC 12, if additional codes are
stored, the Malfunction Indicator lamp will flash the DTC
three times. If more than one DTC has been stored in
the ECM’s memory, the DTCs will flash starting with the
newest DTC set and finishing with the oldest DTC set.
Remember, each DTC will flash three times. When all
DTCs have flashed, the sequence will start over again
with DTC 12.
2200 YRM 611 General

1. LONG PAUSE 3. PAUSE

2. FLASH 4. FLASH-FLASH

Figure 3. Diagnostic Trouble Code (DTC) 12 Example

CLEARING DIAGNOSTIC TROUBLE 1. Display a DTC 12 by flashing the Malfunction Indi-

CODES (DTC’S)
Install the SCAN Tool according to the operator’s
manual for the tool. Select clear DTCs from the tools
menu. This operation electronically clears all ECM
DTCs. Check for DTCs again to see that the DTCs are
cleared.
DIAGNOSTIC MODE
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
three times, then DTC 12 will flash again.
3. The IAC valve moves to its fully extended position,
blocking the idle air passage.

FIELD SERVICE MODE

CAUTION
To prevent ECM damage, the key must be OFF when
disconnecting or reconnecting ECM power.
When the SCAN Tool is connected to the DLC with the
key switch ON and the engine OFF, the system will en-
ter the Diagnostic Mode.
If the SCAN Tool is connected to the DLC and turned
ON with the engine running, the system will enter the
Field Service Mode. This will cause the engine to run at
approximately 1500 rpm and 8 Before Top Dead Cen-
ter (BTDC) spark advance. While the system is in Field
Service Mode, new trouble codes can be kept in the
ECM. See Table 1.

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

Table 1. ECM Diagnostic Codes Available

Code Description Turn On Malfunction

Indicator Lamp
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
42 EST Circuit Malfunction Yes
51 ECM Internal Problem Yes

3
General
ECM LEARNING ABILITY
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 the engine is at oper-
ating temperature. Drive the lift truck at part throttle,
with moderate acceleration, and idle until normal per-
formance returns.
ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK
The On-Board Diagnostic (OBD) System Check is a
troubleshooting chart to find a problem caused by a mal-
function in the electronic engine control system. It must
be the starting point for any troubleshooting.
The SCAN data shown in Table 2 can be used for com-
parison after doing the troubleshooting checks and find-
ing the on-board diagnostics working correctly with no
trouble codes shown. The data are an average of dis-
play values from normally operating vehicles and show
a display of a normally operating system.
After the visual/physical inspection, the OBD System
Check is the starting point for all troubleshooting proce-
dures.
The correct procedure to find a problem is to follow three
basic steps.
4
2200 YRM 611
1. Are the on-board diagnostics working? This is de-
termined by doing the OBD System Check. Since
this is the starting point for the troubleshooting pro-
cedures, always begin here.
If the on-board diagnostics do not work, the OBD
System Check will not lead to a troubleshooting
chart to fix the problem. If the on-board diagnos-
tics are working correctly, go to the next step.
2. Is there a DTC? 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, go to the
next step.
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 oper-
ator’s manual of the tool. Readings for a certain
operating condition can be found in Table 2.
Test Description: The number that follows is a refer-
ence to the bold number in Figure 4.
1. DTC 12 means no rpm reference pulses from the
ignition module. This is correct when engine is not
running.
2200 YRM 611 General

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
Idle Speed rpm ECM idle command (changes with temperature)
Coolant Temp. C ( F) 85 to 100 C (185 to 212 F)
Ignition Volts volts 12.5 to 14.5 V
MAP Volts/kPa 1 to 2 (depends on Vac. and BARO pressure), 30-40
kPa
BARO Volts/kPa 1 to 2 (depends on BARO pressure), 98-102 kPa
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 0 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 - 18:12:15

5
General 2200 YRM 611

Figure 4. On-Board Diagnostic (OBD) System Check

6
2200 YRM 611 General

TROUBLESHOOTING CHARTS • Always disconnect the battery and the ECM con-
nectors if electric-arc-welding must be done on
WARNING the vehicle.
• If the engine compartment is cleaned with steam,
This troubleshooting requires operation of the en-
make sure any water or steam is not sent toward
gine for some tests. Make sure the tests are done
the ECM or its sensors. The heat and steam can
carefully to prevent injury:
damage the electronic components and cause
• Put the lift truck on a level surface. Lower the
corrosion in the electrical connections.
carriage and forks and apply the parking brake.
• Use only the tools and test equipment described
Make sure the lift truck cannot move and cause an
in Tools and Test Equipment to prevent damage
injury during the tests. Use blocks as necessary
to good components and to obtain correct test
to prevent movement of the lift truck.
results.
• The fuel system and the engine must operate cor-
• All voltage measurements must be made with a
rectly. Any problems or leaks in the fuel sys-
digital voltmeter with a rating of 10 megohm input
tem and the engine must be repaired before doing
impedance.
troubleshooting.
• When a test light is used in troubleshooting, the
• The fan and the drive belts can remove fingers or
test light must have less than 0.3 amps (300 mil-
cause other injuries. Be careful that your hands
liamps) of maximum current flow. A test for a cor-
and tools do not touch the moving fan or the drive
rect test light is shown in Figure 5.
belts.
• The engine exhaust and other parts of the engine The troubleshooting charts found in this section are de-
are hot. Do not touch a hot surface and cause a signed to give an efficient method of fault analysis on
burn. the electronic engine controls.

CAUTION TOOLS AND TEST EQUIPMENT

Electronic equipment can be damaged if trou-
The following tools are necessary for troubleshooting
bleshooting and repairs are not done correctly.
the system:
The following CAUTIONS must be followed when
• Ohmmeter.
doing troubleshooting or repairs on an engine with
• Digital voltmeter. The voltmeter must have a mini-
an ECM:
mum input impedance of 10-megohms. (A digital volt-
• Always disconnect the battery negative cable be-
meter and ohmmeter are normally included in a mul-
fore disconnecting and removing any parts ex-
timeter test instrument.)
cept as described in Troubleshooting.
• Tachometer with inductive trigger signal sensor.
• Never start the engine unless the battery is cor-
• Test light that has a low current draw as described in
rectly connected.
Figure 5.
• Never disconnect the battery from any equipment
• Vacuum pump with a gauge. This vacuum pump is
when the engine is running.
held and operated with the hand. The gauge must be
• Never disconnect the battery from the charging
able to indicate a gauge pressure (vacuum) of 34 kPa
system when the engine is running.
(10 inHg). (See the Pressure Conversion Chart at the
• If the battery must be charged with a battery
end of this section.)
charger, ALWAYS disconnect the battery from the
• Spark tester. The spark tester is used to check the
electrical system.
secondary ignition. The spark tester is also called an
• Make sure all electrical connections are clean and
ST125 and creates a 25-kilovolt load on secondary
have good electrical contact.
ignition components.
• Never connect or disconnect the wiring harness
at the ECM when the key switch is ON.
• Never disconnect a jumper wire between the ter-
minals of the Diagnostic Link Connector (DLC).

7
A-1 - No Malfunction Indicator Lamp 2200 YRM 611

Legend for Figure 5

NOTE: IF THE AMMETER INDICATES LESS THAN

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

NOTE: IF THE AMMETER INDICATES MORE THAN

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

Figure 5. Current Flow Test for Test Light

A-1 - No Malfunction Indicator Lamp

CIRCUIT DESCRIPTION
The Malfunction Indicator lamp will be on when the igni-
tion is ON and engine is not running. Voltage from the
ignition switch is supplied to the light bulb. The Elec-
tronic Control Module (ECM) will control the lamp and
turn it on by connecting it to ground through circuit AZ.
See Figure 6.
TEST DESCRIPTION
The numbers below are a reference to the bold numbers
in Figure 7.
1. This test gives a ground circuit for the Malfunction
Indicator lamp circuit. If lamp works now, then the
external circuits are correct.
2. This tests circuits HD, HC, and JM for voltage.
4. If a fuse is open, remember to locate any short cir-
cuits to ground or other high-ampere causes on that
circuit.
OTHER TROUBLESHOOTING CHECKS
If engine runs correctly, check for the following:
• Fault in the light bulb.
• Circuit AZ is open.
• 5-ampere circuit breaker is no good. This will cause
no dash indicator lights, gauges, or seat belt re-
minder.
If engine cranks but will not run:
• ECM Battery + fuse/circuit JY or HD or HC open.
• ECM ignition fuse/circuit JM/JN is open.
• Poor connections to ECM.

3. Using a test light connected to Battery +, check

each of the system ground circuits to be sure there
is a good ground.

8
2200 YRM 611 A-1 - No Malfunction Indicator Lamp

Figure 6. A-1 - Circuit Description

9
A-1 - No Malfunction Indicator Lamp 2200 YRM 611

Figure 7. A-1 - No Malfunction Indicator Lamp

10
2200 YRM 611 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
The Malfunction Indicator lamp (MIL) will be on when
the ignition is ON and the engine is not running. Voltage
from the ignition switch is supplied to the light bulb. The
ECM will control the light and turn it on by connecting it
to ground through circuit AZ to the ECM. See Figure 8.
With the diagnostic terminal connected to ground, the
light will flash a DTC 12, followed by any trouble code(s)
kept in memory. A steady light means a short to ground
in the light control circuit AZ, or an open in circuit HS.
TEST DESCRIPTION
The numbers below are a reference to the bold numbers
in Figure 9.
1. If there is a problem with the ECM that causes a
SCAN Tool to not read data from the ECM, then the
ECM will not flash a DTC 12.
• If DTC 12 flashes, be sure the SCAN Tool is work-
ing correctly on another vehicle.
• If the SCAN is working correctly and circuit HZ
is good, the ECM may 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 ECM connector J2 is dis-
connected, then circuit AZ has a short circuit to
ground.
4. At this point, the Malfunction Indicator lamp wiring
is good. If DTC 12 does not flash, replace the ECM.

Figure 8. A-2 - Circuit Description

11
A-2 - No SCAN Data, No DTC 12, Malfunction Indicator Lamp On 2200 YRM 611

Figure 9. A-2 - No SCAN Data, No DTC 12, Malfunction Indicator Lamp On

12
2200 YRM 611 A-3 - Starter Rotates the Engine, Engine Will Not Run

A-3 - Starter Rotates the Engine, Engine Will Not Run

CIRCUIT DESCRIPTION
Before using this procedure, battery condition, engine
cranking speed, and fuel quantity must be checked to
make sure they are correct. See Figure 10.
• If throttle or coolant sensors are not within these
ranges, the ECM can be using the wrong mode
for starting.
• The SCAN Tool will display RPM during cranking
if pulses are received at the ECM.

TEST DESCRIPTION 2. If RPM was indicated during crank, the ignition

The numbers below are a reference to the bold numbers
in Figure 11.
1. A Malfunction Indicator lamp ON is a test to deter-
mine if there is battery and ignition voltage at the
ECM.
• No SCAN data can be caused by an ECM prob-
lem, A-2 - No SCAN Data, No DTC 12, Malfunc-
tion Indicator Lamp On will diagnose the ECM.
module is receiving a crank signal, but "No Spark"
at this test indicates the ignition module is not
triggering the coil.
3. While cranking the engine, there must be no fuel
spray with the injector electrical connector discon-
nected. Replace the injector or seals if fuel sprays
or drips.

Figure 10. A-3 - Circuit Description

13
A-3 - Starter Rotates the Engine, Engine Will Not Run
4. The test light will flash, indicating the ECM is con-
trolling 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.
14
2200 YRM 611
OTHER TROUBLESHOOTING CHECKS
Check for the following:
• 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 and 3.0
volts can cause a no-start condition. Disconnect the
MAP sensor. If the engine starts, replace the MAP
sensor. See MAP Sensor Replacement.
• 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.
2200 YRM 611 A-3 - Starter Rotates the Engine, Engine Will Not Run

Figure 11. A-3 - Starter Rotates the Engine, Engine Will Not Run

15
A-4 - Fuel Injector Circuit 2200 YRM 611

A-4 - Fuel Injector Circuit

CIRCUIT DESCRIPTION
This troubleshooting procedure is used if A-3 - Starter
Rotates the Engine, Engine Will Not Run indicates a
fuel injector problem. See Figure 12.
TEST DESCRIPTION
The numbers below are a reference to the bold numbers
in Figure 13.
1. This test will determine if the ignition module is gen-
erating a reference pulse and check the wires and
ECM for a fault. If a 12-volt test light is connected to
12 volts and then touched and removed from circuit
GY, a reference pulse is normally generated. If the
test light connected to the fuel injector circuit mo-
mentarily illuminates, the ECM and wires are cor-
rect.
2. This step checks for 12 volts to the fuel injector.
This test will also determine if there is a short circuit
to a voltage source on the ECM side of the circuit.
3. This test checks for a good circuit to the ECM.

Figure 12. A-4 - Circuit Description

16
2200 YRM 611 A-4 - Fuel Injector Circuit

Figure 13. A-4 - Fuel Injector Circuit

17
A-5 - Fuel Pump Relay Circuit
A-5 - Fuel Pump Relay Circuit
CIRCUIT DESCRIPTION
When the ignition switch is turned ON, the ECM will
activate the fuel pump relay with a 12-volt signal and
run the fuel pump. The fuel pump relay will operate as
long as the engine is cranking or running if the ECM is
Figure 14. A-5 - Circuit Description
If the fuel pump relay or the 12-volt relay drive from the
ECM fails, the fuel pump will receive 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.
TEST DESCRIPTION
The numbers below are a reference to the bold numbers
in Figure 15.
1. The test light will connect to ground through the
relay to the fuel pump.
2. If pump does not run, it can be damaged or worn.
18
2200 YRM 611
receiving 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 14.
3. After the fuel pump relay is replaced, continue with
the "Oil Pressure Switch Test," Step 4.
4. At this point, the fuel pump relay is operating cor-
rectly. Test the parallel circuit through the oil pres-
sure switch.
5. If fuse was damaged, check the circuit for too much
current usage (including fuel pump).
OTHER TROUBLESHOOTING CHECKS
Check for the following:
• A fuel pump relay that does not work can cause long
cranking times. The extended crank period is caused
by the time necessary for oil pressure to reach the
pressure required to close the oil pressure switch and
turn on the fuel pump.
2200 YRM 611 A-5 - Fuel Pump Relay Circuit

Figure 15. A-5 - Fuel Pump Relay Circuit

19
A-7 - Fuel System Troubleshooting 2200 YRM 611

A-7 - Fuel System Troubleshooting

CIRCUIT DESCRIPTION
When the ignition switch is turned ON, the ECM will
activate the fuel pump relay with a 12-volt signal and
run the fuel pump. The fuel pump relay will operate as
long as the engine is cranking or running if the ECM is
receiving ignition reference pulses. The ECM will stop
the fuel pump relay signal 2 seconds after the ignition
references stop. This will also occur 2 seconds after the
key was ON and the engine not started. See Figure 16.
through the oil pressure switch circuit when the engine
is running.
When the engine is stopped, the fuel pump can be
turned on by applying Battery + to the fuel pump "test"
terminal. This terminal is located near the pump relay.
The fuel pump delivers fuel to the TBI unit where the
system pressure is controlled to 62 to 90 kPa (9 to
13 psi). Excess fuel is returned to the fuel tank.

If the fuel pump relay or the 12-volt relay drive from the
ECM fails, the fuel pump will receive electrical current

Figure 16. A-7 - Circuit Description

20
2200 YRM 611
TEST DESCRIPTION
The numbers below are a reference to the bold numbers
in Figure 17.
1. Check the fuel pressure while the pump is running.
Pressure will start to drop as soon as the pump
stops because of an internal relief in the pressure
regulator.
2. If engine does not run, use A-3 - Starter Rotates
the Engine, Engine Will Not Run.
3. This test checks the operation of the fuel pump
check valve. A check valve that leaks will cause
fuel in the pressure line to drain back to the tank
and cause long start times. The amount of pres-
sure is not important as long as some pressure is
maintained.
OTHER TROUBLESHOOTING CHECKS
Fuel system pressure that is not correct 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
A-7 - Fuel System Troubleshooting
TEST DESCRIPTION
The numbers below are a reference to the bold numbers
in Figure 18.
1. Fuel pressure less than 62 kPa (9 psi) can cause
several problems. It can cause hard starting in cold
conditions and poor performance. Low fuel pres-
sure can also allow the engine to run at idle or low
speeds, but cause the engine to run poorly or stall
when more fuel is required (such as accelerating or
at high speed).
2. A restriction in the fuel flow at the tank (as shown)
causes the fuel pump to develop its maximum pres-
sure. With the fuel pump running, pressure will in-
crease to more than 90 kPa (13 psi).
NOTE: Do not block the fuel return line completely (out-
let side of TBI assembly), as too much pressure can
damage the TBI pressure regulator.
3. This test determines if the 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
the engine is accelerated, then repair the restriction
in fuel feed line. If there is no restriction, replace the
fuel pump.
5. Wrong fuel pump (too much capacity) can also
cause high pressure.
6. Check that the shutoff valves are open when fin-
ished.
21
A-7 - Fuel System Troubleshooting 2200 YRM 611

Figure 17. A-7 - Fuel System Troubleshooting

22
2200 YRM 611 A-7 - Fuel System Troubleshooting

Figure 18. A-7 - Fuel System Troubleshooting

23
A-7 - Fuel System Troubleshooting 2200 YRM 611

FUEL PRESSURE CHECK 2. Connect fuel pressure gauge.

Tools Required: Fuel Pressure Gauge 3. Energize fuel pump.

4. Compare fuel pressure to specifications.

WARNING
A small amount of fuel may be released when con-
necting the fuel pressure gauge. To prevent a fire
or personal injury, put a shop towel near the fuel
pressure port fitting before connecting the gauge.
Clean any fuel that leaks out. Put the towel in ap-
proved container when connection is completed.
1. Clean any dirt or grease from the cap for the pres-
sure gauge port, then remove it. See Figure 19.
5. Disconnect power supply for the fuel pump.
6. Disconnect fuel pressure gauge.
7. Replace the cap for the pressure gauge port.
8. Turn the ignition switch ON and OFF twice, wait-
ing 10 seconds between cycles, and check for fuel
leaks.

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 19. A-7 - Fuel Pressure Check

24
2200 YRM 611 A-8 Ignition System Troubleshooting

A-8 Ignition System Troubleshooting

TEST DESCRIPTION
If a tachometer has been connected to the TACH
CONN., disconnect it before doing this test. See Fig-
ure 20.
3. A spark indicates that the fault is in the distributor
cap or the rotor.
4. The normal voltage at the C and the + terminals is
battery voltage. A low voltage can indicate:

The numbers below are a reference to the bold numbers a. An open circuit or a high-resistance circuit from
in Figure 21. the distributor to the ignition coil.

1. Check a minimum of two spark plug wires to make
sure one does not have an open circuit (Spark
Tester ST-125). See Figure 21.
2. If a spark occurs when the EST connector is dis-
connected, the output from the sensing coil is too
low for EST operation.
b. An open circuit in the primary winding of the
ignition coil.
If the 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.

Figure 20. A-8 - Test Description

25
A-8 Ignition System Troubleshooting
5. Use the TEST LIGHT to check for a short circuit in
the EST module or in the circuit from the ignition
coil to the EST module. Check for approximately
12 volts between the TACH CONN. and ground.
If the voltage is low (approximately 1 to 6 volts),
there can be a fault in the ignition coil. This condi-
tion 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. The EST module normally goes ON when 1.5 to 8
volts are applied to terminal P. When the EST mod-
ule is ON, the voltage between the TACH CONN.
26
2200 YRM 611
and ground will normally decrease to 7 to 9 volts.
This test checks if the sensing coil or the EST mod-
ule has a fault. When 1.5 to 8 volts are momen-
tarily applied to terminal P, this voltage acts as a
trigger voltage that replaces the voltage from the
sensing coil. The procedure shows a test light, but
any low-voltage, low-current source can be used as
a trigger voltage.
7. When the momentary trigger voltage is removed,
a spark is normally generated through the ignition
coil. If no spark occurs, replace the ignition coil.
If a spark occurs, check the sensing coil and the
rotating timer core.
2200 YRM 611 A-8 Ignition System Troubleshooting

Figure 21. A-8 - Ignition System Troubleshooting (Sheet 1 of 2)

27
A-8 Ignition System Troubleshooting 2200 YRM 611

Figure 21. A-8 - Ignition System Troubleshooting (Sheet 2 of 2)

28
2200 YRM 611 DTC 14 - Engine Coolant Temperature Sensor Circuit (High Temperature Indicated)

DTC 14 - Engine Coolant Temperature Sensor Circuit

(High Temperature Indicated)
CIRCUIT DESCRIPTION
The Engine Coolant Temperature (ECT) sensor uses
a thermistor to control the signal voltage to the ECM.
The ECM applies a reference voltage on circuit GQ
to the sensor. When the engine is cold, the sensor
(thermistor) resistance is high. The ECM will then
sense a high signal voltage. See Figure 22.
As the engine warms up, the sensor resistance de-
creases and the voltage drops. The ECM reads this
voltage as a temperature.

Figure 22. DTC 14 - Circuit Description

TEST DESCRIPTION • A DTC 14 will occur if circuit GQ has a short circuit to

ground.
The numbers below are a reference to the bold numbers • Use Table 3 to test the accuracy of the sensor.
in Figure 23. • If DTC 14 is not constant, see Troubleshooting, Poor
Operation.
1. This test checks to see if DTC 14 was set as result
of current failure or intermittent condition. DTC 14 Table 3. ECT Sensor - Temp. vs Resistance
will set if signal voltage indicates a coolant temper-
ature above 135 C (275 F) for 3 seconds. C F Ohms
2. This test causes the conditions for a DTC 15. If 100 212 177
the ECM sees the open circuit (high voltage) and
70 158 467
displays a low temperature, the ECM and wiring are
correct. 40 104 1459
20 68 3520
OTHER TROUBLESHOOTING CHECKS
5 41 7280
Check for the following:
• After the engine is started, the temperature will in- 10 14 16,180
crease steadily to about 80 C (180 F), then remain 20 4 28,680
there when the thermostat opens.
• If the engine has been allowed to cool to an ambient 40 40 100,700
temperature (overnight), the coolant reading on the
SCAN Tool will be that ambient temperature.

29
DTC 14 - Engine Coolant Temperature Sensor Circuit (High Temperature Indicated) 2200 YRM 611

Figure 23. DTC 14 - Engine Coolant Temperature Sensor Circuit (High Temperature Indicated)

30
2200 YRM 611 DTC 15 - Engine Coolant Temperature Sensor Circuit (Low Temperature Indicated)

DTC 15 - Engine Coolant Temperature Sensor Circuit

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

Figure 24. DTC 15 - Circuit Description

TEST DESCRIPTION • If the engine has been allowed to cool to an ambient

temperature (overnight), the coolant reading on the
The numbers below are a reference to the bold numbers SCAN Tool will be that ambient temperature.
in Figure 25. • A DTC 15 occurs if circuit GQ, GR, or HU is open.
• If circuit GR is open, DTC 33 and DTC 15 can both
1. This test checks that DTC 15 was set by a current
set.
failure or a condition that is not constant. DTC 15
• Use Table 4 to test the accuracy of the sensor.
will set if signal voltage indicates a coolant tempera-
• If DTC 15 is not constant, see Troubleshooting, Poor
ture below 30 C ( 22 F) after engine runs for 120
Operation.
seconds.
Table 4. ECT Sensor - Temp. vs Resistance
2. This test causes the conditions for a DTC 14. If
the ECM sees a circuit to ground (low voltage) and
C F Ohms
displays a high temperature, the ECM and wiring
are correct. 100 212 177
70 158 467
3. This test will determine if there is a wiring problem
or a damaged ECM. If circuit GR is open, there can 40 104 1459
also be a DTC 33 stored. 20 68 3520
5 41 7280
OTHER TROUBLESHOOTING CHECKS
10 14 16,180
Check for the following: 20 4 28,680
• After the engine is started, the temperature will in-
40 40 100,700
crease to approximately 80 C (180 F), then become
stable when the thermostat opens.

31
DTC 15 - Engine Coolant Temperature Sensor Circuit (Low Temperature Indicated) 2200 YRM 611

Figure 25. DTC 15 - Engine Coolant Temperature Sensor Circuit (Low Temperature Indicated)

32
2200 YRM 611 DTC 21 - Throttle Position Sensor Circuit (Signal Voltage High)

DTC 21 - Throttle Position Sensor Circuit (Signal Voltage High)

CIRCUIT DESCRIPTION The signal voltage will vary from less than 1.25 volts at
idle to approximately 4.5 volts at Wide Open Throttle
The Throttle Position (TP) Sensor makes a voltage sig- (WOT). See Figure 26.
nal that changes with the position of the throttle plate.

Figure 26. DTC 21 - Circuit Description

TEST DESCRIPTION OTHER TROUBLESHOOTING CHECKS

The number below are a reference to the bold number
in Figure 27.
1. This test 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 is above 3.9 volts,
MAP reading below 65 kPa, and rpm less than
1750, for 5 seconds, or TP volts above approxi-
mately 4.8 volts any time.
2. This test causes the conditions for a DTC 22. If
the ECM sees the open circuit (low voltage) and
displays a low voltage, the ECM and circuit GU are
correct.
Check for the following:
• 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 the throttle is
moved to Wide Open Throttle (WOT).
• Check that the circuit does not have a short and a
voltage higher than 5.0 volts by testing it with a volt-
meter 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.

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

Sensor, damaged ECM, or an open circuit HV.

33
DTC 21 - Throttle Position Sensor Circuit (Signal Voltage High) 2200 YRM 611

Figure 27. DTC 21 - Throttle Position Sensor Circuit (Signal Voltage High)

34
2200 YRM 611 DTC 22 - Throttle Position Sensor Circuit (Signal Voltage Low)

DTC 22 - Throttle Position Sensor Circuit (Signal Voltage Low)

CIRCUIT DESCRIPTION The signal voltage will vary from less than 1.25 volts
at idle to about 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 22 - Circuit Description

TEST DESCRIPTION OTHER TROUBLESHOOTING CHECKS

The numbers below are a reference to the bold numbers
in Figure 29.
1. This test 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 volt
(200mV), and engine is running.
2. This test causes the conditions for a DTC 21. If the
ECM sees the jumper in the circuit (high voltage)
and displays over 4.0 volts, the ECM and circuits
GU/GT are correct.
Check for the following:
• 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 the 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.

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

Sensor, damaged ECM, or an open circuit HV.

35
DTC 22 - Throttle Position Sensor Circuit (Signal Voltage Low) 2200 YRM 611

Figure 29. DTC 22 - Throttle Position Sensor Circuit (Signal Voltage Low)

36
2200 YRM 611
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.
Depending on the need of the engine for the governor,
the module translates the ECM data into the correct
value of DC current (circuits JP and JQ) to the motor.
This current causes the motor to limit engine speed by
Figure 30. DTC 31 - Circuit Description
TEST DESCRIPTION
The numbers below are a reference to the bold numbers
in Figure 31.
DTC 31 will set if:
• The ECM is commanding near 100 percent authority.
1. This check is to determine if the governor control
module has a voltage supply so that it can 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
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 rpm than governor calibration). See
Figure 30.
2. Applying Battery + to the motor will not let the throt-
tle plate open.
3. This test requires complete governor control to de-
termine if the ECM or the governor system has a
fault. The throttle plate must not open during this
test.
OTHER TROUBLESHOOTING CHECKS
Check for the following:
• A "SCAN Tool displays governor TPS. Watch this
value as the engine rpm increases beyond the gov-
ernor limits, and see the ECM’s control try to limit
engine speed.
37
DTC 31 - Engine Governor Circuit 2200 YRM 611

Figure 31. DTC 31 - Engine Governor Circuit

38
2200 YRM 611
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 32. DTC 33 - Circuit Description
TEST DESCRIPTION
The numbers below are a reference to the bold numbers
in Figure 33.
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 (low manifold vacuum) and the TP sensor is
less than 5%, for longer than 10 seconds.
2. This step causes the conditions for a DTC 34. If
the ECM sees the change, the ECM and circuits
HA and HY/HW are good.
3. See C-2 - Manifold Absolute Pressure (MAP) Sen-
sor Output Test for complete test of MAP sensor.
DTC 33 - Manifold Absolute Pressure (MAP) Sensor Circuit
idle, to 4 to 4.5 volts at wide open throttle (low vacuum).
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 32.
OTHER TROUBLESHOOTING CHECKS
Check for the following:
• With the ignition ON and the engine stopped, the
manifold pressure is equal to atmospheric pressure
and the signal 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
reading with a known good vehicle with the same type
sensor is a good way to check accuracy of a sensor.
Correct readings will be within 0.4 volt of each other.
• A DTC 33 occurs if either circuit HW/HY is open, or if
circuit GR has a short to voltage or to circuit HA.
• If HW is open, DTC 33 and DTC 15 will set.
• If DTC 33 is not constant, see Troubleshooting, Poor
Operation.
39
DTC 33 - Manifold Absolute Pressure (MAP) Sensor Circuit 2200 YRM 611

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

40
2200 YRM 611 DTC 34 - Manifold Absolute Pressure (MAP) Sensor Circuit
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 to 1.5 volts at
Figure 34. DTC 34 - Circuit Description
TEST DESCRIPTION
The numbers below are a reference to the bold numbers
in Figure 35.
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
(high manifold vacuum), rpm is less than 1200 or
TP Sensor more than 15% and these conditions
exist for a time longer than 0.2 second.
2. This step causes the conditions for a DTC 34. If
the ECM sees the change, the ECM and circuits
HA and HY are good.
3. The SCAN Tool does not display 12 volts. What is
important is that the ECM sees that the voltage is
more than 4.0 volts. This would indicate that the
ECM and circuit HA are good.
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 Posi-
tion (TP) Sensor to control fuel delivery. See Figure 34.
OTHER TROUBLESHOOTING CHECKS
Check for the following:
• With the ignition ON and the engine stopped, the
manifold pressure is equal to atmospheric pressure
and the signal 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
reading with a known good vehicle with the same type
sensor is a good way to check accuracy of a sensor.
Correct readings will be within 0.4 volt 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.
41
DTC 34 - Manifold Absolute Pressure (MAP) Sensor Circuit 2200 YRM 611

Figure 35. DTC 34 - Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage Low - High Vacuum)

42
2200 YRM 611 DTC 42 - Electronic Spark Timing (EST)

DTC 42 - Electronic Spark Timing (EST)

CIRCUIT DESCRIPTION
A DTC 42 is indicated if there is an open circuit or a
short circuit in the electronic spark timing signal (EST)
or the bypass circuit.
When the system is running on the ignition module,
there is no voltage on the bypass wire because the ig-
nition module sends the EST to ground. If the ECM
senses a voltage on the EST wire, a Code 42 will be
set and the electronic control system will not go into the
EST mode of operation.
will no longer be grounded in the ignition module and
the 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.
See Figure 36.

When the engine is being started and approximately

400 rpm is sensed, bypass voltage is applied. The EST

Figure 36. DTC 42 - Circuit Description

43
DTC 42 - Electronic Spark Timing (EST) 2200 YRM 611

TEST DESCRIPTION 5000 ohms. The important part of this test is to

check if the module makes the switch.
The numbers below are a reference to the bold numbers
in Figure 37. 4. If the module did not make the switch in Step 3, this
step makes the following checks:
1. A Code 42 is indicated if there is an open circuit or a
short circuit in the EST signal or the bypass circuit. a. Circuit GW has a short circuit to ground.
This test checks that the Code 42 is a real fault.
b. Bypass circuit GZ is open.
2. This test checks that the ground path through the
ignition module is correct. A short circuit in circuit c. Ignition module has a fault or a bad connection.
GW to ground will also indicate less than 500 ohms.
5. This test checks that the Code 42 is from a fault in
A test for this fault will be checked later.
the ECM and not a fault in circuit GW or circuit GZ.
3. When the test light voltage touches circuit GZ, the
module will correctly cause the ohmmeter to "over- OTHER TROUBLESHOOTING CHECKS
range" if the ohmmeter is in the 1000 to 2000 ohms
The SCAN Tool cannot check for a Code 42 fault.
position.
If the Code 42 is not constant or not regular, see Trou-
When the selector switch on the ohmmeter is
bleshooting, Poor Operation. Also see A-8 Ignition Sys-
changed to the 10,000 to 20,000 ohms position,
tem Troubleshooting.
the ohmmeter will correctly indicate more than

44
2200 YRM 611 DTC 42 - Electronic Spark Timing (EST)

Figure 37. DTC 42 - Electronic Spark Timing

45
Troubleshooting, Poor Operation
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. See
Figure 38 and Table 5. The internal program calibration
causes a DTC 51.
Figure 38. DTC 51 - Circuit Description
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
section is used. Make sure the problem is correctly
described. Check the indicated items in this Trou-
bleshooting section under the described problem. If
the starter will crank the engine but the engine will not
start, see A-3 - Starter Rotates the 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:
46
2200 YRM 611
Table 5. ECM Failure
CHECK THAT ALL CONNECTIONS AT THE
ECM ARE CORRECT. CLEAR THE MEMORY
AND CHECK AGAIN FOR DTC 51. IF DTC 51
APPEARS AGAIN, REPLACE THE ECM.
OTHER TROUBLESHOOTING CHECKS
Check for the following:
• The SCAN Tool cannot help find a DTC 51 problem.
• If DTC 51 is not constant, see Troubleshooting, Poor
Operation.
• ground connections for the ECM are clean and tight.
• vacuum hoses for correct connections, 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. The
fault must be present to locate the problem. If a fault
is not constant, use of DTC charts can cause the
replacement of good parts.
Definition:
A problem that does not cause the Malfunction Indicator
lamp to illuminate, and a code is not kept in the ECM.
2200 YRM 611
Check:
Check the following:
• Wires and connectors for damage and bad connec-
tions.
• Operation of the lift truck with a SCAN Tool con-
nected. The SCAN Tool will normally indicate a
trouble code.
• Electrical noise cause by a relay, solenoid or switch.
This problem will occur when the faulty component is
operated.
• Installation of lights, radios, or other electrical equip-
ment by the operator that causes the problem.
• Sensor wires are too close to the 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 (di-
agnostic "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 the
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 Engine Coolant
Temperature (ECT) Sensor Test, Throttle Position (TP)
Sensor Check, Minimum Idle Speed Adjustment, C-1 -
Idle Air Control (IAC) System Check, C-2 - Manifold Ab-
solute Pressure (MAP) Sensor Output Test, PCV Sys-
tem Check, and Governor System Check.
FAULT: ENGINE IS DIFFICULT TO START
Definition:
The starter cranks the engine correctly, but the engine
is difficult to start, or the engine stops immediately after
it starts.
Check:
Make a careful visual check as described in the earlier
paragraphs. Make sure the operator is using the correct
starting procedure.
Troubleshooting, Poor Operation
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 F 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 the charts in DTC
14/15.
• MAP sensor.
• Throttle Position (TP) sensor for binding or a high
TP voltage with the throttle closed (will read between
0.33 and 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-7 - Fuel System Troubleshoot-
ing.
• Dirty fuel.
• Injector driver circuit. Disconnect injector harness
connector at the injector. Connect 12-volt test light
between the harness terminals of the injector connec-
tor and check the light while cranking. If test light fails
to blink at connector, it is a bad injector circuit har-
ness, connector, 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 the fuel pump will allow the fuel
in the lines to drain back to the tank after engine is
stopped. To check for this condition, perform A-7 -
Fuel System Troubleshooting.
IGNITION SYSTEM
• Correct ignition voltage output with spark tester.
• Spark plugs: dirty, cracks, wear, wrong gap, 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
Engine Coolant Temperature (ECT) Sensor Test,
Throttle Position (TP) Sensor Check, Minimum Idle
Speed Adjustment, C-1 - Idle Air Control (IAC) Sys-
tem Check, C-2 - Manifold Absolute Pressure (MAP)
Sensor Output Test, PCV System Check, and Gov-
ernor System Check.
• Circuit GW (Electronic Spark Timing) for short to
ground.
• Idle Air Control (IAC) operation.
47
Troubleshooting, Poor Operation 2200 YRM 611

FAULT: VARIATION IN ENGINE POWER Check:

WHEN THE THROTTLE IS HELD STEADY
Make a careful visual checks as described in the earlier
Definition: paragraphs.
• Remove air filter and check for dirt or other restric-
Engine power variation under steady throttle, feels like tions. Replace as necessary.
the vehicle speeds up and slows down with no change • ECM grounds for being clean, tight and in their correct
in the accelerator pedal. locations. See ECM wiring diagrams at the end of this
section.
Check: • Alternator output voltage. Repair if less than 9 or
more than 16 volts.
Make a careful visual check as described in the earlier • Exhaust system for restriction or damage.
paragraphs.
• ECM grounds for being clean, tight, and in their ENGINE
proper location. • Engine valve timing and compression.
• Vacuum lines for restrictions or leaks. • Engine for correct or worn camshaft.
• Alternator output voltage. Repair if less than 9 or
more than 16 volts. IGNITION SYSTEM
• Governor cables. • For correct operation of Electronic Spark Timing
(EST).
SENSORS • Secondary voltage.
• Manifold Absolute Pressure (MAP) Sensor. The MAP
Sensor must change quickly at different throttle po- FUEL SYSTEM
sitions. Check the MAP Sensor vacuum line for re- • Restriction in fuel filter.
strictions. The ECM will respond to any MAP signal • Dirty fuel.
and can change the amount of fuel sent to the engine, • Fuel pressure. Use A-7 - Fuel System Troubleshoot-
causing operating problems. Also use the SYSTEM ing.
TEST CHARTS to test the MAP sensor. • Low fuel pressure after a cold start or during accel-
eration. If fuel pressure drops below 62 kPa (9 psi),
IGNITION SYSTEM there can be a bad fuel pump or a restriction in the
• For correct ignition voltage output using spark tester. fuel system.
• Spark plugs. Remove spark plugs, check for wet
plugs, cracks, wear, wrong gap, burned, or dirty elec- GOVERNOR SYSTEM
trodes or insulators. Repair or replace as necessary. • Throttle adjustment.
Also, check spark plug cables. • Governor motor.

FUEL SYSTEM FAULT: DETONATION

To check if the condition is caused by a rich or lean sys-
tem, test the vehicle under the same conditions in which
the symptom occurs as described by the customer.
• Fuel pressure while condition exists. Use A-7 - Fuel
System Troubleshooting.
• In-line fuel filter. Replace if dirty.
• Fuel injector.
Definition:
The engine makes sharp, metallic knocking sounds that
change when the throttle position is changed. This
condition is normally worse during acceleration. The
air-and-fuel mixture is exploding in the cylinder instead
of burning evenly.

FAULT: DECREASED ENGINE POWER Check:

Definition: Make a careful visual check as described in the earlier

Engine delivers less than expected power. Little or no
increase in speed when accelerator pedal is pushed
down partway.
paragraphs.
If SCAN Tool readings are normal (see Figure 4) and
there are no engine mechanical faults, fill fuel tank with
a known good grade of gasoline that has a minimum oc-
tane rating of 87 to 89 and check vehicle performance.

48
2200 YRM 611
IGNITION SYSTEM
• Spark plugs for correct heat range.
• Ignition wires and cables for shorts or damaged insu-
lation.
ENGINE
• For oil in the combustion chamber. Valve oil seals for
leaking.
• Combustion chambers for excessive carbon buildup.
Remove carbon with top engine cleaner using the in-
structions on can.
• Combustion chamber pressure by doing a compres-
sion test.
• Basic engine parts, such as cam, head, pistons, are
not correct.
COOLING SYSTEM
• Problems from engine running too hot: - Low engine
coolant level. - Loose water pump belt. - Restriction in
airflow to radiator, or restriction in water 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 the same conditions in which
the symptom occurs as described by the customer.
• Fuel pressure while condition exists. Use A-7 - Fuel
System Troubleshooting.
FAULT: ENGINE MOMENTARILY DOES
NOT INCREASE POWER WHEN THROTTLE
CHANGES
Definition:
The engine momentarily does not increase power when
the throttle is opened further. The engine can stop when
the throttle is opened rapidly from idle.
Check:
Make a careful visual check as described in the earlier
paragraphs.
• 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.
Troubleshooting, Poor Operation
IGNITION SYSTEM
• Dirty spark plugs or damaged secondary cables.
• Ignition system connection, circuit HX.
FUEL SYSTEM
• Fuel pressure. Use A-7 - 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 a restriction in the
fuel system.
GOVERNOR SYSTEM
• Throttle cables.
• Governor motor.
FAULT: ONE OR MORE CYLINDERS DO
NOT OPERATE CORRECTLY. THE ENGINE
DOES NOT IDLE CORRECTLY.
Definition:
The operation of one cylinder is not regular, and the
problem increases when the engine load increases.
Problem normally does not occur above 1500 rpm.
The engine has a rough idle or has a large variation in
idle speed.
Check:
Make a careful visual check as described in the earlier
paragraphs.
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 the cylinder(s) using an oscil-
loscope 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 cylin-
ders 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).
49
Troubleshooting, Poor Operation 2200 YRM 611

ADDITIONAL CHECKS ENGINE

• Do a cylinder compression check. See the engine
Electromagnetic Interference (EMI). An engine that Service Manual.
misses can be caused by EMI on the reference circuit. • For correct camshaft or weak valve springs.
EMI can be found by monitoring engine rpm with a
SCAN Tool. A sudden increase in rpm with little change OTHER CHECKS
in actual engine rpm change, indicates EMI is present. • MAP sensor output.
If the problem exists, check routing of secondary wires, • Throttle linkage for smooth operation.
check the ground circuit. • IAC operation.
• PCV valve for correct operation.
Intake and exhaust manifold passage for restrictions.
FAULT: FUEL USAGE TOO HIGH
ENGINE
• Do a cylinder compression check. If compression is Definition:
low, repair as necessary.
• Remove rocker cover. Check for bent push rods, worn Fuel use is higher than expected or has increased dur-
rocker arms, broken valve springs, worn camshaft ing later operation.
lobes, and valve timing. Repair as necessary.
Check:
FUEL SYSTEM
• Dirty fuel filter, low fuel pressure. Use A-7 - Fuel Make a careful visual check as described in the earlier
System Troubleshooting. paragraphs.
• Dirty fuel. • Vacuum hoses for damage, restriction, or correct con-
nections.
FAULT: ROUGH IDLE OR ENGINE STALLS • Check operator’s methods of operation. Are tires at
DURING IDLE the correct pressure? Are loads more than capacity?
• Check air filter for dirt or other restriction.
Definition: • Check for fuel leaks.

Engine has a rough idle speed or has a large variation IGNITION SYSTEM
in idle speed. The engine stops running during idle. • Spark plugs. Remove spark plugs, check for wet or
dirty plugs, cracks, wear, wrong gap, damaged elec-
Checks: trodes or insulators. Repair or replace as necessary.
Also, check spark plug wires.
Make a careful visual check as described in the earlier
paragraphs. COOLING SYSTEM
• For vacuum leaks. • Engine coolant level.
• ECM ground connections for being clean. See ECM • Engine thermostat for a fault (always open) or for
wiring diagrams. wrong heat range. See Engine Service Manual.
• For broken engine mounts.
• Alternator output voltage. Repair if less than 9 or ENGINE
more than 16 volts. • Compression. See Engine Service Manual.

IGNITION SYSTEM OTHER CHECKS

• For correct ignition voltage output using spark tester • For exhaust system restriction.
(ST-125) or equivalent. • Air intake system and crankcase for air leaks.
• Spark plugs. Remove spark plugs, check for wet or
dirty plugs, cracks, wear, wrong gap, damaged elec- FAULT: DIESELING
trodes or insulators. Repair or replace as necessary.
Also, check spark plug wires. Definition:
• Spark plug wires by connecting ohmmeter to ends of
Engine continues to run after ignition switch is turned
each cable in question. If meter reads over 30,000
OFF but runs very roughly. If engine runs smoothly,
ohms, replace cable(s).
check ignition switch.

50
2200 YRM 611 Engine Coolant Temperature (ECT) Sensor Test

Checks: IGNITION SYSTEM

• Correct output from ignition coil with spark tester.
Make a careful visual check as described in the earlier • Spark plugs. Remove spark plugs, check for wet or
paragraphs. dirty plugs, cracks, wear, wrong gap, damaged elec-
• Fuel injector and TBI for fuel leaks. Use A-7 - Fuel trodes or insulators. Repair or replace as necessary.
System Troubleshooting. Also, check spark plug wires.
• Spark plug wires for damage and correct installation.
FAULT: BACKFIRE Inspect Ignition Coil assembly.
• Do fuel system tests. Use A-7 - Fuel System Trou-
Definition: bleshooting.
Fuel explodes in intake manifold, or in exhaust system, ENGINE
making loud noise. • Compression - Look for valves that stick or leak.
• Valve timing. See Engine Service Manual.
Check: • Intake and exhaust manifold passages for restric-
Make a careful visual check as described in the earlier tions.
paragraphs.

Engine Coolant Temperature (ECT) Sensor Test

NOTE: For location of components, complete engine Table 6. ECT Sensor - Temperature vs.
electronic wiring diagrams, and ECM wiring harness Resistance (Continued)
connector terminal end views, see illustrations at the
end of this section. Ohms
C F
The ECT, using the following procedure, can be tested 60 140 667
at different temperatures. A volt/ohmmeter, a ther-
mometer, engine coolant, and something to heat the 50 122 973
coolant will be needed for the test. 45 113 1188

1. Heat the coolant to one of the temperatures shown 40 104 1459

on the chart. 35 95 1802
2. Position the ECT sensor sensing end into the 30 86 2238
heated coolant.
25 77 2796
3. Wait about 60 seconds to allow the coolant to heat 20 68 3520
the sensor.
15 59 4450
4. Test the sensor resistance and compare the read- 10 50 5670
ing to those in Table 6.
5 41 7280
5. Sensors with a reading within 10 percent of the
0 32 9420
specifications can be used.
5 23 12,300
Table 6. ECT Sensor - Temperature vs. Resistance
10 14 16,180
C F Ohms 15 5 21,450
100 212 177 20 4 28,680
90 194 214 30 22 52,700
80 176 332 40 40 100,700
70 158 467

51
Throttle Position (TP) Sensor Check 2200 YRM 611

Throttle Position (TP) Sensor Check

NOTE: For location of components, complete engine
electronic wiring diagrams, and ECM wiring harness
connector terminal end views, see illustrations at the
end of this section.

Using a SCAN Tool, watch the TP Sensor percentage

and voltage. The reading will increase evenly as the
throttle plate is opened. See Figure 39. There must be
no reading that is lower than the previous reading as the
throttle plate is moved more open. A reading that went
lower or higher, then lower as the plate is opened, in-
dicates a damaged sensor that must be replaced. See
Figure 40.

Figure 40. Damaged TP Sensor Reading

Figure 39. Good TP Sensor Reading

52
2200 YRM 611 Minimum Idle Speed Adjustment

Minimum Idle Speed Adjustment

ADJUST 10. Turn ignition switch OFF.

NOTE: Minimum idle speed (Minimum Air Setting) set 11. Connect IAC valve electrical connector.
only when installing a replacement throttle body.
12. Reset IAC valve pintle position:
NOTE: The idle stop screw is used to hold the minimum
idle speed of the engine. On original equipment throttle a. Start and run engine over 2000 rpm.
bodies, it is adjusted at the factory, then covered with a
b. Select Field Service Mode.
plug.
c. Run engine at 2000 rpm for approximately 10
NOTE: The minimum idle speed adjustment is impor-
seconds.
tant for correct system operation. A minimum idle speed
that is too high can cause the IAC valve pintle to con- d. Exit Field Service Mode.
stantly touch the bottom of its seat and cause valve fail-
ure. If the minimum idle speed is too low, the vehicle e. Allow engine to return to idle.
can be hard to start in cold weather or can cause a stall
during idle. f. Turn ignition switch OFF.

1. Put a block on both sides of drive tires and apply g. Wait 10 seconds, start engine, let idle.
the parking brake. See Figure 41.
h. Check for correct idle. (IAC at 5-40 Counts.)
2. Put the transmission in NEUTRAL Start and run the
i. Disconnect SCAN Tool.
engine until it reaches normal operating tempera-
ture. j. Remove blocks from drive tires.
3. Turn ignition key OFF.

4. Connect a SCAN Tool to the DLC.

5. Turn ignition key to the ON position.

6. Select Field Service Mode on the SCAN Tool. This

will cause the IAC valve pintle to extend, closing the
air passage in the throttle body. Wait 45 seconds,
disconnect the IAC valve connector, then exit the
Field Service Mode.

7. Start and run the engine. It can be necessary to

hold the throttle open slightly to run the engine.

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

engine speed.

IMPORTANT
• Engine must be at normal operating temperature. 1. PLUG
• All accessories must be off. 2. IDLE STOP SCREW
• Make sure throttle and governor cables do not hold
the throttle open. Figure 41. Idle Speed Adjustment
• Correct idle speed is 800 ±25 rpm (for engines that
have more than 10 hours operating time).

9. Remove plug as shown in Figure 41. Adjust mini-

mum idle speed if necessary.

53
C-1 - Idle Air Control (IAC) System Check
C-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, the IAC valve
Figure 42. C-1 - Circuit Description
OTHER TROUBLESHOOTING CHECKS
Check for the following:
• 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 (see Figure 43):
• Vacuum Leak (High Idle) - If idle is too high, stop
the engine. Fully extend (low) IAC with tester. Start
engine. If idle speed is above 800 rpm, fix vacuum
leak, including PCV system. Also, check for smooth
movement of the 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.
54
2200 YRM 611
pintle extends toward its seat, reducing bypass airflow.
A SCAN Tool will read the ECM commands to the IAC
valve in counts. The higher counts indicate more air
bypass (higher idle). The lower counts indicate less air
is allowed to bypass (lower idle). See Figure 42.
• System Too Lean (High Air/Fuel Ratio) - The idle
speed can be too high or too low. Engine speed can
vary up and down and disconnecting the IAC valve
does not help. Check for low fuel pressure, water in
the fuel, or a dirty injector.
• System Too Rich (Low Air/Fuel Ratio) - The 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 611 C-1 - Idle Air Control (IAC) System Check

Figure 43. C-1 - Idle Air Control (IAC) System Check

55
C-2 - Manifold Absolute Pressure (MAP) Sensor Output Test
C-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. The MAP sensor converts 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 the sensor output voltage, the
Figure 44. C-2 - Circuit Description
TEST DESCRIPTION:
The numbers below are a reference to the bold numbers
in Figure 45.
1. When comparing SCAN readings to a known good
vehicle, it is important to compare vehicles that use
a MAP sensor having the same color insert and the
same number. See Figure 45.
2. Apply 34 kPa (10 inHg) vacuum to the MAP sensor
to cause a voltage reading of 1.5 to 2.1 volts less
than the voltage in Step 1. When applying vacuum
to the sensor, the change in voltage must be quick.
A slow voltage change indicates a bad sensor.
56
2200 YRM 611
ECM knows the manifold pressure. A lower pressure
(low voltage) output voltage will be about 1 to 2 volts at
idle. While higher pressure (high voltage) output volt-
age will be about 4 to 4.8 volts at Wide Open Throttle
(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. See Figure 44.
3. Check vacuum source to sensor for leaking or re-
striction. Be sure no other vacuum devices are con-
nected to the MAP vacuum source.
NOTE: Make sure electrical connector remains se-
curely fastened.
4. Remove sensor from the intake manifold and twist
sensor (by hand only) to check for intermittent con-
nection. Output changes greater than 0.10 volt in-
dicate a bad sensor or connection. If good, replace
sensor.
2200 YRM 611 C-2 - Manifold Absolute Pressure (MAP) Sensor Output Test

Figure 45. C-2 - Manifold Absolute Pressure (MAP) Sensor Output Test

57
Governor System Check 2200 YRM 611

PCV System Check

With this system, fumes are sent into the air filter and
CAUTION into the engine intake manifold.
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 the PCV valve or hose can cause (see

Figure 46):
• 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.

If the engine has a rough idle, check for a restriction in 1. CHECK VALVE NEEDLE
the PCV valve or hose. Replace parts as described in
PCV System Repair. Figure 46. PCV Valve

Governor System Check

GOVERNOR SYSTEM NOT OPERATING • Engine power variation (surge)
CORRECTLY • Engine backfire
• Low engine power
A governor system that does not operate correctly can • No acceleration (low engine rpm)
cause any of the following (see Figure 47):
• Engine rpm more than limit of governor

Figure 47. Governor System Circuit Description

58
2200 YRM 611
GOVERNOR SYSTEM FUNCTION, CHECK
Normal testing for governor will include the following:
1. Start engine, keep transmission in NEUTRAL.
2. Accelerate the engine to maximum throttle.
3. Observe the engine speed.
4. Did the engine accelerate smoothly, and to the nor-
mal limit?
Fuel System Components Repair
GENERAL
NOTE: The following is general information to be used
when working on the fuel system.
Do the following when working on the fuel system:
• Always use new O-rings on the fuel line fittings.
• All steel tubing on the 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 of the parts of the TBI can be cleaned in a
cleaner such as Yale Carburetor Cleaner or its equiv-
alent. DO NOT clean the following parts: Throttle Po-
sition Sensor (TPS), IAC valve, fuel injectors, cover
for fuel meter body, ball bearings, and the governor
assembly.
CAUTION
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 the towel in
an approved container when disconnect is completed.
FUEL PRESSURE RELIEF PROCEDURE
1. Disconnect negative battery terminal to avoid fuel
leakage if an accidental attempt is made to start the
engine.
Fuel System Components Repair
If the system appears to function incorrectly, compare
rpm readings from a SCAN Tool with readings from a
secondary tachometer attached to a spark plug wire.
They must be very close or the same.
If they are different, check for EMI, items like spark plug
wires too close to the distributor primary wires, or charg-
ing system wires.
If the readings are close or the same, see DTC 31 -
Engine Governor Circuit for more testing. (It is possible
that the system will not set DTC 31. In this case, the
DTC 31 - Engine Governor Circuit can be used.)
2. Loosen fuel filler cap to relieve tank vapor pressure.
3. The internal relief in the TBI unit relieves fuel pump
pressure when the engine is OFF. Therefore, no
additional pressure relief procedure is required.
FUEL PUMP, REPLACE
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 the negative cable at the battery. See
Figure 48.
2. Loosen the fuel filler cap to release pressure in the
fuel tank.
3. Disconnect the fuel lines at the access plate on the
fuel tank. Disconnect the wiring harness from the
TBI.
4. Remove the capscrews that hold the access plate
to the fuel tank. Remove the access plate, fuel
pump, and sending unit, if attached.
5. Inspect the fittings and fuel lines that are inside the
fuel tank for damage. Inspect the screen for dam-
age.
6. Install the fuel pump and fittings on the access
plate. Install the float assembly.
7. Use a new seal ring and install the access plate
on the tank. Tighten the capscrews for the access
plate.
59
Fuel System Components Repair 2200 YRM 611

8. Connect the fuel lines to the fittings. Connect the Legend for Figure 48
wire connectors.
1. WIRING HARNESS 10. SENDING UNIT
2. COVER (NOT ON ALL
3. SHUT-OFF VALVE UNITS)
4. OUTLET FUEL 11. RETURN FUEL
LINE LINE AND FUEL
5. ACCESS PLATE PUMP SUPPORT
6. SEAL RING 12. CLAMP (2)
7. CAPSCREW 13. FLEXIBLE
8. WASHER COUPLING
9. O-RING 14. FUEL PUMP AND
MOTOR
15. SCREEN

TBI UNIT
Remove
NOTE: The TBI is made of many separate components.
See Figure 49. The TBI can be replaced as a complete
unit, or the parts of the TBI can be replaced while the
TBI is installed on the engine. See the Parts Manual for
repair kits for the components of the TBI. To make sure
the replacement part has the correct part number, see
Figure 50. Replacement of the individual components
is described after the following procedures.

1. Disconnect the negative cable at the battery.

2. Loosen the fuel filler cap to release pressure in the

fuel tank.

3. Disconnect and remove the parts that connect the

TBI to the air filter.

4. Disconnect the wires to the IAC valve, TPS, gover-

nor motor, and the fuel injector. Remove the wiring
harness grommet for the fuel injector.

5. Disconnect the throttle cable at the throttle crank.

6. Disconnect the vacuum hose from the MAP sensor.

7. Disconnect the fuel pressure and fuel return lines

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

8. Remove the fasteners that hold the TBI to the man-

ifold. Remove the TBI. Cover the opening in the
Figure 48. Fuel Pump Arrangement manifold to prevent dirt from entering the engine.

60
2200 YRM 611 Fuel System Components Repair

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 49. Throttle Body Injection (TBI) Unit

Clean and Inspect
See the cleaning instructions in the NOTE under Gen-
eral at the beginning of this procedure. Clean the gas-
ket from the manifold and the TBI. Be careful to pre-
vent damage to the machined surfaces. Check the ma-
chined surfaces for damage. Check the manifold for
loose parts.
Install
1. Use a new gasket and install the TBI on the man-
ifold. Tighten the fasteners for the TBI to 25 N•m
(18 lbf ft).
2. Install the fuel line fitting and gasket on the sup-
ply port. Tighten the fuel line fitting to 41 N•m
(30 lbf ft). Use new O-rings and washers on the
fuel lines. Connect the fuel pressure and fuel return
lines. Tighten the fuel line nuts to 27 N•m (20 lbf ft).
3. Connect the vacuum hose for the MAP sensor.
4. Connect the throttle cable at the throttle cam.
Check the adjustment of the throttle cables as de-
scribed in the procedures for the Governor System
Repair.

61
Fuel System Components Repair 2200 YRM 611

5. Install the wiring harness grommet for the fuel injec- FUEL METER BODY
tor. Connect the wires to the IAC valve, TPS, and
the fuel injector. Remove
6. Connect the negative cable at the battery. 1. Disconnect the negative cable at the battery.

7. Turn the key switch to ON (do not start the engine) 2. Loosen the fuel filler cap to release pressure in the
and check for fuel leaks. fuel tank.

8. Use a new gasket and connect the air filter to the 3. Disconnect and remove the parts that connect the
TBI. air filter to the TBI. See Figure 49.

4. Disconnect the electrical connector at the fuel injec-

tor. Remove the grommet and wires from the body.

5. Disconnect the fuel lines at the fuel meter body.

Hold the fittings in the fuel meter body to keep them
from turning when the fuel lines are disconnected.

6. Remove the fuel line fitting from the inlet port in the
fuel meter body.

7. Remove the screws that hold the fuel meter body to

the throttle body. Remove the fasteners that hold
the TBI to the manifold. Remove the fuel meter
body and gasket.

8. Clean the gasket surfaces on the fuel meter body

and throttle body.

Install

1. DAY OF YEAR 4. SHIFT 1. Use a new gasket and install the fuel meter body
2. YEAR IDENTIFICATION on the throttle body.
3. ASSEMBLY PLANT 5. SOURCE CODE
CODE 2. Use a thread-locking adhesive (Loctite 262) on the
screws for the fuel meter body. Install the screws
Figure 50. TBI Identification and tighten them to 3.5 N•m (31 lbf in). Tighten
the fasteners for the TBI to 25 N•m (18 lbf ft). See
9. Set the position of the pintle valve of the IAC as
Figure 49.
follows:
3. Use a new gasket and install the fuel line fitting in
a. Depress the throttle pedal a small amount.
the inlet port. Tighten the fitting to 41 N•m (30 lbf ft).
b. Start and run the engine for 3 seconds.
4. Use new O-rings and washers on the fuel lines.
c. Turn the key switch to OFF for 10 seconds. Connect the fuel pressure and fuel return lines.
Tighten fuel line fittings to 27 N•m (20 lbf ft).
d. Start the engine and check for correct idle op-
eration. 5. Install the wiring harness grommet for the fuel in-
jectors. Connect the wires at the fuel injector.

62
2200 YRM 611 Fuel System Components Repair

6. Connect the negative cable at the battery. Turn the

key switch to ON (do not start the engine) and check
for fuel leaks.

7. Use a new gasket and connect the air filter to the

TBI.

FUEL INJECTOR
Remove
NOTE: The fuel injector must be replaced as a complete 1. FUEL INJECTOR 3. FULCRUM
unit. To make sure the replacement part has the correct 2. SCREWDRIVER 4. FUEL METER
BODY
part number, see Figure 51.
Figure 52. Fuel Injector Removal
1. Disconnect the negative cable at the battery.

2. Loosen the fuel filler cap to release pressure in the Install

fuel tank.
1. Lubricate the new O-rings with engine oil. See Fig-
ure 53. Install the lower (small) O-ring so that it is
against the fuel filter. Install the upper (large) O-ring
on the fuel injector.

1. FUEL INJECTOR (TOP VIEW)

2. PART NUMBER
3. MONTH, 1-9 (JAN.-SEPT.) O, N, D (OCT., NOV.,
DEC.)
4. DAY
5. YEAR
6. BUILD DATE CODE
7. • = INDICATES HIGH DYNAMIC RANGE

Figure 51. Fuel Injector Identification

3. Disconnect and remove the parts that connect the

air filter to the TBI.
1. FUEL INJECTOR 4. FUEL METER
4. Disconnect the electrical connector at the fuel in- 2. SCREW BODY
jector. 3. RETAINER 5. LOWER O-RING
6. UPPER O-RING
5. Remove the screw and retainer for the fuel injector.
Figure 53. Fuel Injector Installation
6. To remove the fuel injector, use a screwdriver as
shown in Figure 52. Remove and discard the
O-rings on the fuel injector.

63
Fuel System Components Repair 2200 YRM 611

2. Install the fuel injector into the bore of the fuel meter
body. Push the fuel injector until it is against its seat.
Turn the fuel injector so that the electrical connector
is toward the notch.
3. Use a thread-locking adhesive on the screw for the
retainer. Install the retainer and the screw. Tighten
the screws to 3.0 N•m (27 lbf in).
4. Connect the negative cable at the battery. Turn the
key switch to ON (do not start the engine) and check
for fuel leaks.
5. Use a new gasket and connect the air filter to the
TBI.
PRESSURE REGULATOR
Inspect
Inspect the valve seat in the fuel meter body for dam-
age. Replace the fuel meter body if there is any dam-
age.
Install
1. Install a new diaphragm. See Figure 54. Make sure
the diaphragm fits in the groove of the fuel meter
body.
2. Install the seat for the spring and the spring in the
cover, then install the cover. Use a thread-locking
adhesive (Loctite 262) on the screws for the cover.
Install the screws and tighten them to 2.4 N•m
(21 lbf in).

Remove 3. Connect the negative cable at the battery. Turn the

key switch to ON (do not start the engine) and check
1. Disconnect the negative cable at the battery. for fuel leaks.

2. Loosen the fuel filler cap to release pressure in the 4. Use a new gasket and connect the air filter to the
fuel tank. TBI.

3. Disconnect and remove the parts that connect the
air filter to the TBI.
4. Hold the pressure regulator to compress the spring.
See Figure 54. Remove the screws that hold the
pressure regulator to the fuel meter body. Remove
the pressure regulator assembly. Remove the di-
aphragm.
THROTTLE POSITION SENSOR (TPS)
Remove
1. Disconnect and remove the parts that connect the
TBI to the air filter. See Figure 55.
2. Disconnect the electrical connector from the TPS.

3. Remove the screws for the TPS and remove the

TPS.

Install
1. With the throttle valve closed, install the TPS on the
throttle shaft. See Figure 55. Rotate the TPS to
align the screw holes. Use a thread-locking adhe-
sive (Loctite 262) on the screws. Install the screws
and tighten them to 2.0 N•m (18 lbf in).

2. Connect the electrical connector to the TPS. Use a

new gasket and connect the air filter to the TBI.
1. COVER 4. SPRING
2. SCREW 5. DIAPHRAGM
3. SPRING SEAT 6. FUEL METER
BODY

Figure 54. Pressure Regulator

64
2200 YRM 611 Fuel System Components Repair

2. Disconnect the electrical connector from the IAC

valve.

3. Remove the screws for the IAC valve and remove

the valve.

Clean and Inspect

See the cleaning instructions in the NOTE under Gen-
eral at the beginning of this procedure. Use a carburetor
cleaner to clean the carbon from the valve seat for the
pintle, the air passage, and the surface for the O-ring.
Inspect the O-ring for damage.

NOTE: If the IAC valve must be replaced, make sure

the replacement part has the correct part number. The
shape and diameter of the pintle is made for this appli-
1. THROTTLE BODY ASSEMBLY
2. THROTTLE POSITION SENSOR cation.
3. SCREW
4. THROTTLE SHAFT Install
Figure 55. Throttle Position Sensor (TPS) NOTE: When installing a new IAC valve, measure the
distance between the tip of the pintle and the flange,
IDLE AIR CONTROL (IAC) VALVE dimension A in Figure 56. If the distance is more than
28 mm (1.1 in.), use your finger to slowly retract the pin-
Remove tle. This procedure will not damage a NEW IAC valve.
DO NOT do this procedure if the IAC valve has been in
CAUTION service.
If the IAC valve has been in service, DO NOT push 1. Lubricate the O-ring for the IAC valve with engine
or pull on the pintle. Moving the pintle can damage oil and install it on the valve.
the internal parts of the IAC valve.
2. Install the IAC valve on the throttle body. Tighten
1. Disconnect and remove the parts that connect the the screws to 3.0 N•m (27 lbf in).
TBI to the air filter. See Figure 56.
3. Connect the electrical connector to the IAC valve.

4. Use a new gasket and connect the air filter to the

TBI.

5. Do the following procedure to reset the position of

the pintle:

a. Depress the throttle pedal a small amount.

b. Start and run the engine for 5 seconds.

1. SCREW 3. O-RING c. Turn the key switch to OFF for 10 seconds.

2. IAC VALVE BODY 4. PINTLE
d. Start the engine and check for correct idle op-
Figure 56. Idle Air Control Valve eration.

65
Fuel System Components Repair
THROTTLE BODY
Remove and Disassemble
1. Disconnect the negative cable at the battery.
2. Loosen the fuel filler cap to release pressure in the
fuel tank. See Figure 49.
3. Remove the throttle body as described in TBI Unit,
Remove.
4. Remove the fuel meter body.
5. Remove the other components from the throttle
body as described in the Removal procedures for
those parts.
Inspect
Inspect the surfaces of the throttle body for damage.
Check that all air passages are clean.
Assemble and Install
1. Assemble the components on the throttle body as
described in the Assembly procedures for those
parts. See Figure 49.
2. Use a new gasket and install the fuel meter body
on the throttle body.
3. Use a thread-locking adhesive (Loctite 262) on the
threads for the fuel body. Install the screws and
tighten them to 3.5 N•m (31 lbf in).
4. Use a new gasket and install the TBI on the man-
ifold. Tighten the fasteners for the TBI to 22 N•m
(16 lbf ft).
5. Use new O-rings and washers on the fuel lines.
Connect the fuel pressure and fuel return lines.
Hold the fittings in the TBI to keep them from turn-
ing. Tighten the fuel line nuts to 27 N•m (20 lbf ft).
6. Connect the vacuum hose for the MAP sensor.
66
2200 YRM 611
7. Connect the electrical connectors at the fuel injec-
tor, throttle position sensor, and the idle air control
valve.
8. Connect the throttle cable at the throttle cam.
Check the adjustment of the throttle cables as de-
scribed in the procedures for the Governor System
Repair.
9. Connect the negative cable at the battery. Turn the
key switch to ON (do not start the engine) and check
for fuel leaks.
10. Use a new gasket and connect the air filter to the
TBI.
11. Set the position of the pintle valve of the IAC as
follows:
a. Depress the throttle pedal a small amount.
b. Start and run the engine for 3 seconds.
c. Turn the key switch to OFF for 10 seconds.
d. Start the engine and check for correct idle op-
eration.
OIL PRESSURE SWITCH, REPLACE
1. Disconnect the negative battery cable. Disconnect
the connector at the oil pressure switch. See Fig-
ure 57 and Figure 58.
2. Remove the oil pressure switch.
3. Inspect the electrical connectors and terminals for
damage.
4. Install the oil pressure switch in the engine.
5. Connect the connector at the oil pressure switch.
Connect the negative battery cable.
6. Run engine and check for oil leaks.
2200 YRM 611 Fuel System Components Repair

1. THROTTLE BODY INJECTION (TBI) UNIT 6. GOVERNOR MOTOR

2. FUEL INJECTOR FUSE 7. IGNITION COIL
3. IGNITION FUSE 8. DIAGNOSTIC LINK CONNECTOR (DLC)
4. ENGINE COOLANT TEMPERATURE (ECT) 9. FUEL PUMP FUSE
SENSOR 10. ECM FUSE
5. DISTRIBUTOR 11. MAP SENSOR

Figure 57. Electronic Engine Control Components Arrangement (Top View)

67
Governor System Repair
Figure 58. Electronic Engine Control Components
Arrangement (Side View)
Governor System Repair
GOVERNOR MODULE, REPLACE
NOTE: The governor module is installed on the inside
of the cowl, under the plastic panel.
1. Disconnect the negative battery cable.
2. Loosen the panel under instrument panel (pull
panel rearward).
3. Disconnect the electrical connector. Remove the
mounting screws and remove the module.
4. Inspect the electrical connectors and terminals for
damage.
5. Install the governor module with the screws. Con-
nect the connector at the module.
6. Install the panel on the cowl.
7. Connect the negative battery cable.
68
2200 YRM 611
Legend for Figure 58
1. ENGINE COOLANT TEMPERATURE (ECT)
SENSOR
2. DISTRIBUTOR
3. OIL PRESSURE/FUEL PUMP SWITCH
4. IGNITION COIL
5. FUEL PUMP RELAY
GOVERNOR MOTOR, REPLACE
1. Disconnect the negative battery cable.
2. Remove the cover from governor assembly. See
Figure 57.
3. Disconnect throttle cables at the TBI and the throttle
pedal. Disconnect the cables at the governor.
4. Remove the governor assembly from the bracket.
5. Install the governor assembly on the bracket.
6. Install and adjust the throttle cables as described in
Throttle Cables, Install and Adjust.
7. Connect the electrical connector at the governor.
8. Connect the negative battery cable.
2200 YRM 611 Governor System Repair

THROTTLE CABLES, INSTALL AND

ADJUST
1. Connect the throttle cables to the governor actua-
tor as shown in Figure 59. (Only the two pulleys
closest to the governor motor are used.) Install the
lockwashers and flat washers on the cable hous-
ings. Slide each cable housing to the end of the
slot. Each cable will align with a groove in a pul-
ley. The pulley closest to the governor motor is for
the cable that goes to the TBI unit. Install the cable
ends into the pulley, making sure the cables fit in
the grooves. Check for free operation of the cables
on the pulleys. Tighten the nuts on the cable hous-
ings to 18 to 20 N•m (13 to 15 lbf ft).

2. Connect the cable to the pedal as shown in Fig-

ure 60.

1. PEDAL PAD 4. LINK

2. PEDAL FRAME 5. CAPSCREW
3. PEDAL RETURN 6. CRANK
STOP 7. GAS

Figure 60. Foot Directional Control Pedal

3. Push on the throttle pedal and hold it against the

floor plate. Adjust the cable housing at the pedal
bracket until the pulleys in the governor actuator are
rotated fully clockwise against the internal stop. (As
seen from the front of the lift truck.) Adjust the cable
housing only enough so that the cable is not loose.
There also must be no tension in the cable. When
the adjustment is correct, tighten both jam nuts at
the pedal bracket.
1. GOVERNOR MOTOR
2. COVER 4. Connect the cylinder cable anchor on the other ca-
3. CABLE TO TBI UNIT
4. ACTUATOR ASSEMBLY ble to the lever on the TBI unit. Install the cable
5. CABLE TO ACCELERATOR PEDAL housing in the bracket that is fastened to the TBI
adapter. Adjust the cable housing at the bracket to
Figure 59. Throttle Cables get full throttle at the TBI. Tighten the jam nuts at
the bracket when the adjustment is correct.

69
Ignition System Components Repair
5. Install the cover on the governor assembly.
6. Adjust the pedal return stop (see Figure 60) so that
there is no tension on the throttle cable at the idle
position. When the pedal return stop is in the cor-
rect position, tighten the capscrew that holds the
stop to the bracket.
Ignition System Components Repair
ECM, REPLACE
CAUTION
1. Disconnect the negative battery cable.
2. Disconnect the connectors from ECM. See Fig-
ure 57.
3. Remove the capscrews that hold the ECM to the
mount plate on the frame.
CAUTION
To prevent Electrostatic Discharge damage to the
ECM, DO NOT TOUCH the connector pins of the
ECM.
4. Remove the capscrews that hold the ECM to the
mount plate on the frame.
5. Install the ECM in position and install the cap-
screws. Connect the connectors to the ECM.
6. Connect the negative battery cable.
FUNCTION, CHECK
1. Turn ignition key ON.
2. Enter diagnostic mode by connecting the terminals
"A" and "B" together at the DLC.
Let DTC 12 flash four times in a row to check that no
other DTCs are present. This indicates that the ECM
functions correctly.
70
2200 YRM 611
FOOT DIRECTIONAL CONTROL PEDAL,
CHECK
Slowly move the Foot Directional Control pedal pad
from forward to reverse and reverse to forward. See
Figure 60. There must be some movement of the pedal
pad before the pedal frame moves and the throttle
opens.
DISTRIBUTOR
Remove
CAUTION
Carefully lift and release the lock tabs on the con-
nectors to the distributor. The lock tabs can be eas-
ily broken if too much force is applied with a screw-
driver or other tool.
Never permit the TACH CONN. terminal to touch
ground. The ignition module or the ignition coil
can be damaged.
1. Disconnect the battery negative (ground) cable.
2. If removal of the spark plug wires are not required
for the repairs, leave them connected to the distrib-
utor cap. Remove the two capscrews that fasten
the distributor cap to the distributor. Move the dis-
tributor cap away from the work area.
3. Disconnect the distributor four-terminal connector.
4. Disconnect the ignition coil connector.
5. Remove the bolt and clamp that hold the distribu-
tor in the engine. Make a note of the positions of
the rotor to distributor housing and the distributor to
the engine. Slowly pull the distributor from the en-
gine until the rotor just stops turning counterclock-
wise and make a note of the position of the rotor.
This position must be used when the distributor is
installed again.
2200 YRM 611 Ignition System Components Repair

Disassemble 6. Disconnect the sensing coil from the ignition mod-

ule.
1. Remove the rotor. See Figure 61. Make a match-
mark on the gear and the shaft so they can be as-
sembled in the same position. CAUTION
Carefully lift and release the lock tab on the connec-
tor to the sensing coil. The lock tab can be easily
broken if too much force is applied with a screw-
driver or other tool.

7. Use a screwdriver to lift the lock tab. Remove the

sensing coil.

8. Remove the two screws that hold the ignition mod-

ule in the housing. Remove the ignition module.

Inspect
1. Inspect the shaft for a loose fit between the shaft
and its bushing in the housing. If the bushing or the
shaft is worn so that the shaft moves from side to
side in the bushing, replace the shaft or the hous-
ing.

2. Inspect the housing for cracks or damage.

Assemble
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 the package with a new ignition module.

1. Apply silicon grease to the bottom of the ignition

module. See Figure 61. Install the ignition module
into the housing and tighten the two screws.
1. CAP 7. SEAL
2. ROTOR 8. HOUSING 2. Install the sensing coil. The tab on the bottom of the
3. SHAFT/TIMER 9. MODULE
CORE 10. ALIGNMENT PIN sensing coil fits into the anchor hole in the housing.
4. RETAINER 11. POLE PIECE
5. PIN 12. COIL 3. Connect the sensing coil to the ignition module.
6. DRIVE GEAR Make sure the lock tab on the connector is fastened.

Figure 61. Distributor 4. Install the retainer.

2. Use a punch to remove the roll pin (5) from the 5. Install the shaft assembly into the housing.
shaft.
6. Install the seal on the housing. Install the gear on
3. Remove the gear. the end of the shaft.

4. Remove the shaft with the timer core from the hous- 7. Align the marks on the gear and shaft. Install the
ing. roll pin (5). Turn the shaft assembly and make sure
the teeth of the timer core on the shaft assembly do
5. Remove the retainer from the housing. Use a not touch the pole piece.
screwdriver as a pry bar.

71
Ignition Module Repair
8. Install the rotor on the shaft.
Install
1. Put the rotor and distributor in the same position as
they were removed from the engine.
If the engine has been rotated after the distribu-
tor was removed, the following procedure must be
used before the distributor is installed again:
a. Remove the No. 1 spark plug.
b. Put a finger over the No. 1 spark plug hole and
slowly rotate the engine until pressure is felt on
the compression stroke.
c. Align the timing mark on the crankshaft pulley
to 0 (TDC) on the engine timing indicator.
d. Turn the distributor rotor to point between the
positions on the distributor cap for No. 1 and
No. 4 spark plug leads.
e. Install the distributor in the engine. The rotor
and shaft will rotate a few degrees when the
gear on the distributor shaft engages the drive
gear on the engine cam. The timing is correct if
the rotor points at the position on the distributor
cap for the No. 1 spark plug lead.
2. Install the clamp and bolt. Tighten the bolt with your
hand.
3. Install the distributor four-terminal connector.
4. Install the ignition coil connector.
Ignition Module Repair
TEST FOR A FAULT
NOTE: The ignition module can be checked in the dis-
tributor. A test light and three jumper wires are needed
to make the tests. The battery in the vehicle must be
fully charged so that the starter rotates the engine at
the normal speed.
1. Disconnect the four-terminal connector from the
distributor. See Figure 62. Use two jumper wires
between the distributor and the terminal connector
to connect the following circuits:
REFERENCE (Purple/White) Circuit GY
GROUND (Black/Red) Circuit HX
72
2200 YRM 611
5. Install the distributor cap and the two capscrews. If
the spark plug wires were removed, install them in
the correct sequence.
6. Connect the battery negative cable.
7. Start the engine and check the engine timing. See
Ignition Timing.
8. Tighten the bolt for the distributor clamp to 43 N•m
(32 lbf ft).
Ignition Timing
1. Start and run the engine until it is at the normal
operating temperature. Turn the key switch to OFF.
2. Connect the SCAN Tool to the DLC connector.
3. Connect a timing light to the No. 1 spark plug wire.
WARNING
Do not touch moving parts (fan, belt, shafts, pul-
leys).
4. Start the engine and check the initial timing. The
correct setting for the initial timing set point is 8
BTDC.
5. If the timing is not correct, loosen the clamp that
holds the distributor housing. Rotate the housing
right or left to get the correct timing. Tighten the
clamp when the timing is correct.
6. Disconnect the timing light. Disconnect the SCAN
Tool. Put the cover on the DLC.
2. Connect the test light to a 12-volt positive source.
Start the engine. Touch the probe of the test light to
pin B in the four-terminal connector on the distribu-
tor. When 12 volts are applied through the test light
to pin B (BYPASS), the ignition module changes to
EST mode. The EST connection (pin D) is open
and the engine will normally stop. This step checks
the BYPASS operation of the ignition module.
3. Use a jumper to connect pin D (EST) to pin C (REF-
ERENCE) at the distributor. Apply 12 volts through
the test light to pin B (BYPASS) as described in
Step 2. Start the engine. If the engine starts, this
step checks that the EST circuit in the ignition mod-
ule is good.
2200 YRM 611
4. Remove the test light from pin B (BYPASS) while
the engine is running. If the engine stops, this
check shows that the ignition module internally
changes the 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 the engine stops.
Figure 62. Ignition Module Test
IGNITION MODULE, REPLACE
1. Remove the distributor cap and rotor. See Fig-
ure 61.
2. Remove the two screws that hold the ignition mod-
ule in the distributor.
3. Lift the ignition module and disconnect the connec-
tions. Make a note of the connections so that they
can be correctly connected again. Remove the ig-
nition module from the distributor.
NOTE: Do not remove the silicon grease from the igni-
tion module or the distributor if the same ignition mod-
ule will be installed again. If a new ignition module is
Ignition Module Repair
5. If any tests described in Step 2, Step 3, or Step 4
do not work as indicated, check the wiring harness
for a short circuit or an open circuit. If the wiring
harness is good, replace the ignition module.
6. When the tests are complete, connect the system
for normal operation.
installed, a small container of silicon grease is in the
package. Clean the old silicon grease and apply a new
layer of silicon grease to both the ignition module and
the distributor housing. This silicon grease is necessary
for cooling the ignition module.
4. Connect the connectors in the distributor to the ig-
nition module. Make sure the connectors are the
same as when they were removed.
5. Install the ignition module in the distributor.
6. Install the two screws that fasten the ignition mod-
ule in the distributor.
7. Install the distributor cap and rotor.
73
Ignition Module Repair
SENSING COIL
Test
NOTE: Also see A-8 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.
The electrical performance of the ignition module can
only be checked with an Electronic Ignition Analyzer
(see Special Tools at end of section). Follow the proce-
dure that comes with the test device. The procedures
MUST be followed carefully.
1. SENSING COIL CONNECTIONS
2. OHMMETER
3. IGNITION MODULE
Figure 63. Sensing Coil Test
Do the following procedure to check the sensing coil:
• Connect an ohmmeter to either sensing coil connec-
tion and the housing as shown in Step 1 of Figure 63.
If the reading is not infinity (∞), replace the sensing
coil.
• Connect an ohmmeter to both connectors of the sens-
ing coil as shown in Step 2 of Figure 63. Move the
connectors at the sensing coil and at the connector
74
2200 YRM 611
to find any open circuits that are not constant. The
ohmmeter will correctly indicate 500 to 1500 ohms. If
the indication is not constant or is not within the resis-
tance range, replace the sensing coil.
Replace
Remove and disassemble the distributor as described
in the repairs for the Distributor.
IGNITION COIL
Test
This procedure tests for open circuits and short circuits
in the ignition coil. The ignition coil can stay on the
engine for this test.
1. Disconnect the distributor wire and control wires
from the ignition coil.
2. Connect an ohmmeter as shown in Step 1 of Fig-
ure 64. Use the high scale. The correct indication
is infinity (∞). If a short circuit is indicated, replace
the ignition coil.
3. Connect an ohmmeter as shown in Step 2 of Fig-
ure 64. Use the low scale. The indication will be
very low or approximately zero. If the indication is
not low, replace the ignition coil.
A. CLEAN METAL FOR A GOOD GROUND
CONNECTION
Figure 64. Ignition Coil Test
2200 YRM 611
4. Connect an ohmmeter as shown in Step 3 of Fig-
ure 64. Use the high scale. The reading must not
be infinity (∞). If the reading is infinity, replace the
ignition coil.
5. Connect the distributor lead and wiring to the igni-
tion coil.
Remove
1. Turn the key switch to OFF. Apply the parking brake.
2. Disconnect the negative battery cable.
3. Put tags for identification on the connectors and dis-
connect them from the coil.
CAUTION
Do not damage the high-voltage wires (spark plug
wires) during removal. Hold the wire by the boot
near the end of the wire. Rotate the boot before
pulling it and the connection from the terminal.
Sensors Repair
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR, REPLACE
WARNING
The coolant can be very hot. Use caution to prevent
personal injury.
1. Disconnect the battery negative cable. Disconnect
the connector at the ECT sensor. See Figure 57
and Figure 65.
2. Use a wrench and carefully loosen the ECT from
the coolant manifold.
3. Use a liquid sealant on the threads and install the
ECT in its hole in the coolant manifold. Tighten the
ECT carefully to 30 N•m (22 lbf ft).
4. Connect the connector at the ECT. Connect the bat-
tery negative cable.
5. Fill the radiator with coolant as required.
MAP SENSOR REPLACEMENT
1. Disconnect the negative battery cable. Disconnect
the electrical connector. See Figure 57.
Sensors Repair
4. Remove the high-voltage wire.
5. Remove the nuts (or capscrews) that fasten the
bracket for the ignition coil to the engine.
6. Remove the ignition coil and bracket assembly from
the engine.
7. Use a drill and punch to remove the two rivets that
fasten the bracket to the coil.
Install
1. Install the original bracket on the replacement coil
using screws (supplied with replacement coil).
2. Install the ignition coil assembly on the engine with
nuts (or capscrews).
3. Install the control wire connectors and the high-volt-
age wire on the ignition coil.
4. Connect the negative (ground) battery cable.
2. Remove the mounting screws and disconnect the
vacuum hose.
3. Inspect the electrical connectors and terminals for
damage.
4. Install the sensor on the bracket.
5. Connect the electrical connector. Connect the vac-
uum hose from the MAP sensor to the fitting at the
TBI unit.
1. TEMPERATURE SENSOR
2. ELECTRICAL CONNECTOR
3. LOCK TAB
Figure 65. Coolant Temperature Sensor (CTS)
75
Wiring Repair 2200 YRM 611

PCV System Repair

REPLACE
1. Remove the PCV valve from the rocker arm cover.
See Figure 66.

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 the PCV valve,
check for restrictions in the hoses, manifold port, or
PCV valve. Replace damaged parts.

4. Turn OFF the engine and remove valve. Shake

valve and listen for movement of needle inside the
valve. If valve does not move, replace the valve. 1. PCV VALVE 3. VALVE COVER
Connect the hose between the PCV valve and the 2. GROMMET
fitting on the intake manifold.
Figure 66. PCV System

Wiring Repair
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
replaced. These connectors are described in the para-
graphs under Connectors and Terminals.
short circuit between two terminals with opposite volt-
ages. Electronic components can be easily damaged
by a short circuit. Always use a jumper between con-
nectors when checking circuits. Never damage the in-
sulation or a seal on a connector when making a check
or doing troubleshooting. The Connector Test Adapter
Kit has a variation of adapters and connectors that can
be used when troubleshooting 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, make sure of the type
of connector. Some of the smaller connectors can look
similar, but have a different construction.
The Micro-Pack connector is shown in Figure 67. This
connector is normally used to connect the wire harness
to the ECM.

CONNECTORS AND TERMINALS

Be careful when using a probe to check the voltages
on the terminals in a connector. It is easy to cause a

76
2200 YRM 611 Wiring Repair

1. PICK 4. CONNECTOR
2. LOCK TAB BODY
3. TERMINAL

Figure 68. Metri-Pack Push-to-Seat Connector

1. WIRE 4. YALE TOOL KIT

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

Figure 67. Micro-Pack Connector

Metri-Pack® connectors come in several sizes and

types that are used on the wire harness. These con-
nectors are made by Packard Electric Company. The
typical connectors used on lift trucks are No. 56,
No. 150, No. 280, No. 480, and No. 630. Some
of these connectors are push-to-seat and others are
pull-to-seat. Make sure the connector is correctly
identified before it is changed. The terminals can be
damaged if they are removed or installed wrong.
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 the wires and
seals in their positions. Slide the seals along the
wires from the ends of the connector.
2. Hold the wire and use it to push the terminal to its
forward position in the connector body. Hold the
terminal in this position.
3. Find the lock tab for the terminal in the connector
channel. Push a removal tool (pick) of the correct
size into the connector channel. See Figure 68 and
Figure 69.
1. PICK 4. CONNECTOR
2. LOCK TAB BODY
3. TERMINAL
Figure 69. Metri-Pack Pull-to-Seat Connector
4. Use the removal tool to move the lock tab and re-
lease the terminal from its seat.
Push-to-Seat - Gently pull the wire to remove the
terminal from the back of the connector.
Pull-to-Seat - Gently push the wire to remove the
terminal through the front of the connector. See
Figure 70.
CAUTION
Work carefully and do not use enough force to dam-
age the terminal or the connector.
5. Inspect the terminal and connector for damage.
See Figure 71. Make repairs as necessary.

77
Wiring Repair 2200 YRM 611

Legend for Figure 71

NOTE: THE GREATER THE DISTANCE D, A FAULT

CAN OCCUR IN THE CONNECTION.
1. CONTACT TAB

6. If the terminal will be used again, make sure the

lock tab is correctly bent so that the terminal will be
locked in the connector again.

7. Push the terminal into the connector channel. Make

sure that the lock tab correctly locks the terminal in
position.

8. Push the seals into their position and install any

secondary locks.

The Weather-Pack® connectors all have a rubber seal

at the rear end of the connector. All Weather-Pack con-
nectors have a round barrel shape around the terminal.
This connector is used in the engine compartment to
protect against moisture and dirt which can cause cor-
rosion and a fault in the voltage signal. These connec-
tors normally have the low voltage and current used by
the electronic control system. The repair of this type of
1. FEMALE 4. CONNECTOR connector is shown in Figure 72 and Figure 73.
TERMINAL BODY
2. LOCK TAB 5. SEAL
3. YALE TOOL KIT
OTC P/N 7733

Figure 70. Metri-Pack Series 150 Pull-to-Seat

Terminal Removal

A. PUSH-TO-SEAT TERMINAL, MALE

1. TERMINAL 5. REMOVAL TOOL
2. LOCK TAB 6. CONNECTOR
3. WIRE BODY
4. SEAL

Figure 72. Weather-Pack Terminal and Connector

Figure 71. Metri-Pack Series Terminal Inspection

78
2200 YRM 611 Wiring Repair

correctly installed and in good condition so that the elec-

tronic engine control operates correctly.

PROCEDURES FOR SPARK PLUGS,

SPARK PLUG WIRES, AND BOOTS
NOTE: Use a silicon grease on the inside of the spark
plug boots to make a better weather seal and make the
spark plug boot easier to remove. The following silicon
greases are approved for use:

General Electric® GE627

Packard® PM776

Wacker® Silicones G47

1. Do not damage the spark plug wires during re-

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

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

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

3. Make sure the spark plug wires are installed in the

same locations using the clips. The spark plug
wires can be damaged or cause poor engine op-
eration if they are not correctly installed.

4. Special care must be used when spark plug boots

are installed. Make sure the metal terminal within
the boot is fully connected to the spark plug termi-
nal. Make sure the boot has not moved on the wire.
Figure 73. Weather-Pack Terminal Repair
If there is boot-to-wire movement, the boot can ap-
Use a remover tool (from Yale Tool Kit OTC P/N 7733) to pear to be fully installed when it is not.
remove the pin and sleeve terminals. These terminals
5. Make sure to install the insulator in the shield at the
can easily be damaged during removal if the correct tool
boot of all spark plug wires.
is not used. The terminal must then be replaced.
NOTE: The condition of the spark plugs removed from
When making repairs on these connectors, make sure
the engine can show engine operating problems. See
that the terminals are all in their seats correctly and the
the table for Spark Plug Troubleshooting.
sealing rings are installed. These connectors must be

79
Spark Plug Troubleshooting 2200 YRM 611

Spark Plug 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 over- Clean and install the spark plugs.
mum electrode wear. hauled engine.

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

Worn seals on the inlet valves. Replace the seals.

Red, brown, yellow and white Byproducts of combustion. Clean the spark plugs, set electrode
colored coatings on the insu- clearance, and install.
lator. Engine operation is not
constant during difficult oper-
ating conditions.

Heavy deposits on the part Valve seals have leaks if condition is Check the seals. Replace if necessary.
of the plug that goes into the found in only one or two cylinders. Clean, set electrode clearance, and in-
chamber and on the side fac- stall the spark plugs.
ing the intake valve.

Yellow glaze coating on the in- Melted byproducts of combustion. Avoid sudden acceleration with full
sulator of the spark plug. throttle after long periods of low-speed
driving. Replace the spark plugs.

Insulator tips are burned or Overheating. Check the cooling system.

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

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

80
2200 YRM 611 Wiring Diagrams

Wiring Diagrams

Figure 74. ECM Wiring Diagram (Sheet 1 of 2)

81
Wiring Diagrams 2200 YRM 611

Figure 74. ECM Wiring Diagram (Sheet 2 of 2)

82
2200 YRM 611 Wiring Diagrams

ECM Pin Circuit (Wire) Circuit Description

Number Code
J1-1 Not Used Not Used
J1-2 GQ Engine Coolant Temperature Sensor
J1-3 Not Used Not Used
J1-4 Not Used Not Used
J1-5 Not Used Not Used
J1-6 Not Used Not Used
J1-7 HS Fault Analysis Request - DLC "B"
J1-8 Not Used Not Used
J1-9 HA MAP Signal - MAP Terminal "B"
J1-10 GU TPS Signal - TPS Terminal "C"
J1-11 JM ECM Ignition - From Fuse
J1-12 Not Used Not Used
J1-13 HV TPS Ground - TPS Terminal "B"
J1-14 HQ System Ground
J1-15 GT TPS 5 Volt Source - TPS Terminal "A"
J1-16 HD ECB Battery +, Long-Term Memory
J1-17 Not Used Not Used
J1-18 HZ Serial Data - DLC Terminal "M"
J1-19 Not Used Not Used
J1-20 Not Used Not Used
J1-21 Not Used Not Used
J1-22 Not Used Not Used
J1-23 Not Used Not Used
J1-24 Not Used Not Used
J1-25 Not Used Not Used
J1-26 Not Used Not Used
J1-27 Not Used Not Used
J1-28 Not Used Not Used

83
Wiring Diagrams 2200 YRM 611

ECM Pin Circuit (Wire) Circuit Description

Number Code
J1-29 HY MAP and Engine Coolant Temperature Sensor Ground
J1-30 HQA System Ground
J1-31 GR MAP 5 Volt Source - MAP Terminal "C"
J1-32 HC ECM Battery +, Long-Term Memory

ECM Pin Circuit (Wire) Circuit Description

Number Code
J2-1 Not Used Not Used
J2-2 Not Used Not Used
J2-3 Not Used Not Used
J2-4 Not Used Not Used
J2-5 Not Used Not Used
J2-6 HX Ignition Reference Ground
J2-7 Not Used Not Used
J2-8 GY Ignition Reference Signal
J2-9 JA Electronic Driver, Fuel Pump Relay
J2-10 Not Used Not Used
J2-11 Not Used Not Used
J2-12 Not Used Not Used
J2-13 JT Electronic Driver, IAC Coil "A" Low
J2-14 HJ Electronic Driver, IAC Coil "B" High

84
2200 YRM 611 Wiring Diagrams

ECM Pin Circuit (Wire) Circuit Description

Number Code
J2-15 HN ECM System Ground
J2-16 Not Used Not Used
J2-17 Not Used Not Used
J2-18 Not Used Not Used
J2-19 Not Used Not Used
J2-20 JX ECM System Ground
J2-21 JBA Electronic Driver, Fuel Injector
J2-22 Not Used Not Used
J2-23 GW Ignition Control, Timing Signal
J2-24 GZ Electronic Driver, Bypass
J2-25 Not Used Not Used
J2-26 Not Used Not Used
J2-27 Not Used Not Used
J2-28 HG Electronic Driver, IAC Coil "A" High
J2-29 HK Electronic Driver, IAC Coil "B" Low
J2-30 JR Electronic Driver, Governor Control
J2-31 AZ Electronic Driver, Malfunction Indicator Lamp
J2-32 Not Used Not Used

85
Special Tools 2200 YRM 611

Special Tools
SCAN Tool
Reads problem codes from the ECM memory.
Used to analyze and troubleshoot components and
the EMC 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

Connector Test Adapter Kit

Used to make electrical test connections in the
"Weather-Pack," "Metri-Pack," and "Micro-Pack"
terminals.

Circuit Tester
Used to check relays and solenoids before they are
connected to a new ECM. This tester measures
the circuit resistance and indicates correct or
wrong with a green and a red LED. An amber LED
indicates current polarity. This tester can also be
used as a test light (without internal battery).
Spark Tester
Used to check secondary ignition voltage. Also
called an ST125.

Fuel Pressure Gauge

Used to check fuel pressure from fuel pump to TBI.
Has special fitting to fit the Schroeder test port in
the fuel line or Yale Company lift trucks.

86
2200 YRM 611 Special Tools

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.
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.

Tool Kit for Terminal Repair

Terminals cannot be removed from their connectors
nor repaired without special tools. This kit has the
special removal and installation tools and crimping
tools required to make repairs in Micro-Pack,
Metri-Pack, and Weather-Pack connectors. This
repair kit does not have the terminals nor the
connectors.

87
Special Tools 2200 YRM 611

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 ohmmeters 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 indicator 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.

88
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 611 12/03 (2/02) Printed in U.S.A.