Control Electronico Del Motor GM 3

Maintenance
ELECTRONIC ENGINE
CONTROL
TROUBLESHOOTING AND REPAIR
MEFI-4
PART NO. 524162463 2200 YRM 1017

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Electronic Engine Control Table of Contents
TABLE OF CONTENTS
General.................................................................................................................................................................. 1
Troubleshooting Procedure ............................................................................................................................... 1
How This Section Is Arranged........................................................................................................................... 1
Where Do I Start? ............................................................................................................................................. 1
Visual/Physical Inspection................................................................................................................................. 1
Knowledge/Tools Required ............................................................................................................................... 1
Damage From Static Discharge (Static Electricity) ........................................................................................... 1
Troubleshooting Information .............................................................................................................................. 2
Malfunction Indicator Lamp (MIL) ................................................................................................................. 2
Reading Diagnostic Trouble Codes (DTC).................................................................................................... 2
Clearing Diagnostic Trouble Codes (DTCs) .................................................................................................. 6
ECM Diagnostic Codes Available...................................................................................................................... 7
Diagnostic Mode ........................................................................................................................................... 7
Field Service Mode ....................................................................................................................................... 7
ECM Learning Ability .................................................................................................................................... 7
SCAN Tool Information...................................................................................................................................... 8
On-Board Diagnostic (OBD) System Check ................................................................................................... 10
Test Description .......................................................................................................................................... 10
Troubleshooting Charts ....................................................................................................................................... 11
General ........................................................................................................................................................... 11
Tools and Test Equipment........................................................................................................................... 12
Presssure Conversion Chart....................................................................................................................... 13
Troubleshooting Chart Description Summary ................................................................................................. 14
A-1 No Malfunction Indicator Lamp ..................................................................................................................... 15
Circuit Description ........................................................................................................................................... 15
Diagnostic Aids ............................................................................................................................................... 15
Test Description............................................................................................................................................... 15
A-2 No Scan Data, No DTC-12, Malfunction Indicator Lamp ON........................................................................ 17
Diagnostic Aids ............................................................................................................................................... 17
A-3 Engine Cranks but Does Not Run................................................................................................................. 19
Diagnostic Aids ............................................................................................................................................... 19
A-4 Fuel Injector Circuit ....................................................................................................................................... 22
A-5 Fuel Pump Relay Circuit ............................................................................................................................... 24
Diagnostic Aids ............................................................................................................................................... 25
A-6 Fuel System Troubleshooting........................................................................................................................ 27
Diagnostic Aids ............................................................................................................................................... 28
A-7 Ignition System Troubleshooting ................................................................................................................... 32
Diagnostic Aids ............................................................................................................................................... 32
©2004 Yale Materials Handling Corp. i

Table of Contents Electronic Engine Control
TABLE OF CONTENTS (Continued)

DTC 14 ECT Sensor Circuit - Low Temp Indicated (Scan Diagnostics) .............................................................. 37
Diagnostic Aids ............................................................................................................................................... 37
DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit High Temp Indicated ............................................. 39
Diagnostic Aids ............................................................................................................................................... 39
DTC 21 Throttle Position (TP) Sensor Circuit Signal Voltage High ..................................................................... 41
Diagnostic Aids ............................................................................................................................................... 41
DTC 22 Throttle Position (TP) Sensor Circuit Signal Voltage Low ...................................................................... 43
Diagnostic Aids ............................................................................................................................................... 43
DTC 31 Engine Governor Circuit......................................................................................................................... 45
Diagnostic Aids ............................................................................................................................................... 45
DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage High ................................................ 47
Diagnostic Aids ............................................................................................................................................... 48
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage Low ................................................. 50
Diagnostic Aids ............................................................................................................................................... 50
DTC 41 Electronic Spark Timing (EST) - Open EST Circuit ............................................................................... 52
Diagnostic Aids ............................................................................................................................................... 53
DTC 42 EST - Grounded EST Circuit, Open or Grounded Bypass Circuit.......................................................... 54
Diagnostic Aids ............................................................................................................................................... 54
DTC 51 Calibration Checksum Failure ................................................................................................................ 56
Diagnostic Aids ............................................................................................................................................... 56
DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open .............................................................................. 57
Diagnostic Aids ............................................................................................................................................... 58
DTC 81 5-Volt Reference Circuit Out of Range ................................................................................................... 60
Diagnostic Aids ............................................................................................................................................... 60
DTC 81 FPRSENSE Circuit Fault........................................................................................................................ 62
Diagnostic Aids ............................................................................................................................................... 62
ii

Troubleshooting, Poor Operation ......................................................................................................................... 63
General ........................................................................................................................................................... 63
Make a Careful Visual Check .......................................................................................................................... 63
FAULT: Codes or Performance That Is Abnormal ........................................................................................... 64
FAULT: Loss of Diagnostic Trouble Code (DTC) Memory ............................................................................... 64
FAULT: Engine Quits While Driving ................................................................................................................. 64
Additional Checks ....................................................................................................................................... 64
FAULT: Engine Is Difficult to Start ................................................................................................................... 64
FAULT: Variation in Engine Power When Throttle Is Held Steady ................................................................... 65
FAULT: Decreased Engine Power ................................................................................................................... 65
FAULT: Detonation/Spark Knock ..................................................................................................................... 65
FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes ........................................... 66
FAULT: One or More Cylinders Do Not Operate Correctly - Engine Does Not Idle Correctly ......................... 66
FAULT: Rough Idle or Engine Stalls During Idle.............................................................................................. 67
FAULT: Fuel Usage Too High .......................................................................................................................... 67
FAULT: Dieseling ............................................................................................................................................. 67
FAULT: Backfire............................................................................................................................................... 68
System Test Charts ............................................................................................................................................. 68
General ........................................................................................................................................................... 68
Engine Coolant Temperature (ECT) Sensor Test ............................................................................................ 68
Throttle Position (TP) Sensor Check ............................................................................................................... 69
Minimum Idle Speed ....................................................................................................................................... 69
Adjustment.................................................................................................................................................. 69
B-1 - Idle Air Control (IAC) System Check........................................................................................................... 70
Diagnostic Aids ............................................................................................................................................... 71
B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test ............................................................................. 72
B-3 - Check Governor System............................................................................................................................. 74
Governor System Not Operating Correctly...................................................................................................... 74
Check Function of Governor System .............................................................................................................. 74
Check PCV System......................................................................................................................................... 75
Fuel System Components Repair........................................................................................................................ 75
General ........................................................................................................................................................... 75
Fuel Pressure Relief Procedure ...................................................................................................................... 75
Fuel Pump Replacement................................................................................................................................. 75
Throttle Body Injection Unit (TBI) .................................................................................................................... 76
Remove....................................................................................................................................................... 76
Clean and Inspect ....................................................................................................................................... 76
Install .......................................................................................................................................................... 77
Fuel Meter Body.............................................................................................................................................. 77
Remove....................................................................................................................................................... 77
Install .......................................................................................................................................................... 80
Fuel Injector .................................................................................................................................................... 80
Remove....................................................................................................................................................... 80
Install .......................................................................................................................................................... 81
Pressure Regulator ......................................................................................................................................... 81
Remove....................................................................................................................................................... 81
Inspect ........................................................................................................................................................ 81
iii
Table of Contents Electronic Engine Control

Install .......................................................................................................................................................... 81
Throttle Position Sensor (TPS)........................................................................................................................ 82
Remove....................................................................................................................................................... 82
Install .......................................................................................................................................................... 82
Idle Air Control (IAC) Valve ............................................................................................................................. 82
Remove....................................................................................................................................................... 82
Clean and Inspect ....................................................................................................................................... 83
Install .......................................................................................................................................................... 83
Governor System 3.0L Engine Repair................................................................................................................. 83
Governor Module, Replace ............................................................................................................................. 83
Governor Motor, Replace ................................................................................................................................ 83
Throttle Cables, Install and Adjust................................................................................................................... 83
Foot Directional Control Pedal, Check ............................................................................................................ 84
Governor System 4.3L Engine Repair................................................................................................................. 85
Governor Throttle Drive Assembly .................................................................................................................. 85
Remove....................................................................................................................................................... 85
Inspect ........................................................................................................................................................ 86
Install .......................................................................................................................................................... 86
Governor Drive Motor...................................................................................................................................... 86
Remove....................................................................................................................................................... 86
Clean and Lubricate.................................................................................................................................... 87
Install .......................................................................................................................................................... 87
Inspect ........................................................................................................................................................ 87
Foot Directional Control Pedal, Check ............................................................................................................ 88
Ignition System Components Repair ................................................................................................................... 89
ECM Replacement .......................................................................................................................................... 89
Function Check ............................................................................................................................................... 89
Distributor........................................................................................................................................................ 89
Remove....................................................................................................................................................... 89
Disassemble ............................................................................................................................................... 89
Inspect ........................................................................................................................................................ 90
Assemble .................................................................................................................................................... 90
Install .......................................................................................................................................................... 90
Firing Order................................................................................................................................................. 91
Ignition Timing ............................................................................................................................................ 91
Ignition Module Repair......................................................................................................................................... 91
Test For Fault................................................................................................................................................... 91
Replace ........................................................................................................................................................... 92
Sensing Coil .................................................................................................................................................... 92
Test ............................................................................................................................................................. 92
Replace....................................................................................................................................................... 93
Ignition Coil ..................................................................................................................................................... 93
Test ............................................................................................................................................................. 93
Remove....................................................................................................................................................... 93
Install .......................................................................................................................................................... 94
Sensors Repair.................................................................................................................................................... 94
Engine Coolant Temperature (ECT) Sensor, Replace .................................................................................... 94
MAP Sensor, Replace ..................................................................................................................................... 94
PCV System Repair............................................................................................................................................. 95
Replace ........................................................................................................................................................... 95
Wiring .................................................................................................................................................................. 95
iv

Connectors and Terminals .............................................................................................................................. 95
Procedures for Spark Plugs, Spark Plug Wires, and Boots ............................................................................ 98
Wiring Diagram ............................................................................................................................................... 98
Spark Plugs Troubleshooting............................................................................................................................. 102
Special Tools ..................................................................................................................................................... 104
This section is for the following models:
v
2200 YRM 1017 General
General
This section contains troubleshooting and repair proce- 4. System Test Charts
dures for parts of the electronic engine controls. Users 5. Repairs
of this section must know components and operation
as described in the section Electronic Engine Control WHERE DO I START?
Description and Operation 2200 YRM 1016.
There are three things to do to start troubleshooting.
The electronic engine control system is made of many First, become familiar with the electronic engine control
parts. The main parts are the Throttle Body Injection system. Second, always start your work with a com-
(TBI) unit and the Electronic Control Module (ECM). plete visual/physical inspection. See Visual/Physical In-
See Figure 1. These parts and their sensors provide inspection below for more explanation. Third, understand
formation about engine operation and the systems they the On-Board Diagnostic (OBD) System Check.
control. The ECM has the ability to perform some trou-
bleshooting of itself and of other parts of the system. VISUAL/PHYSICAL INSPECTION
When a problem is found, the ECM turns ON the Mal-
function Indicator Lamp that is in the instrument cluster. A careful visual and physical inspection must be done
A Diagnostic Trouble Code (DTC) is kept in the memory as part of any diagnostic procedure. This can solve the
of the ECM. repair of a problem without further steps. Inspect all
vacuum hoses for correct routing, restrictions, cuts, or
bad connections. Be sure to inspect hoses that are dif-
ficult to see beneath the air filter. Inspect all wires in
the engine compartment for proper connections, rout-
ing, damaged spots, or contact with sharp edges or
the exhaust manifolds. This visual/physical inspection
is very important and must be done carefully.
KNOWLEDGE/TOOLS REQUIRED
To use this manual most effectively, a general under-
standing of basic electrical circuits and circuit testing
tools is required. One should be familiar with wiring di-
1. ECM 3. J2 CONNECTOR agrams; the meanings of voltage, ohms, amps, and ba-
2. J1 CONNECTOR sic theories of electricity; and understand what happens
in an open or shorted wire. To perform troubleshoot-
Figure 1. ECM
ing procedures, use of a diagnostic SCAN Tool is re-
quired. A tachometer, test lamp, ohmmeter, digital volt-
TROUBLESHOOTING PROCEDURE
meter with 10 megohms impedance, vacuum gauge,
Before using this part of the manual, knowledge of cor- and jumper wires are also required. Special tools that
rect troubleshooting procedures is required. If the cor- are required for system service and the ones described
rect troubleshooting procedures are not followed, as de- above are shown in the Special Tools section found in
scribed in this section, replacement of good parts can back of this manual.
result. Troubleshooting charts use a SCAN Tool where
possible. The SCAN Tool has the ability to save time DAMAGE FROM STATIC DISCHARGE
in troubleshooting, and it prevents replacement of good (STATIC ELECTRICITY)
parts.
NOTE: To prevent damage by static electricity, DO NOT
HOW THIS SECTION IS ARRANGED touch the ECM connector pins.
This section is in five parts, describing troubleshooting Electronic components used in control systems use a
and repair procedures. They are as follows: very low voltage and can be easily damaged by static
1. General discharge or static electricity. Less than 100 volts of
2. Troubleshooting Charts static electricity can cause damage to some electronic
3. Troubleshooting, Poor Operation components.
1
General 2200 YRM 1017
There are several ways for a person to become stati- problem goes away, the lamp will go out after 10 sec-
cally charged. Most common methods of charging are onds. In either condition a DTC will remain in the ECM.
by friction and by induction. An example of charging
by friction is a person sliding across a car seat, in When the lamp remains ON while the engine is running
which a charge of as much as 2 to 5,000 volts can or when there is a malfunction, On-Board Diagnostic
build up. Charging by induction occurs when a person (OBD) System Check must be done.
with well-insulated shoes stands near a highly-charged
When a problem is not regular or constant, the Malfunc-
object and momentarily touches ground. Charges
tion Indicator Lamp will turn ON for approximately 10
of the same polarity are drained off, leaving the per-
seconds and then turn OFF. However, the Diagnostic
son highly charged with the opposite polarity. Static
Trouble Code (DTC) is kept in memory of the ECM un-
charges of either type can cause damage; therefore,
til DTCs are cleared. (See Clearing Diagnostic Trouble
it is important to use care when handling and testing
Codes (DTCs) in this section.) A DTC that is not con-
electronic components.
stant can reset. If it is a problem that is not constant,
a DTC Chart is not used. However, you can use the
TROUBLESHOOTING INFORMATION
Other Troubleshooting Checks in the section for that
Troubleshooting charts and function checks in this DTC to help locate the problem.
section are designed to find a bad circuit or component
through logic based on the process of elimination. Reading Diagnostic Trouble Codes (DTC)
Charts are prepared with the requirement that the ve-
The Diagnostic Connector (see Figure 2) is used to
hicle functioned correctly at time of assembly and that
communicate with the ECM. The Diagnostic Connec-
there are no multiple failures. ECM does constant test-
tor is installed on the bracket near the valve cover. See
ing on certain control functions. ECM communicates
Figure 3 and Figure 4. It is used in the assembly plant
the source of a malfunction with Diagnostic Trouble
to receive information in checking that the engine is op-
Codes (DTC). DTCs are two-digit numbers that can
erating correctly before it leaves the plant. DTC(s) kept
range from 12 to 99. When a malfunction is found by
in the ECM’s memory can be read with a SCAN Tool
the ECM, a DTC is set and Malfunction Indicator Lamp
connected to the Diagnostic Connector.
is turned ON.
Malfunction Indicator Lamp (MIL)

This lamp is on the instrument cluster and has the fol-
lowing functions:
It lets the operator know that a problem has occurred

and that the vehicle must be taken in for service as soon
as possible. A. GROUND
B. FAULT ANALYSIS TERMINAL
It flashes Diagnostic Trouble Codes (DTCs) kept by the C. NOT USED
D. NOT USED
ECM, which help the technician troubleshoot system E. CHECK ENGINE LIGHT
problems. F. +12 VOLTS
G. SERIAL DATA FOR SCAN TOOL TESTER
As a bulb and system check, the lamp will come ON H. NOT USED
with the ignition switch ON and the engine not running. J. NOT USED
When the engine is started, the lamp will turn OFF. K. NOT USED
If the lamp remains ON, the system has found a prob- Figure 2. Diagnostic Connector
lem. This problem is referred to as a current DTC. If the
2
Figure 3. Electronic Engine Control Components Arrangement (GM 3.0L Engine)
3
Legend for Figure 3

A. TOP VIEW B. SIDE VIEW
1. THROTTLE BODY INJECTION (TBI) UNIT 9. GOVERNOR MOTOR
2. FUEL INJECTOR 10. FUEL PUMP RELAY
3. FUEL INJECTOR FUSE 11. DIAGNOSTIC CONNECTOR
4. ECM FUSE (IGNITION) 12. FUEL PUMP FUSE
5. STARTER FUSE 13. ECM FUSE (B+)
6. ENGINE COOLANT TEMPERATURE (ECT) 14. MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR 15. OIL PRESSURE SWITCH
7. DISTRIBUTOR 16. IGNITION COIL
8. ELECTRONIC CONTROL MODULE (ECM)
4
Figure 4. Electronic Engine Control Components Arrangement (GM 4.3L Engine)
5
Legend for Figure 4

A. TOP VIEW B. VIEW FROM TRANSMISSION
1. ENGINE COOLANT TEMPERATURE SENSOR 10. FUEL PRESSURE TEST PORT
(ECT) 11. FUEL FILTER
2. FUEL PUMP FUSE 12. THROTTLE BODY INJECTOR
3. ECM FUSE (B+) 13. FUEL INJECTORS
4. THROTTLE POSITION SENSOR (TPS) 14. MANIFOLD ABSOLUTE PRESSURE (MAP)
5. ELECTRONIC CONTROL MODULE (ECM) SENSOR
6. IDLE AIR CONTROL (IAC) 15. FUEL PUMP RELAY
7. DIAGNOSTIC CONNECTOR 16. OIL PRESSURE SWITCH
8. IGNITION COIL 17. OIL PRESSURE SENDER
9. TYPE EST DISTRIBUTOR 18. TEMPERATURE GAUGE SENDER
When SCAN Tool is connected to the Diagnostic Con- DTC 12 (which means no crankshaft rpm signal) in-
nector with key switch ON and engine OFF, the system dicates that the ECM’s diagnostic system is operating
will enter the Diagnostic Mode. At this point, the Mal- correctly at this time. If DTC 12 is not indicated, a prob-
function Indicator Lamp will flash DTC 12 two times con- lem is in the diagnostic system itself.
secutively (see Figure 5). The following is the flash se-
quence for DTC 12: Following the output of DTC 12, if additional codes are
1. Long pause stored, the Malfunction Indicator Lamp will flash the
2. Flash DTC two times. If more than one DTC has been stored
3. Pause in the ECM’s memory, the DTCs will be flashed start-
4. Flash-flash ing with the lowest DTC set and finishing with the high-
1. Long pause est DTC set. Remember each DTC will be flashed two
2. Flash times. When all DTCs have been flashed, the sequence
3. Pause will start over again with DTC 12.
4. Flash-flash
1. LONG PAUSE 2. FLASH 3. PAUSE 4. FLASH-FLASH
Figure 5. Diagnostic Trouble Code 12 Example
Clearing Diagnostic Trouble Codes (DTCs) Install the SCAN Tool according to the operator’s
manual for the tool. Select clear DTCs from the tools
NOTE: When clearing DTCs with or without the use of menu. This operation electronically clears all ECM
a SCAN Tool, the ignition must be cycled to the OFF DTCs. Check for DTCs again to see that the DTCs are
position or the DTCs will not clear. cleared.
6
ECM DIAGNOSTIC CODES AVAILABLE

Table 1. ECM Diagnostic Codes Available
Turn On Malfunction
Code Description
Indicator Lamp
12 Indicates that Fault Monitor System is working correctly No
14 Engine Coolant Temperature Sensor Circuit - Low Temperature (High Volts) Yes
15 Engine Coolant Temperature Sensor Circuit - High Temperature (Low Volts) Yes
21 Throttle Position Sensor - High Volts Yes
22 Throttle Position Sensor - Low Volts Yes
31 Governor Circuit Malfunction Yes
33 MAP Sensor Circuit - High Volts Yes
34 MAP Sensor Circuit - Low Volts Yes
41 Ignition Control (IC) System. Yes
42 Electronic Spark Timing (EST)-Grounded EST Circuit, Open or Grounded Yes
Bypass Circuit
51 Calibration Checksum Failure Yes
81 Fuel Pump High, Low, or Open Yes
81 Recirc J1-32 Fault Yes
81 5-Volt Reference Circuit Out of Range Yes
Diagnostic Mode If the SCAN Tool is connected to the Diagnostic Con-

nector and turned ON with the engine running, system
will enter Field Service Mode. For the GM 3.0L en-
CAUTION gine, this will cause the engine to run at approximately
To prevent ECM damage, the key must be OFF when 1500 rpm and 8 before top dead center spark advance.
disconnecting or reconnecting ECM power. For GM 4.3L engine, the numbers are approximately
1000 rpm and 0 before top dead center spark advance.
When the SCAN Tool is connected to the Diagnostic
While the system is in Field Service Mode, new trouble
Connector with the key switch ON and the engine OFF,
codes can be kept in the ECM.
the system will enter the Diagnostic Mode.
1. Display a DTC 12 by flashing the Malfunction Indi- ECM Learning Ability

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

NOTE: The ignition timing can be set with a timing light.
7
SCAN TOOL INFORMATION

Table 2. Rinda SCAN Tool Information
Test under following conditions:

Idle speed, upper radiator hose hot, throttle closed, NEUTRAL, all accessories OFF
SCAN Position Units Displayed Expected Values at Idle
Barometric Press kPa/Volts 98 to 102 kPa (14 to 15 psi)/3 to 5 Volts
Battery Volts Volts 12.5 to 14.5 Volts
Check Engine Lamp Discrete Off
Coolant Temperature C/ F 85 to 100 C (180 to 212 F)
Des Idle Speed rpm ECM idle command (changes with
temperature)
Engine Speed rpm ±100 rpm from desired idle
Engine Type ID Numeric XXXX (varies with calibration) - 3001
Fuel Pump Output Discrete On
IAC Follower Counts 0
IAC Position Counts 5 to 50
Inj "A" On Time Milliseconds 0.8 to 3.0 ms
Inj "B" On Time Milliseconds 0.8 to 3.0 ms
MAP Volts kPa/Volts 1 to 2 Volts (depends on Vac. and Baro
Pressure), 30 to 40 kPa (4 to 6 psi)
MEMCAL Checksum Numeric 0-65535
RPM CTRL Output Discrete No
Spark Advance Degrees Varies
Throttle Percent Hr:Min:Sec 00:00:00 - 18:12:15
TPS Volts Volts 0.45 to 1.25
Table 3. TECH 1 SCAN Tool Information
Oxygen
Reading Units Expected Values at Idle Standard Governor (O2)
Sensor
Baro kPa/Volts 98 to 102 kPa (14 to 15 psi)/3 to 5 Volts X X X
Battery/ Volts 12.5 to 14.5 Volts
Ignition X X X
Voltage
Block Learn Numeric 1-16
X
Cell
Calibration Numeric 0-65535
X X X
Checksum
8
Table 3. TECH 1 SCAN Tool Information (Continued)
Oxygen
Sensor
Calibration ID Numeric XXXX (varies with calibration) - 3001 X X X
Closed Loop Discrete Yes/No
X
Fuel
Closed Yes/No Yes
X X X
Throttle
Desired Idle rpm ECM Idle Command (changes with
X X X
temperature)
Desired Percent 1
X
Throttle
ECT C, F 85 to 100 C (180 to 212 F) X X X
Engine Hour Hours 0.0-1193046.47
X X X
Meter
Engine Speed rpm ±100 rpm from desired idle X X X
Fuel Pump Discrete On
X X X
Relay
Governor Percent 0
X
Duty Cycle
IAC Position Counts 5 to 50 X X X
IAC Throttle Counts 0
X X X
Follower
Injector A Milliseconds 0.8 to 3.0 ms
X X X
Pulse Width
Injector B Milliseconds 0.8 to 3.0 ms
X X X
Pulse Width
Malfunction Discrete Off
Indicator X X X
Lamp
MAP kPa/Volts 30 to 40 kPa (4 to 6 psi), 1 to 2 volts
X X X
(depends on Vac. and Baro pressure)
O 2 Sensor 1 Voltage 0-1.00 X
O 2 Sensor 1, Multiplier 0-1.99
X
Blk LM Corr
O 2 Sensor 1, Counts 0-255
X
Cross Counts
O 2 Sensor Discrete Rich/Lean
1, Sensor 1 X
Status
RPM Control Discrete No X
9
Table 3. TECH 1 SCAN Tool Information (Continued)
Oxygen
Sensor
Spark Degrees Varies
X X X
Advance
System Discrete OK
Voltage X X X
Warning
Throttle Angle Percent 0 X X X
Time From Hr:Min:Sec 00:00:00-18:12:15
X X X
Start
TP Sensor Volts 0.45 to 1.25 Volts X X X
MPH Control Discrete No X
Vessel Speed mph 0 X X X
ON-BOARD DIAGNOSTIC (OBD) SYSTEM 2. Is there a Diagnostic Trouble Code? If there is a

CHECK DTC, go directly to the DTC chart for that number.
This will determine if the fault is still there. If there
On-Board Diagnostic (OBD) System Check is a trou- is no DTC, proceed to Step 3.
bleshooting chart to find a problem caused by a
malfunction in the electronic engine control system. 3. SCAN serial data transmitted by the ECM. This in-
See Table 4. It must be the starting point for any volves reading the information available on the se-
troubleshooting. rial data stream with one of the tools available for
that purpose. Information on these tools and the
SCAN data shown in Table 1 can be used for com- meaning of the displays can be found in the opera-
parison after doing troubleshooting checks and finding tor’s manual of the tool. Readings for certain oper-
On-Board Diagnostics working correctly with no trouble ating conditions can be found in Table 1.
codes shown. The data are an average of display val-
ues from normally operating vehicles and show a dis- Test Description
play of a normally operating system.
The numbers below are a reference to the bold numbers
After visual/physical inspection, On-Board Diagnostic in Table 4.
(OBD) System Check is the starting point for all trou-
bleshooting procedures. 1. Diagnostic Trouble Code (DTC) 12 means no rpm
reference pulses from the ignition module. This is
The correct procedure to find a problem is to follow three correct when engine is not running.
basic steps.
2. Checks the Serial Data Circuit (HZ) in A-1 No Mal-
1. Are On-Board Diagnostics working? This is deter- function Indicator Lamp and ensures ECM is able
mined by doing the OBD System Check. Since this to transmit serial data.
is the starting point for troubleshooting procedures,
always begin here. 3. A SCAN Tool parameter that is not within typical
ranges may help isolate the area that is causing the
If On-Board Diagnostics do not work, the OBD System problem.
Check will not lead to a troubleshooting chart to fix the
problem. If On-Board Diagnostics are working correctly,
go to the next step.
10
2200 YRM 1017 Troubleshooting Charts
Table 4. On-Board Diagnostic System Checks
Step Action Value Yes No

1 Turn ignition ON, leaving engine OFF Go to Step 2. Go to A-1 No
Is Malfunction Indicator Lamp (MIL) Go to Step 7. Malfunction Indicator
illuminated steady? Lamp.
or is MIL flashing DTC 12?
2 Install SCAN Tool Go to Step 3. Go to A-2 No Scan
Does SCAN Tool display DTC 12? Data, No DTC-12,
Malfunction Indicator
Lamp ON.
3 Does SCAN Tool display ECM data? Go to Step 4. Go to A-2 No Scan
Data, No DTC-12,
Lamp ON.
4 Does engine start? Go to Step 5. Go to A-3 Engine
Cranks but Does
Not Run.
5 Were any other DTCs displayed? Go to applicable Go to Step 6.
DTC chart.
Start with lowest
numbered DTC.
6 Compare SCAN Tool data with typical values Go to Troubleshoot the
shown in Rinda SCAN Tool Information Troubleshooting, components, circuit,
Are values normal or within range? Poor Operation. or system the SCAN
Tool indicates is not
within normal values.
7 Check for grounded diagnostic test circuit Go to Step 1. Go to Step 8.
438.
Was problem found?
8 Replace ECM. Verify repair.
Is action complete?
Troubleshooting Charts
GENERAL • The fuel system and the engine must operate cor-
rectly. Any problems or leaks in the fuel sys-
WARNING tem and the engine must be repaired before doing
troubleshooting.
This troubleshooting requires the operation of the
• The fan and the drive belts can remove fingers or
engine for some tests. Make sure tests are done
cause other injuries. Be careful that your hands
carefully to prevent injury:
and tools do not touch the moving fan or the drive
• Put the lift truck on a level surface. Lower the
belts.
carriage and forks and apply the parking brake.
Make sure the lift truck cannot move and cause an
injury during the tests. Use blocks, as necessary,
to prevent movement of the lift truck.
11
Troubleshooting Charts 2200 YRM 1017
• The engine exhaust and other parts of the engine Tools and Test Equipment
are hot. Do not touch a hot surface and cause a
burn. The following tools are necessary for troubleshooting
the system: (Also, see Special Tools in back of section.)
• Digital multimeter. Voltmeter must have a minimum
CAUTION input impedance of 10 megohms. (A digital voltmeter
Electronic equipment can be damaged if trou- and ohmmeter are normally included in a multimeter
bleshooting and repairs are not done correctly. test instrument.
The following CAUTIONS must be followed when • Tachometer with inductive trigger signal sensor.
doing troubleshooting or repairs on an engine with • Test light that has a low current draw as described in
an ECM: Figure 6.
• Always disconnect the battery negative cable be- • Vacuum pump with a gauge. This vacuum pump is
fore disconnecting and removing any parts, ex- held and operated with the hand. The gauge must be
cept as described in Troubleshooting. able to indicate a gauge pressure (vacuum) of 34 kPa
• Never start the engine unless the battery is cor- (10 inHg). See Presssure Conversion Chart.
rectly connected. • Spark tester. Spark tester is used to check the sec-
• Never disconnect the battery from any equipment ondary ignition. Spark tester is also called an ST125
when the engine is running. and creates a 25-kilovolt load on secondary ignition
• Never disconnect the battery from the charging components.
system when the engine is running.
• If the battery must be charged with a battery
charger, ALWAYS disconnect the battery from the
electrical system.
• Make sure that all electrical connections are clean
and have good electrical contact.
• Never connect or disconnect the wiring harness
at the ECM when the key switch is ON.
• Always disconnect the battery and the ECM con-
nectors if electric arc welding must be done on
the vehicle.
• If the engine compartment is cleaned with steam,
make sure that any water or steam is not directed
toward the ECM or its sensors. The heat and
steam can damage the electronic components
and cause corrosion in the electrical connec-
tions.
• Use only the tools and test equipment described
in Tools and Test Equipment to prevent damage
to good components and to obtain correct test
results.
• All voltage measurements must be made with a
digital voltmeter with a rating of 10 megohm input
impedance. NOTE: IF THE AMMETER INDICATES LESS THAN
• When a test light is used in troubleshooting, the 0.3 amps (300 milliamps), THE TEST LIGHT CAN BE
test light must have less than 0.3 amps (300 mil- USED.
liamps) of maximum current flow. A test for a cor-
rect test light is shown in Figure 6. IF THE AMMETER INDICATES MORE THAN 0.3 amps
(300 milliamps), THE TEST LIGHT CANNOT BE USED
The following troubleshooting charts are designed to BECAUSE IT CAN CAUSE DAMAGE TO THE ELEC-
give an efficient method of fault analysis on electronic TRONIC COMPONENTS.
engine controls.
1. DC AMPS 3. BATTERY
2. TEST LIGHT
Figure 6. Current Flow Test for Test Light
12
2200 YRM 1017 Troubleshooting Charts
Presssure Conversion Chart Service people normally use gauge pressure as the ref-
erence point, which does not add the atmospheric pres-
Vacuum and pressure readings often cause confusion sure. The reference point for gauge pressure is atmo-
because everyone does not use the same point of ref- spheric pressure. It is important to know when reading
erence. Absolute pressure is gauge pressure plus at- a pressure chart whether the units are given in absolute
mospheric pressure. Standard atmospheric pressure pressure or gauge pressure.
is also called the standard barometric pressure and is
equal to 101.325 kPa (14.695 psi) or 29.92 inHg at sea The gauges used by most service people indicate
level. The reference point for these measurements is gauge pressure. However, most gauges calibrated in
zero pressure or an absolute vacuum. The following a metric scale (kilopascals) and used to measure less
formula is used in converting inches of mercury to kilo- than atmospheric pressure normally indicate absolute
pascals: inHg x 3.37685 = kPa. pressure as shown in the chart. A gauge calibrated in
inHg and used to measure a vacuum begins at zero
and increases its indication as the vacuum increases.
Table 5. Voltage and Pressure Chart
ATMOSPHERIC 5-VOLT REFERENCE

PRESSURE 4.80 4.90 5.00 5.10 5.20
kPa inHg MAP SENSOR SIGNAL VOLTAGE
64.35 19.0 2.75 2.80 2.86 2.92 2.97
66.04 19.5 2.83 2.89 2.95 3.01 3.07
67.73 20.0 2.92 2.98 3.04 3.10 3.16
69.43 20.5 3.00 3.07 3.13 3.19 3.25
71.12 21.0 3.09 3.15 3.22 3.28 3.35
72.81 21.5 3.18 3.24 3.31 3.37 3.44
74.51 22.0 3.26 3.33 3.40 3.47 3.53
76.20 22.5 3.35 3.42 3.49 3.56 3.63
77.89 23.0 3.43 3.51 3.58 3.65 3.72
79.59 23.5 3.52 3.59 3.67 3.74 3.81
81.28 24.0 3.61 3.68 3.76 3.83 3.91
82.97 24.5 3.69 3.77 3.85 3.92 4.00
84.67 25.0 3.79 3.86 3.94 4.01 4.09
86.36 25.5 3.86 3.94 4.03 4.11 4.19
88.05 26.0 3.95 4.03 4.11 4.20 4.28
89.75 26.5 4.04 4.12 4.20 4.29 4.37
91.44 27.0 4.12 4.20 4.29 4.38 4.47
93.13 27.5 4.21 4.30 4.38 4.47 4.56
94.83 28.0 4.29 4.38 4.47 4.56 4.65
96.49 28.5 4.38 4.47 4.56 4.65 4.75
98.19 29.0 4.47 4.56 4.65 4.75 4.84
99.88 29.5 4.55 4.65 4.74 4.84 4.93
13
Troubleshooting Charts 2200 YRM 1017
Table 5. Voltage and Pressure Chart (Continued)
ATMOSPHERIC 5-VOLT REFERENCE

PRESSURE 4.80 4.90 5.00 5.10 5.20
kPa inHg MAP SENSOR SIGNAL VOLTAGE
101.57 30.0 4.64 4.74 4.83 4.93 5.03
103.27 30.5 4.72 4.84 4.92 5.02 5.12
104.96 31.0 4.81 4.91 5.01 5.11 5.21
TROUBLESHOOTING CHART DESCRIPTION SUMMARY

Table 6 below provides a descriptive summary of the troubleshooting charts that follow this section.
Table 6. Troubleshooting Chart Description Summary
Chart Malfunction Indicator

Description
Number Lamp Status
A-1 A-1 No Malfunction Indicator Lamp ON
A-2 A-2 No Scan Data, No DTC-12, Malfunction Indicator Lamp ON ON
A-3 A-3 Engine Cranks but Does Not Run OFF
A-4 A-4 Fuel Injector Circuit OFF
A-5 A-5 Fuel Pump Relay Circuit OFF
A-6 A-6 Fuel System Troubleshooting OFF
A-7 A-7 Ignition System Troubleshooting OFF
14
2200 YRM 1017 A-1 No Malfunction Indicator Lamp
A-1 No Malfunction Indicator Lamp

CIRCUIT DESCRIPTION The Electronic Control Module (ECM) will control the
lamp and turn it ON by connecting it to ground through
Malfunction Indicator Lamp (MIL) will be ON when the circuits 420A and 420. See Figure 7.
ignition is ON and engine is not running. Voltage from
the ignition switch is supplied to the light bulb.
Figure 7. No Malfunction Indicator Lamp
DIAGNOSTIC AIDS TEST DESCRIPTION

Check for the following conditions: NOTE: The numbered paragraphs directly correspond
with the numbered steps in Table 7 below.
If the engine runs correctly, check the following:
• Faulty light bulb. 3. This test provides a ground circuit for the MIL circuit.
• Circuits 420A and 420 are open. If the lamp works at this time, external circuits are
• 5-ampere circuit breaker in instrument cluster is bad. correct.
This will cause no dash indicator lights, gauges, or 4. This tests circuits 358A and 112A for voltage.
seat belt reminder in the 3.0L engine. 6. Using a test light connected to Battery +, check
each of the system ground circuits to be sure there
If the engine cranks but will not run: is a good ground.
• ECM Battery + fuse/circuit 358A is open. 7. If a fuse is open, remember to locate any short cir-
• ECM ignition fuse/circuit 112A is open. cuits to ground or other high ampere causes on that
• Poor connections to ECM. circuit.
After repairs, clear DTC’s following Troubleshooting In-
formation, Clearing Diagnostic Trouble Codes (DTCs).
Failure to do so may result in DTC’s not properly being
cleared.
15
A-1 No Malfunction Indicator Lamp 2200 YRM 1017
Table 7. No Malfunction Indicator Lamp (GM 3.0L Engine Only)

1 Was the On-Board Diagnostics (OBD) Go Step 2. Go to On-Board
System Check performed? Diagnostic (OBD)
System Check
2 Turn key switch to ON and start the engine. Go to Step 3. Go to Step 4.
Does the engine start?
3 Perform the following: Go to Step 5 Go to Diagnostic Aids.
• Turn ignition OFF.
• Disconnect ECM connectors.
• Connect test light to ground and circuit
420A at ECM harness connectors.
Is Malfunction Indicator Light on?

4 Perform the following: Go to Step 6. Go to Step 7.
• Turn ignition key switch OFF.
• Disconnect ECM connectors.
• Turn ignition key switch ON.
• Connect test light to ground and circuits
358A and 112A at harness connectors.
Is test light on for all circuits?

5 Check for and repair damaged connections Verify repair.
or replace ECM.
Is action complete?
6 Check for and repair damaged ground Verify repair.
connections or replace ECM.
Is action complete?
7 Repair any circuits that did not energize the Verify repair.
test light.
Is action complete?
16
2200 YRM 1017 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 When SCAN Tool is connected and turned ON, the Mal-
function Light will flash a DTC 12, followed by any trou-
Malfunction Indicator Lamp (MIL) will be ON when igni- ble codes kept in memory. A steady light means a short
tion is ON and engine is not running. Voltage from ig- to ground in the light control circuit 420A, 420, or an
nition switch is supplied to the light bulb. ECM will con- open in circuit 438.
trol the light and turn it ON by connecting it to ground
through circuit 420A to the ECM. See Figure 8.
Figure 8. No Scan Data, No DTC-12, Malfunction Indicator Lamp ON
DIAGNOSTIC AIDS • If DTC 12 does flash, be sure Scan Tool is working

correctly on another lift truck.
Check for the following conditions: • If Scan Tool is working correctly and circuit 439 is
good, the ECM can be the cause for the NO SCAN
After repairs, clear DTCs following Troubleshooting In-
DATA symptom.
4. This step will check for an open diagnostic circuit
Failure to do so may result in DTC’s not properly being
438.
cleared.
5. If the light turns OFF after the ECM connector J2 is
disconnected, then circuit 420A, 420 is not shorted
TEST DESCRIPTION
to ground.
NOTE: The numbered paragraphs directly correspond
If 10 to 12 volts are present between A and B, check
Scan Tool on a known good lift truck. If, when used on
2. If there is a problem with the ECM that causes a a known good lift truck, the Scan Tool does not cause
Scan Tool not to read data from the ECM, the ECM Malfunction Indicator Lamp to flash DTC 12, the Scan
will not flash a DTC 12. Tool is faulty.
17
A-2 No Scan Data, No DTC-12, Malfunction Indicator Lamp ON 2200 YRM 1017
Table 8. No Scan Data, No DTC-12, Malfunction Indicator Lamp ON

1 Did you perform the On-Board Diagnostic Go to Step 2. On-Board Diagnostic
(OBD) System Check? (OBD) System Check.
2 Turn ignition switch to ON. Go to Step 3. Go to A-1 No
Is Malfunction Indicator Light (MIL) ON? Malfunction Indicator
Lamp.
3 Connect Scan Tool to diagnostic connector. Go to Step 6. Go to Step 4.
Does Malfunction Indicator Lamp flash DTC
12?
4 Test the voltage between diagnostic 10-12 Go to Step 5. Go to Step 7.
connector terminals B and A. See Figure 8. Volts
Is voltage within specified limits?
5 1. Turn ignition switch to OFF. Go to Step 8. Go to Step 9.
2. Disconnect ECM connectors.
3. Turn ignition switch to ON, and observe
MIL.
Does MIL come on?

6 Repair open or short in circuit 439. If there is Verify repair.
no open or short in circuit 439, repair faulty
ECM connections or replace faulty ECM.
Is action complete?
7 Repair open or ground circuit 438 or open Verify repair.
ground circuit. If these circuits are correct,
repair faulty ECM connections or replace
faulty ECM.
Is action complete?
8 Repair short to ground on circuit 420A, 420. Verify repair.
Is action complete?
9 Repair faulty ECM connections or replace Verify repair.
faulty ECM.
Is action complete?
18
2200 YRM 1017 A-3 Engine Cranks but Does Not Run
A-3 Engine Cranks but Does Not Run

CIRCUIT DESCRIPTION
Before using this chart, battery condition, engine crank-
ing speed, and fuel quantity must be checked to make
sure they are correct. See Figure 9.
Figure 9. Engine Cranks but Does Not Run
DIAGNOSTIC AIDS Failure to do so may result in DTCs not properly being

cleared.
Check for the following conditions:
TEST DESCRIPTION
Water or foreign material can cause a no-start condition
during freezing weather. The engine can start after ap- NOTE: The numbered paragraphs directly correspond
proximately 5 minutes in a heated shop. with the numbered steps in Table 9 below.
A MAP sensor voltage reading between 0.5 to 3.0 volts 2. A Malfunction Indicator Lamp ON is a test to deter-
can cause a no-start condition. Disconnect the MAP mine if there is battery and ignition voltage at the
sensor. If the engine starts, replace the MAP sensor. ECM.
See MAP Sensor, Replace. 3. If no Scan data is caused by a ECM problem, go to
A-2 No Scan Data, No DTC-12, Malfunction Indica-
If the fuel pump fuse is damaged, test current draw of
tor Lamp ON.
the pump motor located in the fuel tank. If more than 5
4. If throttle position sensor is higher than the range,
to 6 amps, correct the circuit or replace the fuel pump
the ECM can be using the wrong mode for starting.
motor.
5. If throttle position sensor is less than the range, the
After repairs, clear DTCs following Troubleshooting In- ECM can be using the wrong mode for starting.
formation, Clearing Diagnostic Trouble Codes (DTCs). 6. If coolant sensor is not within range, the ECM can
be using the wrong mode for starting.
19
A-3 Engine Cranks but Does Not Run 2200 YRM 1017
10. If rpm was indicated during crank, the ignition mod- 12. Test light will flash, indicating the ECM is controlling
ule is receiving a crank signal; but no spark at this the injector.
test indicates the ignition module is not triggering 13. Fuel spray from the injector indicates that fuel is
the coil. available. However, the engine can be getting too
11. While cranking engine, there must be no fuel spray much fuel. No fuel spray from the injector indicates
with the injector electrical connector disconnected. a fault in the fuel system or no ECM control of the
Replace injector seals if fuel sprays or drips. injector.
Table 9. Engine Cranks but Does Not Run

1 Did you perform the On-Board Diagnostic Go to Step 2. Go to On-Board
(OBD) System Check? Diagnostic (OBD)
System Check.
2 Turn ignition switch to ON, leaving engine Go to Step 3. Go to A-1 No
OFF. Malfunction Indicator
Does Malfunction Indicator Light (MIL) come Lamp.
on?
3 Install SCAN Tool. Go to Step 4. Go to A-2 No Scan
Is data present? Data, No DTC-12,
Lamp ON.
4 Using SCAN Tool, check Throttle Position 0.2 to 2.5 Go to DTC 21 Go to Step 5.
Sensor voltage. Volts Throttle Position
Is voltage above 2.5 volts? (TP) Sensor
Circuit Signal
Voltage High.
5 Using SCAN Tool, check Throttle Position 0.2 to 2.5 Go to DTC 22 Go to Step 6.
Sensor voltage. Volts Throttle Position
Is voltage less than 0.2 volt? (TP) Sensor
Circuit Signal
Voltage Low.
6 Using SCAN Tool, check coolant 30 C Go to Step 7. Go to DTC 15 Engine
temperature. (22 F) Coolant Temperature
Is temperature above specified temperature? (ECT) Sensor Circuit
High Temp Indicated.
7 Using SCAN Tool, check Manifold Absolute 3.0 Volts Go to Step 8. Go to Diagnostic Aids.
Pressure (MAP) voltage.
Is voltage above specified volts?
8 Check fuel pump fuse. Go to Step 9. Replace fuse and go
Is fuse OK? to step 9.
9 1. Turn ignition to OFF for 10 seconds. Go to Step 10. Go to A-4 Fuel Injector
2. Turn ignition to ON and listen for fuel Circuit.
pump to run for about 2 seconds.
Does fuel pump run?
20
2200 YRM 1017 A-3 Engine Cranks but Does Not Run
Table 9. Engine Cranks but Does Not Run (Continued)

10 Crank engine without starting, and check Go to Step 11. Go to A-7
for spark at each spark plug using a spark Ignition System
plug tester. Troubleshooting.
Is there spark at each spark plug?
11 Disconnect injector connectors; crank Go to Step 15. Go to Step 12.
engine; do not start.
Is there fuel spray from injector(s)?
12 1. Connect an injector test light to the har- Go to Step 13. Go to A-4 Fuel Injector
ness connector at the injector. Circuit.
2. Crank the engine.
Does the light flash?

13 1. Reconnect the injector connector. Go to A-6 Go to Step 14.
2. Crank engine; do not start. Fuel System
Troubleshooting.
Does fuel spray from injector?
14 1. Turn ignition OFF. 72 ±3 kPa Go to Step 16. Go to A-6 Fuel System
2. Install fuel pressure gauge. (10.5 Troubleshooting.
3. Turn ignition ON. ±0.5 psi)
Is fuel pressure within limits?

15 Replace damaged injector or injector seals. Verify repair.
Is action complete?
16 Replace injector. Verify repair.
Is action complete?
21
A-4 Fuel Injector Circuit 2200 YRM 1017
A-4 Fuel Injector Circuit

CIRCUIT DESCRIPTION
This troubleshooting chart is used if A-3 Engine Cranks
but Does Not Run indicates a fuel injector problem. If
both fuel injector circuits indicate a problem, test one
circuit at a time. See Figure 10.
Figure 10. Fuel Injector Circuit
TEST DESCRIPTION 435, a reference pulse is normally generated. If the

fuel injector test light, connected to the fuel injector
NOTE: The numbered paragraphs directly correspond circuit, momentarily illuminates, the ECM and wires
with the numbered steps in Table 10 below. are correct.
5. This step checks for 12 volts to the fuel injector.
2. This test will determine if the Ignition Module is gen-
This test will also determine if there is a short circuit
erating a reference pulse and check the wires and
to a voltage source on the ECM side of the circuit.
ECM for a fault. If a 12-volt test light is connected to
7. This test checks for a good circuit to the ECM.
12 volts and then touched and removed from circuit
Table 10. Fuel Injector Circuit

1 During the performance of A-3 Engine Go to Step 3. Go to Step 2.
Cranks but Does Not Run, step 12, the
injector test light should pulse with each
pulse.
Does the test light flash?
22
2200 YRM 1017 A-4 Fuel Injector Circuit
Table 10. Fuel Injector Circuit (Continued)

2 1. Disconnect the four-pin connector from Go to Step 12. Go to Step 5.
the distributor.
2. Connect injector test light to the injector
harness connector.
3. Turn ignition ON, leaving engine OFF.
4. Connect test light to a 12-volt source.
5. Momentarily touch pin C of the ignition
module with the test light probe. The
injector test light that is connected to the
fuel injector circuit will flash each time the
test light probe is removed from pin C of
the ignition module.
Does the injector test light flash?

3 Test for short circuit to ground in circuit Go to Step 10. Go to Step 4.
between injector and ECM.
Is there a short circuit?
4 Check resistance across the fuel injector 1.2 Ohms Go to Step 10. Go to Step 13.
terminals.
Is resistance the value given?
5 Test for open/short in circuit 435. Go to Step 14. Go to Step 6.
Is there a short/open indicated?
6 1. Turn ignition ON, leaving engine OFF. Light turns ON Go to Step 9.
2. Install test light between each injector on one terminal;
wire connection and ground. go to Step 7.
Light turns ON
Does light turn on? on two terminals;
go to Step 8.
7 1. Turn ignition OFF. Go to Step 10. Go to Step 11.
2. Connect fuel harness connector to fuel
injectors.
3. Disconnect J1 (32 pin) connector from
ECM.
5. For the 3.0L engine, connect a test light
between connector terminal J1-26 and
ground.
6. For the 4.3L engine, connect a test light
between connector terminals J1-26 and
ground and J1-11 and ground.
Does test light illuminate?

8 Repair short circuit to voltage in the circuit Verify repair.
between injector and ECM.
Is action complete?
23
A-5 Fuel Pump Relay Circuit 2200 YRM 1017
Table 10. Fuel Injector Circuit (Continued)

9 Repair open circuit between injector and Verify repair.
ignition switch.
Is action complete?
10 Replace ECM. Verify repair.
Is action complete?
11 Repair connection or open circuit between Verify repair.
injector and ECM.
Is action complete?
12 Replace faulty ignition module or replace Verify repair.
4-pin connector.
Is action complete?
13 Replace fuel injector and ECM. Verify repair.
Is action complete?
A-5 Fuel Pump Relay Circuit

CIRCUIT DESCRIPTION If the fuel pump relay or relay ground circuit from the
ECM fails, the fuel pump will receive an electrical cur-
When the ignition is turned ON, the ECM will activate rent through the circuit for the oil pressure switch when
the fuel pump relay with a ground path and run the fuel the engine is running.
pump. The fuel pump relay will operate as long as the
engine is cranking or running if the ECM is receiving The fuel pump test terminal is near the relay in the en-
ignition reference pulses. The ECM will stop the fuel gine compartment. When the engine is stopped, the
pump relay signal 2 seconds after the ignition reference pump can be turned ON by applying battery + to the
pulses stop. This will also occur 2 seconds after the key fuel pump prime terminal.
is ON and the engine not started. See Figure 11.
Figure 11. Fuel Pump Relay Circuit
24
2200 YRM 1017 A-5 Fuel Pump Relay Circuit
DIAGNOSTIC AIDS 1. Test light will connect to ground through relay to the
fuel pump.
A fuel pump relay that does not work can cause long 6. After fuel pump relay has been replaced, continue
cranking times. Extended crank period is caused by the with the Oil Pressure Switch Test, Step 8.
time necessary for oil pressure to reach the pressure 7. If pump does not run, it is either damaged or worn
required to close the oil pressure switch and turn on the and must be replaced.
fuel pump. 8. At this point, fuel pump relay is operating correctly.
Test parallel circuit through the oil pressure switch.
TEST DESCRIPTION 11. If the fuse is damaged, check circuit for excessive
current usage (including fuel pump).
Table 11. Fuel Pump Relay Circuit

1 During the test performance from A-3, Step Go to Step 2. Go to Step 3.
13, the fuel pump does not operate.
1. Turn the ignition to OFF.
2. With the test light connected to battery +,
probe the fuel pump drive connector.
Does the test light come on?

2 1. Turn the ignition to ON. Go to Step 4. Go to Step 5.
2. Test light should go OFF for approxi-
mately 2 seconds.
Does test light turn off?

3 1. Disconnect fuel pump relay harness con- Go to Step 9. Go to Step 10.
nector.
2. With the test light connected to battery +,
probe fuel pump relay harness connector
terminal 30.

nector.
2. With the test light connected to ground,
terminal 87.

nector.
2. With the test light connected to ground,
terminal 86.
25
A-5 Fuel Pump Relay Circuit 2200 YRM 1017
Table 11. Fuel Pump Relay Circuit (Continued)

6 1. With a test light connected to battery +, Go to Step 13. Go to Step 14.
probe relay harness connector 85.
2. Turn ignition to OFF for 10 seconds.
3. Turn ignition to ON.
4. Test light should light for approximately 2
seconds.
Did the test light turn on?

7 Apply battery + to relay pin 30. Go to Step 13. Go to Step 15.
Does fuel pump turn on?
8 Oil pressure switch test: Go to Step 17. Go to Step 16.
1. Run engine at normal temperature and
oil pressure.
2. Disconnect fuel pump relay harness con-
nector from fuel pump relay.
Does engine continue to run?

9 Repair circuit 827 between fuel pump test Verify repair.
terminal and relay or replace damaged relay.
Is action complete?
10 Repair open circuit 826 or 826A or 645 or Verify repair.
damaged connections or replace fuel pump.
Is action complete?
11 Repair open circuit 360A. Verify repair.
Check fuel pump fuse, wiring, and
connections.
Is action complete?
12 Repair open circuit 360B. Verify repair.
Is action complete?
13 Replace pump relay. Go to Step 8.
Is action complete?
14 Repair grounded circuit 651 or replace ECM. Verify repair.
Is action complete?
15 Replace fuel pump. Verify repair.
Is action complete?
16 Check circuits 360C and 826A/826B to Verify repair.
oil pressure switch. If the circuits are OK,
replace oil pressure switch.
Is action complete?
17 No trouble found.
26
2200 YRM 1017 A-6 Fuel System Troubleshooting
A-6 Fuel System Troubleshooting

CIRCUIT DESCRIPTION through the oil pressure switch circuit when engine is
running.
When ignition switch is turned ON, the Electronic Con-
trol Module (ECM) will activate the fuel pump relay with When engine is stopped, the fuel pump can be turned
a ground path and run the fuel pump. Fuel pump relay ON by applying battery + to fuel pump test terminal.
will operate as long as the engine is cranking or run- This terminal is located near the fuel pump relay.
ning if the ECM is receiving ignition reference pulses.
The ECM will stop the fuel pump relay signal 2 seconds The fuel pump delivers fuel to the Throttle Body Injec-
after the ignition references’ pulses stop. This will also tor (TBI) unit where system pressure is controlled to 72
occur 2 seconds after the key is turned ON and the en- ±3 kPa (10 ±0.5 psi). Excess fuel is returned to the fuel
gine is not started. See Figure 12. tank.
If the fuel pump relay or relay ground circuit from the

ECM fails, the fuel pump will receive electrical current
Figure 12. Fuel System
27
A-6 Fuel System Troubleshooting 2200 YRM 1017

Fuel system pressure that is incorrect can cause one of
the following symptoms: 2. Check fuel pressure while pump is running. Pres-
• Cranks but will not start sure will start to drop as soon as pump stops be-
• Starts but will not continue to run cause of an internal relief in the pressure regulator.
• Long cranking times before engine starts 4. If engine does not run, go to A-3 Engine Cranks but
• Rough idle or low idle speed Does Not Run.
• Engine miss, feels like ignition problem 6. This test checks operation of the fuel pump check
• High fuel usage, loss of power, poor performance valve. A check valve that leaks will cause fuel in
pressure line to drain back to the tank and cause
long start times. The amount of pressure is not
important as long as some pressure is maintained.
Table 12. A-6A Fuel System Troubleshooting

System Check.
2 1. Turn the ignition OFF. 72 ±3 kPa Go to Step 4. No fuel pressure, go
2. Check fuel tank quantity. (10.5 to Step 5.
3. Install pressure gauge. See Figure 13. ±0.5 psi)
4. Apply Battery + to the Fuel Pump Primer
using a 10-amp fused jumper wire.
5. Observe fuel pressure.
Is fuel pressure within specifications?

3 1. Turn the ignition OFF. 72 ±3 kPa Go to Table 13.
2. Check fuel tank quantity. (10.5
3. Install pressure gauge. See Figure 13. ±0.5 psi)
4. Apply Battery + to the Fuel Pump Primer
Is fuel pressure outside of specifications?

4 Engine runs. Go to Step 6. System is correct.
Is there a long crank time before starting?
5 Listen for fuel pump running at fuel tank. Go to Step 7. Go to Step 8.
Is fuel pump running?
6 1. Apply Battery + to the Fuel Pump Primer Go to Step 10. Go to Step 9.
2. Disconnect jumper wire and immediately
close the fuel return shutoff valve at the
tank.
Does some pressure hold?
28
Table 12. A-6A Fuel System Troubleshooting (Continued)

7 1. Check the in-line filter. Go to Step 11. Go to Step 13.
2. Check fuel pump strainer.
3. Check fuel feed line.
Are they restricted?

8 1. Disconnect fuel pump relay. Go to Step 14. Go to Step 15.
2. Using a 10-amp fused jumper wire, con-
nect circuit 826 to battery +.
Does fuel pump run?

9 Inspect for partially disconnected pump Go to Step 12. Go to Step 13.
coupling hose.
Is hose disconnected?
10 Problem is not constant, open shutoff valve. Verify repair.
Is action complete?
11 Clean/replace as required. Verify repair.
Is action complete?
12 Reconnect fuel pump coupling hose. Verify repair.
Is action complete?
Is action complete?
14 Repair connection at the relay or if the Verify repair.
connection is OK, replace fuel pump.
Is action complete?
15 Repair open in circuit 826/826A or if circuit Verify repair.
is OK, replace fuel pump.
Is action complete?
29
A-6 Fuel System Troubleshooting 2200 YRM 1017
Figure 13. Fuel System Troubleshooting
TEST DESCRIPTION CAUTION

1. Fuel pressure less than 69 kPa (10 psi) can cause Do not block the fuel return line completely (out-
several problems. It can cause hard starting in cold let side of TBI assembly). Too much pressure
conditions and poor performance. Low fuel pres- can damage the TBI pressure regulator.
sure can also allow engine to run at idle or low
3. This test determines if high fuel pressure is caused
speeds but cause engine to run poorly or stall when
by a restriction in the fuel return line or a problem
more fuel is required (i.e., accelerating or at high
with the pressure regulator.
speed).
4. If pressure is correct at idle, yet becomes lower as
2. Causing a restriction in fuel flow at the tank causes
engine is accelerated, repair restriction in fuel feed
the fuel pump to develop its maximum pressure.
line. If there is no restriction, replace fuel pump.
With fuel pump running, pressure will increase to
5. Wrong fuel pump installed (too much capacity) can
more than 75 kPa (11 psi).
also cause high pressure.
6. Check that shutoff valves are open when finished.
Table 13. A-6B Fuel system Troubleshooting

1 1. Turn the ignition OFF. 69 kPa Go to Step 3. Go to Step 2.
2. Check fuel tank quantity. (10 psi)
3. Install pressure gauge. See Figure 13.
4. Using a 10-amp fused jumper wire, apply
Battery + to the Fuel Pump Primer.
Is fuel pressure less than specifications?
30
Table 13. A-6B Fuel system Troubleshooting (Continued)

2 1. Turn the ignition OFF. 75 kPa Go to Step 4. Go to Step 3.
2. Check fuel tank quantity. (11 psi)
3. Install pressure gauge. See Figure 13.
Battery + to the Fuel Pump Primer.
Is fuel pressure above specifications?

3 Check for restricted fuel filter or restricted Go to Step 7. Go to Step 6.
fuel line between fuel pump and pressure
gauge.
Is there a restriction?
4 1. Disconnect 10-amp fused jumper wire. 69-75 kPa If pressure is If pressure is below
2. Disconnect fuel return line at throttle (10-11 psi) above 75 kPa 69 kPa (10 psi), go
body. (11 psi), go to to Step 10.
3. Install pressure gauge. See Figure 13. Step 5.
4. Attach correct-sized flexible hose to
throttle body outlet fitting. Insert other
end of hose in an approved gasoline
container.
battery + to fuel pump test connector and
observe pressure.
Is pressure above or below specified value?

5 Check for restricted fuel line inside the Go to Step 8. Go to Step 9.
throttle body.
Is there a restriction?
6 1. Turn the ignition OFF. 69-75 kPa If pressure is If pressure is below
2. Install pressure gauge. See Figure 13. (10-11 psi) above 75 kPa 69 kPa (10 psi), go
3. Using a 10-amp fused jumper wire, apply (11 psi), go to to Step 11.
battery + to fuel pump test terminal. Step 9.
4. While observing pressure, gradually
close valve on return fitting at the fuel
tank.
Is pressure above or below specified value?

7 Replace filter or clear restriction and retest. Verify repair.
Is action complete?
8 Clear restricted fuel return inside the throttle Verify repair.
body.
Is action complete?
9 Replace pressure regulator. Verify repair.
Is action complete?
31
A-7 Ignition System Troubleshooting 2200 YRM 1017
Table 13. A-6B Fuel system Troubleshooting (Continued)

10 Clear restriction from fuel tank return line. Verify repair.
Is action complete?
Is action complete?
A-7 Ignition System Troubleshooting

CIRCUIT DESCRIPTION When engine is being started and approximately 400
rpm are sensed, bypass voltage is applied. The EST
When system is running on ignition module, there is no will no longer be grounded in the ignition module, and
voltage on the bypass wire because the ignition mod- EST voltage will normally have a variation during oper-
ule sends the Electronic Spark Timing (EST) signal to ation. See Figure 14.
ground.
Figure 14. Ignition System
DIAGNOSTIC AIDS 3. If spark occurs when EST connector is discon-

nected, output from the sensing coil is too low for
Check wiring harness connectors for tight fit into ECM EST operation.
and loose or broken pins. 4. A spark indicates that the fault is in the distributor
cap or the rotor.
TEST DESCRIPTION 5. The normal voltage at C and + terminals is battery
voltage. A low voltage can indicate:
a. An open circuit or a high resistance circuit from
distributor to ignition coil or
NOTE: If a tachometer has been connected to the b. An open circuit in the primary winding of the
TACH CONN., disconnect it before doing this test. ignition coil.
If voltage at C is less than battery voltage and there
2. Check a minimum of two spark plug wires to make are 10 volts or more at +, there is an open circuit
sure that one spark plug wire does not have an from C to the ignition coil or an open circuit in the
open circuit. primary winding of the ignition coil. See Figure 15.
32
2200 YRM 1017 A-7 Ignition System Troubleshooting
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.
9. EST module normally goes ON when 1.5 to 8 volts
are applied to terminal P. When EST module is ON,
voltage between TACH CONN. and ground will nor-
mally decrease to 7 to 9 volts. This test checks if
the sensing coil or EST module has a fault. When
1.5 to 8 volts are momentarily applied to terminal P,
this voltage acts as a trigger voltage that replaces
Figure 15. Ignition Module voltage from sensing coil. The procedure shows a
6. Use the test light to check for a short circuit in the test light, but any low-voltage, low-current source
EST module or in circuit from the ignition coil to can be used as a trigger voltage.
the EST module. Check for approximately 12 volts 10. When momentary trigger voltage is removed, a
between the TACH CONN. and ground. spark is normally generated through the ignition
If the voltage is low (approximately 1 to 6 volts), coil. If no spark occurs, replace ignition coil. If a
there can be a fault in the ignition coil. This condi- spark occurs, check sensing coil and rotating timer
tion can cause a failure in the ignition coil from too core.
Table 14. Ignition System Troubleshooting

System Check.
2 1. Disconnect tachometer. Go to Step 13. Go to Step 3.
2. Turn ignition switch to ON.
3. Use the starter to rotate the engine; do
not start the engine.
4. Using a spark tester, check for a spark at
the No. 1 spark plug wire. If there is no
spark on the No. 1 wire, check another
wire.
Is spark present?
3 Disconnect the four-terminal ignition module Go to Step 14. Go to Step 4.
connector located on the distributor and
check for spark. See Figure 15.
Is there spark?
4 1. Turn ignition switch to ON, leaving the Go to Step 15. Go to Step 5.
engine OFF.
2. Use the starter to rotate the engine; do
not start the engine.
3. Using a spark tester, check for a spark at
the coil wire.
Is spark present?
33
Table 14. Ignition System Troubleshooting (Continued)

5 1. Turn ignition switch to ON, leaving the If voltage is If voltage is less than 10
engine OFF. greater than 10 volts on both terminals,
2. Disconnect the two-pin connector from volts on both go to Step 16.
the ignition module. See Figure 14. terminals, go to If voltage is less than
3. Using a voltmeter, check the voltage be- Step 6. 10 volts on terminal C
tween ground and C and also + at the only, go to Step 17.
connector. See Figure 15.
Is voltage present?
6 1. Turn ignition switch to OFF. If greater than If less than 1 volt, go
2. Connect the two-pin connector to the ig- 10 volts, go to to step 18.
nition module. See Figure 14. Step 8. If 1 to 10 volts, go
3. Turn ignition switch to ON, leaving the to Step 7.
engine OFF.
4. Using a voltmeter, check the voltage be-
tween ground and Tachometer connec-
tor. See Figure 14.
Is voltage present.
7 Replace the ignition module and check for System is Go to Step 19.
spark from ignition as described in Step 10. correct.
Is there spark?
8 1. Connect a test light between Tach Con- If the test light If the test light blinks,
nector and ground. is steady, go to go to Step 20.
2. Rotate the starter, being careful not to Step 9.
start the engine, and check the test light.
Is the test light on?
34
2200 YRM 1017 A-7 Ignition System Troubleshooting

9 1. Disconnect the four-terminal ignition Go to Step 10. Go to Step 21.
module connector located on the distrib-
utor.
2. Remove the distributor cap and discon-
nect the sensing coil from the ignition
module, which is located under the timer
core.
3. Connect a voltmeter from the TACH Con-
nector to ground.
4. Turn ignition switch to ON, leaving the
engine OFF.
5. Insulate the probe on the test light to
6 mm (0.24 in.) from the tip.
6. Connect the uninsulated probe of the test
light to a 1.5- to 8-volt DC power supply.
7. Check the voltmeter when the insulated
probe of the test light is touched to termi-
nal P of the ignition module.
Is there a voltage decrease?

10 Using a spark tester, check for spark from Go to Step 11. Go to Step 12.
the coil wire when the test light is removed
from terminal P.
Is there spark?
11 Check the rotating timer core to see if it is Go to Step 22. Go to Step 23.
magnetized.
Is the rotating timer core magnetized?
12 Replace the ignition coil and repeat Step 10. System is Go to Step 24.
Is there spark? correct.
13 Check for fuel supply to engine. Check Verify repair.
spark plugs. Check for other faults not in the
ignition system.
Is action complete?
14 Replace sensing coil. Verify repair.
Is action complete?
15 Inspect the distributor cap for water, cracks, Verify repair.
or other damage. If the distributor cap is in
good condition, replace the distributor rotor.
Is action complete?
16 Repair the pink wire from the ignition module Verify repair.
+ terminal to the + terminal on the ignition
coil.
Is action complete?
35

17 Check for open or short circuit in the white Verify repair.
wire from terminal C on the ignition coil. If
the circuit is correct, repair the connector or
replace ignition coil.
Is action complete?
18 Repair the wire or the connector for the Verify repair.
TACH Connector and repeat Step 6.
Is action complete?
19 Replace ignition coil. Verify repair.
Is action complete?
20 Replace ignition coil and check for spark Verify repair.
with the spark tester. If there is no spark,
install original ignition coil and replace
ignition module.
Is action complete?
21 Check the ground connection on the ignition Verify repair.
module. If connection is correct, replace
ignition module.
Is action complete?
22 Check resistance of sensing coil. 500 to System is OK. Go to Step 25.
Is resistance within specified limits? 1500
ohms
23 Replace rotating timer core and shaft. Verify repair.
Is action complete?
24 Install original ignition coil and check wire Verify repair.
from distributor cap. If correct, replace
ignition module.
Is action complete?
25 Replace sensing coil. Verify repair.
Is action complete?
36
2200 YRM 1017 DTC 14 ECT Sensor Circuit - Low Temp Indicated (Scan Diagnostics)
DTC 14 ECT Sensor Circuit - Low Temp Indicated (Scan Diagnostics)

CIRCUIT DESCRIPTION sensor resistance becomes less. See Table 15. At nor-
mal operating temperature [85 to 95 C (185 to 203 F)],
The Engine Coolant Temperature (ECT) sensor uses a the voltage will measure about 1.5-2.0 volts. See Fig-
thermistor to control the signal voltage to the ECM. The ure 16.
ECM applies 5 volts on circuit 430 to the sensor. When
the engine coolant is cold, the sensor (thermistor) re-
sistance is high. As the engine coolant warms up, the
Figure 16. Engine Coolant Temperature (ECT) Sensor Circuit Low Temp Indicated
DIAGNOSTIC AIDS Failure to do so may result in DTC’s not properly being

cleared.
• Poor connection at ECM. Inspect harness connec- Table 15. Engine Coolant Temperature Sensor
tors for backed-out terminals, improper mating, bro-
ken locks, improperly formed or damaged terminals, C F Ohms
and poor terminal-to-wire connection.
100 212 177
• Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK, observe 80 176 332
the ECT display on the SCAN Tool while moving con-
60 140 667
nectors and wiring harnesses related to the ECT sen-
sor. A change in the ECT display will indicate the lo- 45 113 1188
cation of the fault. 35 95 1802
• The SCAN Tool displays engine coolant temperature
in degrees Celsius and Fahrenheit. If the engine 25 77 2796
is cold (not running within 8 hours), the SCAN Tool 15 59 4450
should display a ECT sensor value within a few de-
grees of outside air temperature. This may help in 5 41 7280
diagnosing a "shifted" coolant sensor. After the en- 5 23 12,300
gine is started, the temperature should rise steadily
and then stabilize at operating temperature when the 15 5 21,450
thermostat opens. 30 22 52,700
• If DTC 33 is also set, check for open ground circuit
649/648. 40 40 100,700
After repairs, clear DTC’s following Troubleshooting In-

37
DTC 14 ECT Sensor Circuit - Low Temp Indicated (Scan Diagnostics) 2200 YRM 1017
TEST DESCRIPTION 3. This test simulates a DTC 15. If the ECM recog-
nizes the low-voltage signal and displays a high
NOTE: The numbered paragraphs directly correspond temperature, the ECM and wiring are OK.
with the numbered steps in Table 16.
NOTE: Temperature vs. Resistance Values in the fol-
2. DTC 14 will set if signal voltage indicates a coolant lowing table are approximate.
temperature below 30 C ( 22 F).
Table 16. DTC 14 Engine Coolant Temperature (ECT) Sensor Circuit Low Temp Indicated

1 Was the On-Board Diagnostic (OBD) Go to Step 2. Go to On-Board
System Check Performed? Diagnostic (OBD)
System Check.
2 Turn ignition ON, leaving engine OFF. -30 C Go to Step 3. Go to Step 4.
Does SCAN Tool display a coolant (-22 F)
temperature less than the specified value?
3 1. Turn ignition OFF. 130 C Go to Step 6. Go to Step 5.
2. Disconnect the ECT sensor harness (266 F)
connector.
3. Connect a jumper wire from harness ter-
minal "A" (circuit 649/648) to harness ter-
minal "B" (circuit 430).
Does SCAN Tool display a coolant

temperature above the specified value?
4 DTC 14 is intermittent. Locate and repair Verify repair.
intermittent faulty connections.
• Refer to Diagnostic Aids.
5 Locate and repair open in circuit 430 or Verify repair. Go to Step 7.
circuit 649/648. If a problem is found, repair
as necessary.
Was a problem found?
6 Repair faulty ECT Sensor. Verify repair.
Is action complete?
faulty ECM.
Is action complete?
38
2200 YRM 1017 DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit High Temp Indicated
DTC 15 Engine Coolant Temperature (ECT) Sensor

Circuit High Temp Indicated
CIRCUIT DESCRIPTION sensor resistance becomes less. See engine coolant
temperature sensor table under Diagnostic Aids. At
The Engine Coolant Temperature (ECT) sensor uses a normal operating temperature 80 C (180 F), the volt-
thermistor to control the signal voltage to the ECM. The age will measure about 1.5-2.0 volts. See Figure 17.
ECM applies 5 volts on circuit 430 to the sensor. When
the engine coolant is cold, the sensor (thermistor) re-
sistance is high. As the engine coolant warms up, the
Figure 17. Engine Coolant Temperature (ECT) Sensor Circuit
DIAGNOSTIC AIDS • Check harness routing for a potential short to ground

in circuit 430.
• Poor connection at ECM. Inspect harness connec- After repairs, clear DTCs following Troubleshooting In-
tors for backed-out terminals, improper mating, bro- formation, Clearing Diagnostic Trouble Codes (DTCs).
ken locks, improperly formed or damaged terminals, Failure to do so may result in DTCs not properly being
and poor terminal-to-wire connection. cleared.
• Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK, observe TEST DESCRIPTION
the ECT display on the SCAN Tool while moving con-
nectors and wiring harnesses related to the ECT sen- NOTE: The numbered paragraphs directly correspond
sor. A change in the ECT display will indicate the lo- with the numbered steps in Table 18.
cation of the fault.
2. DTC 15 will set if signal voltage indicates a coolant
• The SCAN Tool displays engine coolant temperature
temperature above 130 C (266 F).
in degrees Celsius and Fahrenheit. If the engine
3. This test simulates a DTC 14. If the ECM recog-
is cold (not running within 8 hours), the SCAN Tool
nizes the high voltage signal and displays a low
should display a ECT sensor value within a few de-
temperature, the ECM and wiring are OK.
grees of outside air temperature. This may help in
diagnosing a "shifted" coolant sensor. After engine is NOTE: Temperature vs. Resistance Values in the fol-
started, the temperature should rise steadily and then lowing table are approximate.
stabilize at operating temperature when the thermo-
stat opens.
39
DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit High Temp Indicated 2200 YRM 1017
Table 17. Engine Coolant Temperature Table 17. Engine Coolant Temperature
Sensor Table Sensor Table (Continued)
C F Ohms
C F Ohms
100 212 177
5 41 7280
80 176 332
-5 23 12,300
60 140 667
-15 5 21,450
45 113 1188
-30 -22 52,700
35 95 1802
-40 -40 100,700
25 77 2796
15 59 4450
Table 18. DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit High Temp Indicated

1 Was the On-Board Diagnostic (OBD) system Go to Step 2. Go to On-Board
check performed? Diagnostic (OBD)
System Check.
2 Turn ignition ON, leaving engine OFF. 130 C Go to Step 3. Go to Step 4.
Does the scan tool display a coolant (266 F)
temperature greater than the specified
value?
3 1. Turn ignition OFF. -30 C Go to Step 6. Go to Step 5.
2. Disconnect ECT sensor harness con- (-22 F)
nector.
Does SCAN Tool display a coolant

temperature below the specified value?
Refer to Diagnostic Aids.
5 Locate and repair short to ground in circuit Verify repair. Go to Step 7.
430. If a problem is found, repair as
necessary.
6 Repair faulty ECT sensor. Verify repair.
Is action complete?
faulty ECM.
Is action complete?
40
2200 YRM 1017 DTC 21 Throttle Position (TP) Sensor Circuit Signal Voltage High
DTC 21 Throttle Position (TP) Sensor Circuit Signal Voltage High

CIRCUIT DESCRIPTION The ECM supplies a 5-volt signal to the sensor through
circuit 432. Circuit 434 is the TP sensor ground circuit.
The Throttle Position (TP) sensor is a potentiometer that The TP sensor will send a voltage signal back to the
provides a voltage signal that changes relative to the ECM, through circuit 433, according to where the throt-
throttle blade. Signal voltage should vary from about tle blades are positioned. See Figure 18.
0.7 volt at idle to about 4.8 volts at Wide Open Throttle
(WOT).
The TP sensor signal is one of the most important in-

puts used by the ECM for fuel control and for IAC con-
trol.
Figure 18. Throttle Position (TP) Sensor Circuit Signal Voltage High
DIAGNOSTIC AIDS After repairs, clear DTCs following Troubleshooting In-

Check for the following conditions: Failure to do so may result in DTCs not properly being
• Poor connection at ECM. Inspect harness connec- cleared.
ken locks, improperly formed or damaged terminals, TEST DESCRIPTION
• Damaged harness. Inspect the wiring harness for NOTE: The numbered paragraphs directly correspond
damage. If the harness appears to be OK, observe with the numbered steps in Table 19 below.
the TP sensor display on the SCAN Tool while mov-
ing connectors and wiring harnesses related to the 2. With the throttle closed, the TP sensor voltage
TP sensor. A change in the TP sensor display will in- should read 0.3-0.9 volt. If it does not, check the
dicate the location of the fault. throttle cable adjustment or for bent or binding
• The SCAN Tool reads throttle position in voltage and linkage.
percentage relative to the throttle blade opening. With 3. This test simulates a DTC 22. If the ECM recog-
ignition ON, engine OFF, throttle blades closed (idle), nizes the low voltage signal, the ECM and wiring
the voltage should be 0.3-0.9 volt. The voltage should are OK.
steadily increase as the throttle is moved toward Wide 4. Using DVOM from harness terminal "A" (circuit
Open Throttle (WOT). 432), harness terminal "B" (circuit 434) checks
• If a TP sensor circuit failure is present, the MAP sen- the sensor ground circuit. A faulty sensor ground
sor default value will be used along with the TP sensor circuit 434 will cause a DTC 21.
default value.
41
DTC 21 Throttle Position (TP) Sensor Circuit Signal Voltage High 2200 YRM 1017
Table 19. DTC 21 Throttle Position (TP) Sensor Circuit Signal Voltage High

System Check.
2 1. Throttle closed. 4 volts Go to Step 3. Go to Step 5.
Does SCAN Tool indicate TP sensor voltage

greater than the specified value?
3 1. Throttle closed. 0.36 volt Go to Step 4. Go to Step 6.
2. Disconnect TP sensor harness connec-
tor.
Does DVOM indicate a voltage less than the

specified value?
4 Connect DVOM from harness terminal A 4 volts Go to Step 8. Go to Step 7.
(circuit 432) to harness terminal B (circuit
434).
Does DVOM indicate a voltage greater than
the specified value?
5 DTC 21 is intermittent. Locate and repair
6 Locate and repair short to voltage in circuit Verify repair. Go to Step 9.
433.
If a problem is found, repair as necessary.
7 Locate and repair open in ground circuit 434. Verify repair. Go to Step 9.
8 Replace faulty TP sensor. Verify repair.
Is action complete?
faulty ECM.
Is action complete?
42
2200 YRM 1017 DTC 22 Throttle Position (TP) Sensor Circuit Signal Voltage Low
DTC 22 Throttle Position (TP) Sensor Circuit Signal Voltage Low

CIRCUIT DESCRIPTION The TP sensor signal is one of the most important in-
puts used by the ECM for fuel control and for IAC con-
The Throttle Position (TP) sensor is a potentiometer that trol.
provides a voltage signal that changes relative to the
throttle blade. Signal voltage should vary from about The ECM supplies a 5-volt signal to the sensor through
0.7 volt at idle to about 4.8 volts at Wide-Open Throttle circuit 432. Circuit 434 is the TP sensor ground circuit.
(WOT). The TP sensor will send a voltage signal back to the
ECM, through circuit 433, according to where the throt-
tle blades are positioned. See Figure 19.
Figure 19. Throttle Position (TP) Sensor Circuit Signal Voltage Low
DIAGNOSTIC AIDS After repairs, clear DTCs following Troubleshooting In-

Check for the following conditions: Failure to do so may result in DTCs not properly being
• Poor connection at ECM. Inspect harness connec- cleared.
ken locks, improperly formed or damaged terminals, TEST DESCRIPTION
• Damaged harness. Inspect the wiring harness for NOTE: The numbered paragraphs directly correspond
damage. If the harness appears to be OK, observe with the numbered steps in Table 20 below.
the TP sensor display on the SCAN Tool while mov-
ing connectors and wiring harnesses related to the 2. With the throttle closed, the TP sensor voltage
TP sensor. A change in the TP sensor display will in- should read 0.3-0.9 volt. If it does not, check
dicate the location of the fault. the throttle cable adjustment or check for bent or
• The SCAN Tool reads throttle position in voltage and binding linkage.
percentage relative to the throttle blade opening. With 3. This test simulates a DTC 21. If the ECM recog-
ignition ON, engine OFF, and throttle blades closed nizes the low-voltage signal, the ECM and wiring
(idle), the voltage should be 0.3-0.9 volt. The voltage are OK.
should steadily increase as the throttle is moved to- 4. This test checks for the 5-volt reference on circuit
ward Wide Open Throttle (WOT). 432.
• If DTC 34 is also set, check for a short to ground in
circuit 432.
• If a TP sensor circuit failure is present, the MAP sen-
sor default value will be used along with the TP sensor
default value.
43
DTC 22 Throttle Position (TP) Sensor Circuit Signal Voltage Low 2200 YRM 1017
Table 20. DTC 22 Throttle Position (TP) Sensor Circuit Signal Voltage Low

System Check.
2 1. Throttle closed. 0.36 volts Go to Step 3. Go to Step 5.

3 1. Turn ignition OFF. 4 volts Go to Step 8. Go to Step 4.
2. Disconnect TP sensor harness connec-
tor.
minal A (circuit 432) to harness terminal
C (circuit 433).

2. Connect DVOM from harness terminal A
(circuit 432) to a known good ground.
Does DVOM indicate a voltage greater than

5 DTC 22 is intermittent. Locate and repair
6 Locate and repair open or short to ground Verify repair. Go to Step 9.
in circuit 432.
7 Locate and repair open or short to ground Verify repair. Go to Step 9.
in circuit 433.
8 Replace faulty TP sensor. Verify repair.
Is action complete?
faulty ECM.
Is action complete?
44
2200 YRM 1017 DTC 31 Engine Governor Circuit
DTC 31 Engine Governor Circuit

CIRCUIT DESCRIPTION by loosening the throttle cable on the 4.3L engine only.
The system is capable of reducing the throttle back to
The ECM sends a controlled signal pulse to the gov- near idle position.
ernor control module (circuit 431) to drive the governor
motor. A DTC 31 will find a damaged ECM, governor module,
motor, linkage, or wiring. If DTC 31 is set, the ECM
Depending on the need of the engine for the governor, will limit engine rpms by momentarily shutting off fuel
the module translates the ECM data into the correct (at slightly higher rpms than governor calibration). See
value of DC current (circuits 825 and 641) to the mo- Figure 20.
tor. This current causes the motor to limit engine speed
Figure 20. Engine Governor Circuit
DIAGNOSTIC AIDS DTC 31 will set if the ECM is commanding near 100%
authority.
• Poor connection at ECM. Inspect harness connec- 2. This check determines if the governor control mod-
tors for backed-out terminals, improper mating, bro- ule has a voltage supply to operate.
ken locks, improperly formed or damaged terminals,
CAUTION
After repairs, clear DTCs following Troubleshooting In- DO NOT hold current to the motor for longer
formation, Clearing Diagnostic Trouble Codes (DTCs). than 30 seconds, as the motor can be damaged.
Failure to do so may result in DTCs not properly being
cleared. 3. Applying Battery + to motor will not let the throttle
plate open.
TEST DESCRIPTION 4. This test requires complete governor control to de-
termine if ECM or governor system has a fault.
NOTE: The numbered paragraphs directly correspond Throttle plate must not open during this test.
45
DTC 31 Engine Governor Circuit 2200 YRM 1017
Table 21. DTC 31 Engine Governor Circuit

System Check.
2 1. Turn ignition ON, leaving engine OFF. Go to Step 3. Go to Step 6.
2. Disconnect governor control module.
3. Using a test lamp connected to a known
good ground, probe harness terminal A.
Is the test lamp illuminated?

3 Connect a test lamp between harness Go to Step 4. Go to Step 7.
connector terminals A and C.
4 1. Using connector test adapter Kit Go to Step 8. Go to Step 5.
#J-356176, install a jumper between
harness terminals E and C.
3. Using a fused jumper, connect terminals
D to A for a maximum of 30 seconds.
4. Depress the accelerator pedal.
Did the throttle plate open?

5 1. Turn the ignition OFF. Go to Step 12. Go to Step 9.
2. Using connector test adapter Kit
#J-356176, install a jumper between
Governor Controller Module and its con-
nector, except terminal B of the wiring
harness.
4. With a test light connected to battery +,
touch test probe to terminal B of the Gov-
ernor Controller Module.
5. Depress the accelerator pedal.
Did the throttle plate open?

6 Repair open in Battery + circuit 112B. Verify repair.
Is action complete?
7 Repair open ground circuit 646. Verify repair.
Is action complete?
8 Test for an open in circuit 825 or circuit 641, Go to Step 13. Go to Step 10.
including plug near governor motor.
Are the circuits and plug OK?
9 Test for an open or grounded circuit 431 or Go to Step 12. Go to Step 11.
damaged terminal.
Are the circuit and terminal OK?
46
2200 YRM 1017 DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage High
Table 21. DTC 31 Engine Governor Circuit (Continued)

10 Repair open in circuit 825 or circuit 641 or Verify repair.
plug near governor motor.
Is action complete?
11 Repair grounded circuit 431 or damaged Verify repair.
terminal.
Is action complete?
12 Replace Electronic Control Module. Verify repair.
Is action complete?
13 Replace governor control module. Verify repair.
Is action complete?
DTC 33 Manifold Absolute Pressure (MAP) Sensor

Circuit Signal Voltage High
CIRCUIT DESCRIPTION The MAP sensor voltage of 5 volts is delivered to the
MAP sensor through circuit 428. Circuit 649 is the
The Manifold Absolute Pressure (MAP) sensor re- ground circuit for the MAP sensor. The MAP signal
sponds to changes in manifold pressure (vacuum). circuit 429 will send a voltage signal back to the ECM
The ECM receives this information as a signal voltage according to what the manifold pressure is. See Fig-
that will vary from about 1.0-1.5 volts at idle to about ure 21.
4.0-4.5 volts at Wide Open Throttle (WOT).
If the MAP sensor fails, the ECM will substitute a default

MAP value that will vary with RPM.
Figure 21. Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage High
47
DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage High 2200 YRM 1017
DIAGNOSTIC AIDS • If a MAP sensor circuit failure is present, the TP sen-

sor default value will be used along with the MAP sen-
Check for the following conditions: sor default value.
• Poor connection at ECM. Inspect harness connec-
tors for backed-out terminals, improper mating, bro- After repairs, clear DTCs following Troubleshooting In-
ken locks, improperly formed or damaged terminals, formation, Clearing Diagnostic Trouble Codes (DTCs).
and poor terminal-to-wire connection. Failure to do so may result in DTCs not properly being
• Damaged Harness. Inspect the wiring harness for cleared.
damage. If the harness appears to be OK, observe
the MAP sensor display on the SCAN Tool while mov- TEST DESCRIPTION
ing connectors and wiring harnesses related to the
MAP sensor. A change in the MAP sensor display NOTE: The numbered paragraphs directly correspond
will indicate the location of the fault. with the numbered steps in Table 22 below.
• If the idle is rough or unstable, refer to symptoms for
2. This step will determine if there is an adequate
items that may cause an unstable idle.
vacuum supply to the MAP sensor. If the vacuum
• With the ignition ON, engine OFF, the manifold pres-
gauge reading is erratic, refer to the rough or un-
sure is equal to atmospheric pressure; and the sig-
stable idle symptom.
nal voltage will be high. This information is used by
4. This step emulates a DTC 34. If the ECM recog-
the ECM as an indication of altitude and is referred to
nizes the low signal voltage and sets a DTC 34, the
as BARO. Comparison of this BARO reading, with a
ECM and wiring are OK.
known good MAP sensor, is a good way to check the
5. This step checks for an open in ground circuit 649.
accuracy of a suspect sensor. Reading should be the
same, plus or minus 0.4 volt.
• If DTC 14 is also set, check for open in ground circuit
649.
Table 22. DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage High

System Check.
2 1. Install a vacuum gauge to a manifold vac- 356 mm Hg Go to Step 3. Go to Step 6.
uum source. (14 inHg)
2. Start the engine and allow engine to idle.
3. The vacuum reading should be steady.
Is the vacuum gauge reading steady and

above the specified value?
3 1. Install a SCAN Tool. 4 volts Go to Step 4. Go to Step 7.
Does SCAN Tool indicate MAP sensor

voltage greater than the specified value?
4 1. Turn ignition OFF. 1 volt Go to Step 5. Go to Step 8.
2. Disconnect MAP sensor harness con-
nector.

voltage less than the specified value?
48
2200 YRM 1017 DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage High
Table 22. DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage High (Continued)

5 1. Turn the ignition OFF. 4 volts Go to Step 10. Go to Step 9.
2. Connect DMM from harness terminal A
(circuit 649) to harness terminal C (circuit
428).
Does DMM indicate a voltage greater than

6 Repair low or unsteady vacuum problem. Verify repair.
Is action complete?
Is action complete?
8 Locate and repair short to voltage in circuit Verify repair. Go to Step 11.
necessary.
9 Locate and repair open in circuit 649. If a Verify repair. Go to Step 11.
problem is found, repair as necessary.
10 Check for plugged or leaking sensor vacuum Verify repair.
fitting. If OK, replace faulty MAP sensor.
Is action complete?
faulty ECM.
Is action complete?
49
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage Low 2200 YRM 1017
DTC 34 Manifold Absolute Pressure (MAP) Sensor

Circuit Signal Voltage Low
CIRCUIT DESCRIPTION If the MAP sensor fails, the ECM will substitute a default
MAP value that will vary with RPM.
The Manifold Absolute Pressure (MAP) sensor re-
sponds to changes in manifold pressure (vacuum). The MAP sensor voltage of 5 volts is delivered to the
The ECM receives this information as a signal voltage MAP sensor through circuit 428. Circuit 649 is the
that will vary from about 1.0-1.5 volts at idle to about ground circuit for the MAP sensor. The MAP signal
4.0-4.5 volts at Wide-Open Throttle (WOT). circuit 429 will send a voltage signal back to the ECM
according to what the manifold pressure is. See Fig-
ure 22.
Figure 22. Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage Low
DIAGNOSTIC AIDS • If a MAP sensor circuit failure is present, the TP sen-

sor default value will be used along with the MAP sen-
Check for the following conditions: sor default value.
• Poor connection at ECM. Inspect harness connec-
tors for backed-out terminals, improper mating, bro- After repairs, clear DTCs following Troubleshooting In-
ken locks, improperly formed or damaged terminals, formation, Clearing Diagnostic Trouble Codes (DTCs).
and poor terminal-to-wire connection. Failure to do so may result in DTCs not properly being
• Damaged Harness. Inspect the wiring harness for cleared.
damage. If the harness appears to be OK, observe
the MAP sensor display on the SCAN Tool while mov- TEST DESCRIPTION
ing connectors and wiring harnesses related to the
MAP sensor. A change in the MAP sensor display NOTE: The numbered paragraphs directly correspond
will indicate the location of the fault. with the numbered steps in Table 23 below.
• If the idle is rough or unstable, refer to symptoms for
2. This step will determine if there is an adequate
items that may cause an unstable idle.
vacuum supply to the MAP sensor. If the vacuum
• With the ignition ON, engine OFF, the manifold pres-
gauge reading is erratic, refer to the rough or un-
sure is equal to atmospheric pressure, and the sig-
stable idle symptom.
nal voltage will be high. This information is used by
3. This step determines if DTC 34 is the result of a
the ECM as an indication of altitude and is referred to
hard failure or an intermittent condition. A DTC will
as BARO. Comparison of this BARO reading, with a
set when MAP signal voltage is too low with engine
known good MAP sensor, is a good way to check the
running.
accuracy of a suspect sensor. Reading should be the
4. This step emulates a DTC 33. If the ECM recog-
same, plus or minus 0.4 volt.
nizes the high signal voltage, the ECM and wiring
are OK.
50
2200 YRM 1017 DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage Low
5. This step checks for 5-volt reference on circuit 428.
Table 23. DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage Low

System Check.
2 1. Turn the ignition OFF. 356 mm Hg Go to Step 3. Go to Step 6.
2. Install a vacuum gauge to a manifold vac- (14 inHg)
uum source.
3. Start the engine and raise to about 1000
RPM in neutral.
4. The vacuum reading should be steady.
Is the vacuum gauge reading steady and

above the specified value?
3 1. Install a SCAN Tool. 1 volt Go to Step 4. Go to Step 7.

voltage less than the specified value?
2. Disconnect MAP sensor harness con-
nector.
minal B (circuit 429) to harness terminal
C (circuit 428).

voltage greater than the specified value?
5 1. Turn the ignition OFF. 4 volts Go to Step 9. Go to Step 8.
2. Connect DMM from harness terminal C
(circuit 428) to a known good ground.
Does DMM indicate a voltage greater than

6 Repair low or unsteady vacuum problem. Verify repair.
Is action complete?
Is action complete?
51
DTC 41 Electronic Spark Timing (EST) - Open EST Circuit 2200 YRM 1017
Table 23. DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Voltage Low (Continued)

8 Locate and repair open or short to ground in Verify repair. Go to Step 11.
circuit 428. If a problem is found, repair as
necessary.
9 Locate and repair open or short in circuit Verify repair. Go to Step 11.
necessary.
10 Check for plugged or leaking sensor vacuum Verify repair.
fitting. If OK, replace faulty MAP sensor.
Is action complete?
faulty ECM.
Is action complete?
DTC 41 Electronic Spark Timing (EST) - Open EST Circuit

CIRCUIT DESCRIPTION When the engine is being started and approximately
400 rpm are sensed, bypass voltage is applied. The
A DTC 41 is indicated if there is an open circuit in the EST will no longer be grounded in the ignition module,
Electronic Spark Timing Signal (EST). and EST voltage will normally have a variation during
operation.
When the system is running on the ignition module,
there is no voltage on the bypass wire because the ig- If the bypass wire is open or grounded, the ignition mod-
nition module sends the Electronic Spark Timing Signal ule will not change to EST mode; and a Code 42 will be
(EST) to ground. If the ECM senses a voltage on the indicated.
EST wire, a Code 41 will be set and the electronic con-
trol system will not go into the EST mode of operation. 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 23.
Figure 23. Electronic Spark Timing (EST) Open EST Circuit
52
2200 YRM 1017 DTC 41 Electronic Spark Timing (EST) - Open EST Circuit

• Poor connection at ECM. Inspect harness connec- with the numbered steps in Table 24 below.
ken locks, improperly formed or damaged terminals, 2. A code 41 is indicated if there is an open circuit
and poor terminal-to-wire connection. in the Electronic Timing Signal (EST). This test
checks that the Code 41 is a real fault.
After repairs, clear DTCs following Troubleshooting In- 3. This test checks that the ground path through the
formation, Clearing Diagnostic Trouble Codes (DTCs). ignition module is correct. A short circuit in circuit
Failure to do so may result in DTCs not properly being 436 to ground will also indicate less than 500 ohms,
cleared. and a code 42 will be indicated.
Table 24. DTC 41 Electronic Spark Timing (EST) - Open EST Circuit

System Check.
2 1. Clear Codes from ECM. Go to Trou- Go to Step 3. Code 41 is not constant
bleshooting Information, Clearing Diag- or not regular. If
nostic Trouble Codes (DTCs). additional codes
2. Start engine and run at idle speed at are not stored, go
least 1 minute. to Troubleshooting,
Poor Operation.
Is Code 41 present?
3 1. Turn ignition switch to OFF. Go to Step 4. Go to Step 5.
2. Disconnect connectors at ECM.
3. Turn ignition switch to ON.
4. Set ohmmeter selection switch to 1,000-
to 2,000-ohm range.
5. Check resistance between ground and
circuit 436 at the ECM connector.
Is resistance less than 1500 ohms?

4 1. Clear codes from ECM. Go to Trou- Go to Step 6. Code 41 is not constant
bleshooting Information, Clearing Diag- or not regular. If
nostic Trouble Codes (DTCs). additional codes
2. Connect the ECM. are not stored, go
3. Start engine and run at idle for at least 1 to Troubleshooting,
minute. Poor Operation.
Is Code 41 present?
5 Locate and repair open in circuit 436, or Verify repair.
replace faulty ignition module if no open in
circuit 436 is found.
Is action complete?
6 Replace faulty ECM. Verify repair.
Is action complete?
53
DTC 42 EST - Grounded EST Circuit, Open or Grounded Bypass Circuit 2200 YRM 1017
DTC 42 EST - Grounded EST Circuit, Open or Grounded

Bypass Circuit
CIRCUIT DESCRIPTION EST will no longer be grounded in the ignition module,
and EST voltage will normally have a variation during
A DTC 42 is indicated if there is a grounded circuit in operation.
the Electronic Spark Timing Signal (EST) or open or
grounded bypass circuit. If the bypass wire is open or grounded, the ignition mod-
ule will not change to EST mode; and a Code 42 will be
When the system is running on the ignition module, indicated.
there is no voltage on the bypass wire because the ig-
nition module sends the Electronic Spark Timing Signal If the EST wire has a short circuit to ground, there will
(EST) to ground. If the ECM senses a voltage on the not be an EST signal; and a Code 42 will be indicated.
EST wire, a Code 41 will be set and the electronic con- See Figure 24.
trol system will not go into the EST mode of operation.
When the engine is being started and approximately

400 rpm are sensed, bypass voltage is applied. The
Figure 24. Electronic Spark Timing (EST) Grounded EST Circuit, Open or Grounded Bypass Circuit
DIAGNOSTIC AIDS 3. When TEST LIGHT voltage touches circuit 437,

the module correctly causes the ohmmeter to over-
After repairs, clear DTCs following Troubleshooting In- range if the ohmmeter is in the 1000-ohm position
formation, Clearing Diagnostic Trouble Codes (DTCs). to the 2000-ohm position.
Failure to do so may result in DTCs not properly being When the selector switch on the ohmmeter is
cleared. changed to the 10,000- to 20,000-ohms position,
the ohmmeter correctly indicates more than 5000
TEST DESCRIPTION ohms. The important part of this test is to check if
the module makes the switch.
4. If the module did not make the switch in step above,
this step makes the following checks:
2. Code 42 is indicated if there is a grounded circuit in a. Circuit 436 has a short circuit to ground.
the electronic spark timing signal (EST) or open or b. Bypass circuit 437 is open.
grounded bypass circuit. This test checks that the c. Ignition module has a fault or bad connection.
Code 42 is a real fault.
54
2200 YRM 1017 DTC 42 EST - Grounded EST Circuit, Open or Grounded Bypass Circuit
Table 25. DTC 42 Electronic Spark Timing (EST) - Grounded EST Circuit, Open or Grounded Bypass Circuit

System Check.
2 1. Clear codes from the ECM. Go to Diag- Go to Step 3. Code 42 is not constant
nostic Aids. or regular. If no other
2. Start engine and run at idle speed for at codes are stored, go
least 1 minute and check for Code 42. to Troubleshooting,
Poor Operation.
Does Code 42 appear?
3 Connect a test light between battery voltage Go to Step 4. Go to Step 7.
and circuit 437 at the ECM connector.
Is the light off?
4 1. Connect an ohmmeter between ground Go to Step 6. Go to Step 5.
and circuit 436 at the ECM cable connec-
tor.
2. Connect a test light between battery volt-
age and circuit 437 at the ECM cable
connector.
3. When the test light probe touches circuit
437, the resistance will correctly make
a switch from less than 1,000 ohms to
greater than 2,000 ohms.
Does resistance change?

5 With the ohmmeter still connected between Go to Step 8. Go to Step 9.
ground and circuit 436 at the ECM connector,
disconnect the four-way connector at the
ignition module.
Does resistance go high (open circuit)?
6 1. Connect the ECM connector to the ECM. Go to Step 10. Code 42 is not constant
2. Start the engine and run at idle for at or regular. If no other
least 1 minute and check for Code 42. codes are stored, go
to Troubleshooting,
Is Code 42 present? Poor Operation.
7 Disconnect the four-way connector at the Go to Step 11. Go to Step 12.
ignition module.
Is the light off?
8 Locate and repair open in circuit 437 or Verify repair.
replace faulty ignition module if open in
circuit 437 is not found.
Is action complete?
55
DTC 51 Calibration Checksum Failure 2200 YRM 1017
Table 25. DTC 42 Electronic Spark Timing (EST) - Grounded EST Circuit, Open or
Grounded Bypass Circuit (Continued)

9 Locate and repair short between circuit 436 Verify repair.
and ground.
Is action complete?
10 Replace faulty ECM. Verify repair.
Is action complete?
11 Locate and repair short in circuit 437 to Verify repair.
ground.
Is action complete?
12 Replace faulty ignition module. Verify repair.
Is action complete?
DTC 51 Calibration Checksum Failure

CIRCUIT DESCRIPTION
This test allows the ECM to check for a calibration failure
by comparing the calibration value to a known value
stored in the EEPROM.
This test is also used as a security measure to prevent

improper use of calibration or changes to these calibra-
tions that may alter the designed function of MEFI. See
Figure 25.
DIAGNOSTIC AIDS
If DTC 51 failed more than once, but is intermittent, re-
place the ECM.
TEST DESCRIPTION
with the numbered steps in Table 26. Figure 25. Electronic Control Module
2. This step checks to see if the fault is present during

diagnosis. If present, the ECM is not functioning
properly and must be replaced or reprogrammed.
56
2200 YRM 1017 DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open
Table 26. DTC 51 Calibration Checksum Failure

System Check.
2 1. Install Diagnostic Trouble Code (DTC) Go to Step 3. Refer to Diagnostic
tool. Aids.
2. Using Clear DTC Procedure, Clear DTC
51.
4. Switch DTC tool to "service mode," or
ON.
Does DTC 51 reset?

3 Replace or reprogram faulty ECM and verify Verify repair.
DTC does not reset.
Is action complete?
DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open

CIRCUIT DESCRIPTION commands the relay OFF, the voltage should be high,
near battery voltage. If the fault detection circuit senses
The Engine Control Module (ECM) controls the relay a voltage other than what the ECM expects, the fault line
by grounding the control circuit via an internal switch status changes, causing the DTC to set.
called a driver. The primary function of the driver is to
supply the ground for the controlled component. This The relay controls the high current flow to the fuel pump.
driver has a fault line that the ECM monitors. When This allows the ECM driver only to have to control the
the ECM commands the relay ON, the voltage of the relatively low current used by the relay. See Figure 26.
control circuit should be low, near 0 volt. When the ECM
Figure 26. Fuel Pump Relay Driver Circuit
57
DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open 2200 YRM 1017
DIAGNOSTIC AIDS 2. Listen for an audible click when the relay operates.
Command both the ON and OFF states. Repeat
Check for the following conditions: the commands if necessary.
• Poor connection in harness. Inspect harness connec- 3. This test can detect a partially shorted coil, which
tors for backed-out terminals, improper mating, bro- would cause an excessive current flow. Leaving
ken locks, improperly formed or damaged terminals, the circuit energized for 2 minutes allows the coil
and poor terminal-to-wire connection. to warm up. When warm, the coil may open, and
the current drops to 0; or the coil may short, and
After repairs, clear DTCs following Troubleshooting In-
the current goes above 0.75 amp.
5. Identify and test the relay coil terminals in order to
avoid improper diagnosis.
cleared.
TEST DESCRIPTION
Table 27. DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open

System Check.
2 1. Turn the ignition ON, leaving the engine Go to Step 3. Go to Step 5.
OFF.
2. Using the SCAN Tool, command the re-
lay ON and OFF.
Does the relay turn ON and OFF when

commanded?
3 1. Turn the ignition to OFF. 0.75 A Go to Diagnostic Go to Step 4.
2. Disconnect the ECM connector J1. Aids.
3. Install a 5-amp fused jumper wire from a
known good ground to the control circuit
at the ECM harness connector J1-6.
4. Turn the ignition ON, leaving the engine
OFF.
Important: Replace the relay if the DMM
goes to 0 during the current draw test.
5. Using a DMM on the 40 amp scale, mea-
sure the current from the relay control cir-
cuit in the harness to ground for 2 min-
utes.
Does the current draw measure less than

58
2200 YRM 1017 DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open
Table 27. DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open (Continued)

4 1. Turn the ignition to OFF. Go to Step 12. Go to Step 10.
2. Disconnect the fuel pump relay connec-
tor.
3. Using a DMM, measure the resistance
from the relay control circuit in the ECM
harness connector to ground.
Does the DMM display infinite resistance or

OL?
2. Disconnect the fuel pump relay connec-
tor.
3. Connect a test lamp between the fuel
pump relay control circuit and the fuel
pump relay ignition feed circuit, on the
coil side of the relay, at the fuel pump
relay harness connector.
OFF.
5. Using a SCAN Tool, command the relay
ON and OFF.
Does the lamp turn ON and OFF when

commanded?
6 Using a test lamp connected to ground, Go to Step 7. Go to Step 11.
probe the ignition feed circuit on the coil side
of the fuel pump relay harness connector.
7 1. Turn the ignition OFF. Go to Step 9. Go to Step 10.
2. Reconnect the relay.
3. Disconnect ECM connector J2.
OFF.
5. Using a fused jumper wire connected
to ground, momentarily probe the relay
control circuit in the ECM harness con-
nector.
Does the relay turn ON when the circuit

is grounded and OFF when the circuit is
opened?
8 Locate and repair faulty connections at the Verify repair. Go to Step 12.
relay.
9 Locate and repair faulty connections at the Verify repair. Go to Step 13.
ECM.
59
DTC 81 5-Volt Reference Circuit Out of Range 2200 YRM 1017
Table 27. DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open (Continued)

10 Repair the faulty relay control circuit. Verify repair.
Is action complete?
11 Repair the faulty relay ignition feed circuit. Verify repair.
Is action complete?
12 Replace the faulty relay. Verify repair.
Is action complete?
13 Replace the ECM. Verify repair.
Is action complete?
DTC 81 5-Volt Reference Circuit Out of Range

CIRCUIT DESCRIPTION (MAP) sensor and the Throttle Position (TP) sensor.
The ECM monitors the voltage on the 5-volt reference
The Engine Control Module (ECM) uses a common circuit. This DTC sets if the voltage is out of range.
5-volt reference circuit as a sensor feed. This circuit See Figure 27.
supplies 5 volts to the Manifold Absolute Pressure
Figure 27. Fuel Pump Relay Driver Circuit

• Poor connection in harness. Inspect harness connec- with the numbered steps in Table 28 below.
ken locks, improperly formed or damaged terminals, 3. The 5-volt reference circuit may be shorted to an-
and poor terminal-to-wire connection. other ECM circuit. The shorted circuit may not be
apparent when the ECM harness connector is dis-
After repairs, clear DTCs following Troubleshooting In- connected.
cleared.
60
2200 YRM 1017 DTC 81 5-Volt Reference Circuit Out of Range
Table 28. DTC 81 5 Volt Reference Circuit Out of Range

System Check.
2 1. Disconnect the ECM harness connector 5.1 V Go to Step 6. Go to Step 3.
J2.
3. Using DMM connected to a known good
ground, probe the other lead of the DMM
to the 5-volt reference circuit (J2-2) at the
ECM harness connector.
Does the circuit measure more than the

specified value?
3 Before proceeding, remove the following 0-2 ohms Go to Step 7. Go to Step 9.
fuses:
• ECM/BAT
• INJ/ECM
• MEFI System Relay
1. Disconnect the MAP sensor and the TP
sensor harness connectors.
2. Using a DMM, test the continuity from the
5-volt reference circuit to all other ECM
circuits at the ECM J2 harness connec-
tor.
Do any of the circuits indicate a resistance

within the specified range?
2. Disconnect ECM connector J2.
3. Using a test lamp connected to B+, probe
5-volt reference circuit (J2-2) at the ECM
harness connector.
Does test lamp illuminate?

5 Using a DMM, test the continuity from the 0-2 ohms Go to Step 7. Go to Step 9.
5-volt reference circuit to all other ECM
circuits at the ECM J2 harness connector.
Do any circuits indicate a resistance within
the specified range?
6 Locate and repair a short to voltage on the 5 Verify repair.
volt reference circuit.
Is action complete?
7 Locate and repair short between the 5 volt Verify repair.
reference circuit and the ECM circuit that
had continuity.
Is action complete?
61
DTC 81 FPRSENSE Circuit Fault 2200 YRM 1017
Table 28. DTC 81 5 Volt Reference Circuit Out of Range (Continued)

8 Locate and repair short to ground on the 5 Verify repair.
volt reference circuit.
Is action complete?
Is the action complete?
DTC 81 FPRSENSE Circuit Fault

CIRCUIT DESCRIPTION then the FPRSENSE should be near 0 volt. An inter-
nal counter increments or decrements based on the re-
When running the diagnostic for the fuel pump relay sults of the diagnostics. Each time the diagnostics fails,
sense circuit, the ECM first checks for ignition voltage the counter is incremented. Each time the diagnostics
to be greater than 7.0 volts. It then checks to see if the passes, the counter is decremented. When the counter
ECM is commanding the fuel pump to be ON. If the fuel reaches a calibrated amount, a DTC 81 is set. If the
pump is commanded ON, the FPRSENSE should be counter reaches 0, then an active DTC 81 is cleared.
ignition voltage. It the fuel pump is commanded OFF, See Figure 28.
Figure 28. Fuel Pump Relay Sense Circuit
DIAGNOSTIC AIDS Failure to do so may result in DTCs not properly being

cleared.
• Poor connection in harness. Inspect harness connec- TEST DESCRIPTION
ken locks, improperly formed or damaged terminals, NOTE: The numbered paragraphs directly correspond
and poor terminal-to-wire connection. with the numbered steps in Table 29 below.
After repairs, clear DTCs following Troubleshooting In- 2. This test checks for a short to ground on the fuel
formation, Clearing Diagnostic Trouble Codes (DTCs). pump relay circuit.
62
2200 YRM 1017 Troubleshooting, Poor Operation
Table 29. DTC 81 FPRSENSE Circuit Fault

System Check.
2 1. Install a SCAN Tool. Go to Step 3. Problem may be
2. Clear diagnostic trouble codes. intermittent.
3. Run the engine for 5 minutes or until a Go to Diagnostic Aids.
DTC is set.
4. Check for DTCs.
Is DTC 81 (FPRSENSE Circuit Fault)

present?
3 Turn ignition ON, leaving engine OFF. Go to Step 5. Go to Step 4.
Does the fuel pump continue to run longer
than the calibrated "prime" time?
4 Check the FPRSENSE circuit for a short to Verify repair. Go to Step 7.
ground or a short to voltage. If a problem is
found, repair as necessary.
5 Check for shorted contacts within the relay. Verify repair. Go to Step 6.
6 Repair the short to ground in circuit 651. Verify repair.
Is action complete?
7 Inspect for poor connection at the ECM. If a Verify repair. Go to Step 8.
problem is found, repair as necessary.
Is the action complete?
Troubleshooting, Poor Operation

NOTE: Before using the following information, make under described problem. If starter will crank engine
sure you have done the On-Board Diagnostic (OBD) but engine will not start, see A-3 Engine Cranks but
System Check and found that: Does Not Run.
1. The ECM and Malfunction Indicator Lamp are op- MAKE A CAREFUL VISUAL CHECK
erating correctly.
This check is very important because some problems
2. There are no Diagnostic Trouble Codes (DTC) or can be corrected without doing a fault analysis. Check
there is a DTC but no Malfunction Indicator Lamp. the following items:
• Ground connections for the ECM are clean, tight, and
GENERAL in their proper location
• Vacuum hoses for correct connections or damaged
Make sure you have done the On-Board Diagnostic
hoses
(OBD) System Check before this Troubleshooting sec-
• Vacuum leaks at the mount for the TBI and the intake
tion is used. Make sure problem is correctly described.
manifold
Check indicated items in this Troubleshooting section
63
Troubleshooting, Poor Operation 2200 YRM 1017
• Condition of the ignition wires for cracks, bad connec- Additional Checks
tions, and indications of electric arcs
• Wires and connectors for damage and bad connec- If problem has not been found, see System Test Charts.
tions
FAULT: ENGINE IS DIFFICULT TO START
FAULT: CODES OR PERFORMANCE THAT
Definition: The starter cranks the engine correctly, but
IS ABNORMAL the engine is difficult to start; or the engine stops imme-
diately after it starts.
NOTE: DO NOT use the Diagnostic Trouble Code
(DTC) charts for problems that are not constant. Fault Check:
must be present to locate problem. If a fault is not
constant, use of DTC charts can cause replacement of Make a CAREFUL VISUAL CHECK as described in
good parts. Make a Careful Visual Check. Make sure the opera-
tor is using the correct starting procedure.
Definition: A problem that does not cause Malfunction
Indicator Lamp (MIL) to illuminate and a code is not kept SENSORS
in the ECM. • Engine Coolant Temperature (ECT) sensor. Using a
SCAN Tool, compare coolant temperature with ambi-
Check: ent temperature when engine is cold. If coolant tem-
• Wires and connectors for damage and bad connec- perature reading is 5 degrees greater than or less
tions. than ambient air temperature on a cold engine, check
• Operation of lift truck with a SCAN Tool connected. resistance at the ECT sensor circuit or sensor itself.
SCAN Tool will normally indicate a trouble code. Compare ECT resistance value to charts in DTC 14
• Electrical noise caused by a relay, solenoid, or switch. and DTC 15.
This problem will occur when faulty component is op- • MAP sensor.
erated. • Throttle Position (TP) sensor for binding or a high TP
• Installation of lights, radios, or other electrical acces- voltage with throttle closed (will read between 0.33 to
sory equipment. 1.33 volts).
• Sensor wires are not too close to high voltage igni-
tion system wires. Wire for circuit 650 from ECM to FUEL SYSTEM
Ignition Control Module (ICM) must be a good con- • Fuel pump relay operation - pump must turn ON for
nection. 2 seconds when ignition is turned ON. Use A-5 Fuel
• Ignition secondary has a short to ground. Pump Relay Circuit.
• Circuit 420A Malfunction Indicator Lamp or circuit 438 • Fuel pressure, use A-6 Fuel System Troubleshooting.
(diagnostic test terminal) has a short circuit to ground. • Dirty fuel.
• Injector driver circuit. Disconnect injector harness
FAULT: LOSS OF DIAGNOSTIC TROUBLE connector at injector. Connect a 12-volt test light be-
CODE (DTC) MEMORY tween harness terminals of injector connector and
check light while cranking. If test light fails to blink,
To check, disconnect Throttle Position (TP) sensor and it is a bad injector circuit harness, connector, or ter-
run engine at idle speed until Malfunction Indicator minal.
Lamp comes ON. DTC 21 will be kept in memory when • Injector resistance. Measure resistance of injector.
ignition is turned OFF for at least 10 seconds. If not, Nominal resistance of injector is 1.6 ohms or greater
the ECM is bad. at 20 C (68 F). Resistance will increase at higher
temperatures.
DTCs will be erased after 50 starts if they do not reoc- • A bad check valve for fuel pump will allow fuel in
cur. lines to drain back to the tank after engine is stopped.
To check for this condition, perform A-6 Fuel System
FAULT: ENGINE QUITS WHILE DRIVING Troubleshooting.
Check for a failure of the injector driver in ECM. If injec-
IGNITION SYSTEM
tor driver fails, replace the ECM.
• Correct ignition voltage output with spark tester.
• Spark plugs: dirty, cracks, wear, wrong gap, burned
electrodes, and correct heat ranges.
• Wires or cables are damaged or shorted.
64
• Connections at Ignition Module are loose. FAULT: DECREASED ENGINE POWER

• Bad ECM or ignition grounds.
• Engine misses or quits under load or at idle. See Definition: Engine delivers less than expected power.
System Test Charts. Little or no increase in speed when accelerator pedal is
• Circuit 436 (Electronic Spark Timing) shorted to pushed down part way.
ground.
Check:
• Idle Air Control (IAC) operation.
Make a CAREFUL VISUAL CHECK as described in
FAULT: VARIATION IN ENGINE POWER Make a Careful Visual Check.
WHEN THROTTLE IS HELD STEADY • Remove air filter and check for dirt or other restric-
tions. Replace as necessary.
Definition: Engine power variation under steady throt- • ECM grounds are clean, tight, and in their correct lo-
tle feels like vehicle speeds up and slows down with no cations. See Wiring section for ECM wiring diagrams.
change in accelerator pedal position. • Alternator output voltage. Repair if less than 9 or
Check: more than 16 volts.
• Exhaust system for restriction or damage.
Make a CAREFUL VISUAL CHECK as described in
Make a Careful Visual Check. ENGINE
• ECM grounds are clean, tight, and in their proper lo- • Engine valve timing and compression.
cation. • Engine for correct or worn camshaft.
• Vacuum lines for restrictions or leaks. • Leaky valve seals.
• Alternator output voltage. Repair if less than 9 or • Excessive carbon buildup in combustion chambers.
more than 16 volts. IGNITION SYSTEM
• Governor cables. • For correct operation of Electronic Spark Timing
SENSORS (EST).
• Manifold Absolute Pressure (MAP) sensor. MAP sen- • Secondary voltage circuit.
sor must change quickly at different throttle positions. FUEL SYSTEM
Check MAP sensor vacuum line for restrictions. The • Restriction in fuel filter.
ECM will respond to any MAP signal and can change • Dirty fuel.
amount of fuel sent to engine, causing operating prob- • Fuel pressure, use A-6 Fuel System Troubleshooting.
lems. Also, use System Test Charts to test MAP sen- • Low fuel pressure after a cold start or during accel-
sor. eration. If fuel pressure drops below 62 kPa (9 psi),
IGNITION SYSTEM there can be a bad fuel pump or restriction in fuel sys-
• For correct ignition voltage output using spark tester. tem.
• Spark plugs. Remove spark plugs, check for wet GOVERNOR SYSTEM
plugs, cracks, wear, wrong gap, burned or dirty elec- • Throttle adjustment.
trodes, insulators, and correct heat range. Repair or • Governor motor.
replace as necessary.
• Check spark plug cables. FAULT: DETONATION/SPARK KNOCK
FUEL SYSTEM Definition: Engine makes sharp metallic knocking
sounds that change when throttle position is changed.
To check if condition is caused by a rich or lean sys-
This condition is normally worse during acceleration.
tem, test vehicle under same conditions that symptom
Air and fuel mixture is exploding in the cylinder instead
occurs as described by the customer.
of burning evenly.
• Fuel pressure while condition exists. Use A-6 Fuel
System Troubleshooting. Check:
• In-line fuel filter. Replace if dirty.
• Fuel injector. Make a CAREFUL VISUAL CHECK as described in
• Poor fuel quality. Make a Careful Visual Check.
65
Troubleshooting, Poor Operation 2200 YRM 1017
If SCAN Tool readings are normal (see On-Board Di- • MAP sensor output.
agnostic (OBD) System Check) and there are no en-
gine mechanical faults, fill fuel tank with a good grade IGNITION SYSTEM
of gasoline that has a minimum octane rating of 87 and • Spark plugs. Remove spark plugs, check for wet
check vehicle performance. plugs, cracks, wear, wrong gap, burned or dirty elec-
trodes, insulators, and correct heat range. Repair or
IGNITION SYSTEM replace as necessary.
• Spark plugs for correct heat range. • Ignition system connection, circuit 650.
ENGINE FUEL SYSTEM

• For oil in combustion chamber caused by leaky valve • Fuel pressure, use A-6 Fuel System Troubleshooting.
oil seals. • Dirty fuel.
• Combustion chambers for excessive carbon buildup. • Low fuel pressure after a cold start or during accel-
Remove carbon with top engine cleaner using instruc- eration. If fuel pressure drops below 62 kPa (9 psi),
tions on the can. there can be a bad fuel pump or restriction in fuel sys-
• Low cylinder pressure by doing a compression test. tem.
• Basic engine parts such as cam, head, pistons that
are not correct or are worn. GOVERNOR SYSTEM
• Throttle cables.
COOLING SYSTEM • Governor motor.
• Problems from engine running too hot:
– Low engine coolant level. FAULT: ONE OR MORE CYLINDERS DO
– Loose water pump belt. NOT OPERATE CORRECTLY - ENGINE
– Restriction in airflow to radiator, or restriction in wa- DOES NOT IDLE CORRECTLY
ter flow through radiator.
– Incorrect coolant mixture. Definition: Operation of one cylinder is not regular and
problem increases when engine load increases. Prob-
FUEL SYSTEM lem normally does not occur above 1500 rpm. En-
To check if the condition is caused by a rich or lean sys- gine has a rough idle or has noticeable variation at idle
tem, test the vehicle under same conditions that symp- speed.
tom occurs as described by the customer. Make a CAREFUL VISUAL CHECK as described in
• Fuel pressure while condition exists. Use A-6 Fuel Make a Careful Visual Check.
System Troubleshooting.
IGNITION SYSTEM
FAULT: ENGINE MOMENTARILY DOES • Start engine, let engine become steady, then discon-
NOT INCREASE POWER WHEN THROTTLE nect Idle Air Control (IAC) motor. Remove one spark
CHANGES plug cable at a time, using pliers with insulation. Be
sure to connect the cable that was removed to ground
Definition: Engine momentarily does not increase while testing.
power when throttle is opened further. Engine can stop • If there is a decrease in rpm on all cylinders (equal
when throttle is opened rapidly from idle. to within 50 rpm), go to FAULT: Rough Idle or Engine
Stalls During Idle. Connect IAC valve.
Make a CAREFUL VISUAL CHECK as described in • If there is no decrease in rpm on one or more cylin-
Make a Careful Visual Check. ders, check for spark on cylinder(s) using an oscillo-
scope or spark tester. Check one spark plug cable at
Check:
a time. If no spark, see System Test Charts. If there is
• Engine thermostat operates correctly and at the cor-
a spark, remove spark plug(s) in these cylinders and
rect heat range.
check for:
• Alternator output voltage. Repair if less than 9 or
• Cracks in the insulator, wrong gap, burned elec-
more than 16 volts.
trodes, or wear.
SENSORS • Spark plug cables by connecting ohmmeter to ends
• Throttle Position (TP) sensor. Check TP sensor for of each cable in question. If meter reads over 30,000
correct operation. Voltage will increase evenly as ohms, replace cable(s).
throttle is moved toward Wide-Open Throttle (WOT).
66
ADDITIONAL CHECKS ENGINE

• Do a cylinder compression check. See GM Engine
An engine that misses can be caused by Electromag- 3.0L 600 YRM 1020 or GM Engines 4.3L V6 600
netic Inference (EMI) on the reference circuit. EMI can YRM 590
be found by monitoring engine rpm with a SCAN Tool. • For correct camshaft or weak valve springs.
A sudden increase in rpm with little change in actual
engine rpm change indicates EMI is present. If prob- OTHER CHECKS
lem exists, check routing of secondary wires and check • MAP sensor output.
ground circuit. • Throttle linkage for smooth operation.
• IAC operation.
ENGINE • PCV valve for correct operation.
• Do a cylinder compression check. If compression is • Check motor mounts.
low, repair as necessary.
• Remove rocker cover. Check for bent push rods, worn FAULT: FUEL USAGE TOO HIGH
rocker arms, broken valve springs, worn camshaft
lobes, and valve timing. Repair as necessary. Definition: Fuel use is higher than expected or has in-
• Check intake and exhaust manifold passage for re- creased during later operation; make a CAREFUL VI-
strictions. SUAL CHECK as described in Make a Careful Visual
Check.
FUEL SYSTEM
• Low fuel pressure. Use A-6 Fuel System Trou- Check:
bleshooting. • Vacuum hoses for damage, restriction, or correct con-
• Dirty fuel. nections.
• Dirty fuel filter. • Check operator’s methods of operation. Are tires at
correct pressure? Are loads more than capacity?
FAULT: ROUGH IDLE OR ENGINE STALLS • Check air filter for dirt or other restriction.
DURING IDLE • Check for fuel leaks.
Definition: Engine has a rough idle speed or has a IGNITION SYSTEM

large variation in idle speed. Engine stops running dur- • Spark plugs. Remove spark plugs, check for wet or
ing idle. dirty plugs, cracks, wear, correct heat range, wrong
gap, damaged electrodes, or insulators. Replace as
Make a CAREFUL VISUAL CHECK as described in necessary.
Make a Careful Visual Check.
COOLING SYSTEM
Check:
• For vacuum leaks. ENGINE
• ECM ground connections are clean and secure. See • Compression. See GM Engine 3.0L 600 YRM 1020
ECM wiring diagrams. or GM Engines 4.3L V6 600 YRM 590
• For broken engine mounts.
OTHER CHECKS
• Alternator output voltage. Repair if less than 9 or
• For exhaust system restriction.
more than 16 volts.
• Air intake system and crankcase for air leaks.
IGNITION SYSTEM • Excessive mechanical drag.
• For correct ignition voltage output using spark tester
or equivalent. FAULT: DIESELING
• Spark plugs. Remove spark plugs, check for wet or
Definition: Engine continues to run after ignition switch
dirty plugs, cracks, wear, wrong gap, damaged elec-
is turned OFF but runs very roughly. If engine runs
trodes, or insulators. Replace as necessary.
smoothly, check ignition switch.
• Spark plug wires by connecting an ohmmeter to ends
of each cable in question. If meter reads over 30,000 Make a CAREFUL VISUAL CHECK as described in
ohms, replace cable(s). Make a Careful Visual Check.
Check:
• Fuel injector and TBI for fuel leaks. Use A-6 Fuel
System Troubleshooting.
67
System Test Charts 2200 YRM 1017
• Check ECM grounds. • Spark plug wires for damage and correct installation.
Inspect ignition coil assembly.
FAULT: BACKFIRE • Do fuel system tests. Use A-6 Fuel System Trou-
bleshooting.
Definition: Fuel explodes in intake manifold or in ex-
haust system, making loud noise. ENGINE
• Compression - Look for valves that stick or leak.
Make a CAREFUL VISUAL CHECK as described in • Valve timing. See GM Engine 3.0L 600 YRM 1020
Make a Careful Visual Check. or GM Engines 4.3L V6 600 YRM 590
• Intake and exhaust manifold passages for restric-
Check:
tions.
IGNITION SYSTEM • Check the crankcase ventilation valve for proper op-
• Correct output from ignition coil with spark tester. eration. place a finger over the inlet hole in the valve
• Spark plugs. Remove spark plugs, check for wet or end several times. The valve should snap back. If
dirty plugs, cracks, wear, wrong gap, damaged elec- not, replace the valve.
trodes, or insulators. Replace as necessary. Also,
check spark plug wires.
System Test Charts

GENERAL Table 30. ECT Sensor - Temperature vs. Resistance
This part of the section has the following: C F Ohms

• Components tests
• Circuit tests 100 212 177
• Function tests and adjustments 90 194 214
For location of components, complete engine electronic 80 176 332
wiring diagrams, and ECM wiring harness connector
70 158 467
terminal end views, see Wiring in this section.
60 140 667
ENGINE COOLANT TEMPERATURE (ECT) 50 122 943
SENSOR TEST
45 113 1188
The ECT, using the following procedure, can be tested 40 104 1459
at different temperatures. A volt/ohmmeter, a ther-
mometer, engine coolant, and something to heat the 35 95 1802
coolant will be needed for the test. 30 86 2238
• Heat coolant to one of the temperatures shown in Ta-
ble 30. 25 77 2796
• Position ECT sensor (sensing end) into heated 20 68 3520
coolant.
• Wait about 60 seconds to allow coolant to heat sen- 15 59 4450
sor. 10 50 4670
• Test sensor resistance and compare reading to those
in Table 30. 5 41 7280
• Sensors with a reading within 10% of specifications 0 32 9420
shown in Table 30 can be used.
5 23 12,300
10 14 16,180
15 5 21,450
20 4 28,680
68
2200 YRM 1017 System Test Charts
Table 30. ECT Sensor - Temperature vs. If minimum idle speed is too low, lift truck can be hard
Resistance (Continued) to start in cold weather or can cause a stall during idle.
1. Put a block on both sides of the drive tires and apply

C F Ohms parking brake.
30 22 52,700
2. Put transmission in NEUTRAL. Start and run en-
40 40 100,700 gine until it reaches normal operating temperature.
3. Turn ignition key OFF.

THROTTLE POSITION (TP) SENSOR
CHECK 4. Connect a SCAN Tool to Diagnostic Connector.
Using a SCAN Tool, watch the TP sensor percent and 5. Turn ignition key to ON position.
voltage. The reading will increase evenly as throttle
plate is opened. See Figure 29. The reading must not
be lower than previous reading as throttle plate opens
up. A reading that goes lower or higher then lower as
plate is opened indicates a damaged sensor that must
be replaced. See Figure 30.
Figure 30. Damaged TP Sensor Reading
6. Select Field Service Mode on the SCAN Tool. This

will cause IAC valve pintle to extend, closing the
air passage in the throttle body. Wait 45 seconds,
disconnect IAC valve connector, then exit Field Ser-
Figure 29. Good TP Sensor Reading vice Mode.
7. Start and run engine. It may be necessary to hold

MINIMUM IDLE SPEED throttle open slightly to run engine.
Minimum idle speed (minimum air setting) should only 8. Select Engine RPM on the SCAN Tool, and read
be set when installing a replacement throttle body. engine speed.
The idle stop screw is used to hold minimum idle speed NOTE:
of engine. On original equipment throttle bodies, it is • Engine must be at normal operating temperature.
adjusted at the factory, then covered with a plug. • All accessories must be OFF.
• Make sure throttle and governor cables do not hold
Adjustment throttle open.
NOTE: The minimum idle speed adjustment is impor- • Correct idle speed for engines that have more than 10
tant for correct system operation. A minimum idle speed hours’ operating time is 800 ±25 rpm (GML 4-3.0L) or
that is set too high can cause IAC valve pintle to touch 650 rpm (GM V-6 4.3L).
the bottom of its seat constantly, leading to valve failure.
9. Remove plug as shown in Figure 31. Adjust mini-
mum idle speed only if necessary.
69
B-1 - Idle Air Control (IAC) System Check 2200 YRM 1017
10. Turn ignition switch OFF.
11. Connect IAC valve electrical connector.
12. Reset IAC valve pintle position:
a. Start and run engine over 2000 rpm.
b. Select Field Service Mode.
c. Run engine at 2000 rpm for approximately 10

seconds.
d. Exit Field Service Mode.
e. Allow engine to return to idle.
f. Turn ignition switch OFF.
g. Wait 10 seconds, start engine, let idle.

1. PLUG 2. IDLE STOP SCREW
h. Check for correct idle. (IAC at 5-40 Counts.)
Figure 31. Minimum Idle Speed Adjustment
i. Disconnect SCAN Tool.
j. Remove blocks from drive tires.
B-1 - Idle Air Control (IAC) System Check

CIRCUIT DESCRIPTION pintle extends toward its seat, reducing bypass airflow.
A SCAN Tool will read the ECM commands to the IAC
The ECM controls engine idle speed with the IAC valve. valve in counts. Higher counts indicate more air bypass
To increase idle speed, the ECM retracts the IAC valve (higher idle). Lower counts indicate less air is allowed
pintle away from its seat, allowing more air to bypass to bypass (lower idle). See Figure 32 and Table 31.
the throttle bore. To decrease idle speed, IAC valve
Figure 32. Chart B-1 - Idle Air Control (IAC) System Check
70
2200 YRM 1017 B-1 - Idle Air Control (IAC) System Check
DIAGNOSTIC AIDS • System Too Lean (High Air/Fuel Ratio) - Idle speed
can be too high or too low. Engine speed can vary
• A slow, unstable, or fast idle speed can be caused by up and down and disconnecting IAC valve does not
a problem other than the IAC system. Out-of-control help. Check for low fuel pressure, water in fuel, or a
range IAC SCAN Tool counts will be above 50 if idle dirty injector.
is too high, and zero counts if idle is too low. Make • System Too Rich (Low Air/Fuel Ratio) - Idle speed
the following checks to identify a problem that is not will be too low. SCAN Tool IAC counts will usually be
in the IAC system: above 50. System is rich and can cause black smoke
• Vacuum Leak (High Idle) - If idle is too high, stop en- in exhaust. Check for high fuel pressure or an injector
gine. Fully extend (low) IAC with tester. Start engine. that leaks or sticks.
If idle speed is above 800 RPM, fix vacuum leak, in- • Throttle Body - Remove IAC valve and inspect bore
cluding PCV system. Also, check for smooth move- for dirt.
ment of throttle plate and linkage. • See Troubleshooting, Poor Operation.
• PCV Valve - If a high idle condition exists (900 to 1000 • If problems are fixed by disconnecting the IAC, care-
RPM), check for vacuum leaks and correct PCV valve fully check connections and IAC valve terminal resis-
operation. A missing PCV valve or grommet or a valve tance, or replace IAC.
that sticks can cause this condition.
Table 31. Idle Air Control (IAC) System Check

System Check.
2 1. Install SCAN Tool. 40 to 80 Go to Step 3. Go to Step 4.
2. Apply parking brake. ohms
3. Run engine to normal operating temper-
ature.
4. Turn ignition OFF.
NOTE: Ignition must be OFF for at least

10 seconds continuing.
5. Disconnect the IAC connector.

6. Check resistance between IAC terminals
A to B and C to D.
Is resistance within specified limits?

3 Check resistance between IAC terminals B Go to Diagnostic Go to Step 4.
and C and A and D. Aids.
Was resistance infinite?
4 Replace IAC Valve. Verify repair.
Is action complete?
71
B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test 2200 YRM 1017
B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test

CIRCUIT DESCRIPTION voltage, the ECM knows manifold pressure. A lower
pressure (low voltage) output voltage will be about 1
The Manifold Absolute Pressure (MAP) sensor mea- to 2 volts at idle while higher pressure (high voltage)
sures the changes in the intake manifold pressure that output voltage will be about 4 to 4.8 at Wide-Open
come from engine load (intake manifold vacuum) and Throttle (WOT). The MAP sensor is also used, under
rpm changes. See Figure 33. The MAP sensor con- certain conditions, to measure barometric pressure
verts these changes into a voltage output. The ECM (BARO), allowing the ECM to make adjustments for
sends a 5-volt reference voltage to the MAP sensor. As altitude changes. The ECM uses the MAP sensor to
the manifold pressure changes, the output voltage of control fuel delivery and ignition timing.
the sensor also changes. By monitoring sensor output
Figure 33. Manifold Absolute Pressure (MAP) Sensor Output
TEST DESCRIPTION
The numbers below directly correspond to the numbers
in Table 33.
2. Using a SCAN Tool, take MAP sensor voltage read-

ing of a known good vehicle. When comparing
SCAN readings to a known good vehicle, it is im-
portant to compare vehicles that use a MAP sensor
having the same number. See Figure 34.
3. Apply 34 kPa (10 inHg) vacuum to the MAP sensor
to cause voltage readings of 1.5 to 2.1 volts less
than voltage reading gathered from known good
vehicle in Step 2. When applying vacuum to sen-
sor, change in voltage must be quick. Slow voltage
change indicates a bad sensor.
4. Check vacuum source to sensor for leaking or re-
striction. Be sure that no other vacuum devices are
connected to the MAP vacuum source.
Figure 34. Map Sensor
72
2200 YRM 1017 B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test
NOTE: Make sure the electrical connector remains Table 32. Altitude Voltage Chart (Continued)
securely fastened.
5. Remove sensor from intake manifold and twist sen- Range

Altitude (Feet) Voltage (Volts)
sor, by hand only, to check for intermittent connec- (Meters)
tion. Output changes greater than 0.10 volt indicate 1219 to 1524 4,000 to 5,000 3.2 to 4.8
a bad sensor or connection. If bad, replace sensor.
1524 to 1829 5,000 to 6,000 3.0 to 4.6
Table 32. Altitude Voltage Chart 1829 to 2133 6,000 to 7,000 2.9 to 4.5
Range 2133 to 2438 7,000 to 8,000 2.8 to 4.3
Altitude (Feet) Voltage (Volts)
(Meters) 2438 to 2743 8,000 to 9,000 2.6 to 4.2
Below 305 Below 1,000 3.8 to 5.5 2743 to 3048 9,000 to 10,000 2.5 to 4.0
305 to 610 1,000 to 2,000 3.6 to 5.3 Low Altitude = High Pressure = High Voltage
610 to 914 2,000 to 3,000 3.5 to 5.1
914 to 1219 3,000 to 4,000 3.3 to 5.0
Table 33. Manifold Absolute Pressure (MAP) Sensor Output Test

System Check.
2 1. Turn ignition ON, Leaving engine OFF. Go to Step 3. Go to Step 4.
2. Install Scan Tool. Scan Tool should indi-
cate a MAP sensor voltage.
3. Compare this reading with the reading of
a known good vehicle. Voltage reading
should be within +0.4 Volts. (If another
vehicle is not available see Table 32).
Is voltage within specified limits?

3 1. Disconnect vacuum source to MAP sen- Go to Step 6. Go to Step 5.
sor and plug end of hose.
2. Connect a hand vacuum pump to MAP
sensor
3. Note MAP sensor voltage shown on
SCAN Tool.
4. Apply 34 kPa (10 inHg) of vacuum and
note voltage change.
5. Subtract the two readings. The value
should be grater than 1.5 volts.
Is voltage greater than 1.5 volts?

4 Check vacuum hose for collapsed condition. Very repair.
If collapsed, replace MAP sensor.
Is action complete?
73
B-3 - Check Governor System 2200 YRM 1017
Table 33. Manifold Absolute Pressure (MAP) Sensor Output Test (Continued)

5 Check MAP sensor connector. If the Verify repair.
connector is damaged, replace MAP sensor.
Is action complete?
6 No trouble found. Check sensor vacuum Verify repair.
source for leakage or restriction. This
source supplies vacuum to the MAP
sensor only.
Is action complete?
B-3 - Check Governor System

GOVERNOR SYSTEM NOT OPERATING 2. Accelerate engine to wide open throttle (WOT).
CORRECTLY
3. Observe engine speed.
A governor system that does not operate correctly can
4. Did engine accelerate smoothly and to the normal
cause any of the following:
limit?
• Engine rpm more than limit of governor
• Engine power variation (surge) If system appears to function incorrectly, compare RPM
• Engine backfire readings from a SCAN Tool with readings from a sec-
• Low engine power ondary tachometer attached to a spark plug wire. They
• No acceleration (low engine rpm) must be very close or the same.
CHECK FUNCTION OF GOVERNOR If they are different, check for Electromagnetic Inference
SYSTEM (EMI). Inspect for spark plug wires too close to the dis-
tributor primary wires or charging system wires.
Normal testing for governor will include the following
(see Figure 35): If readings are close or the same, see chart for DTC 31
for more testing. It is possible that the system will not
1. Start engine, keep transmission in NEUTRAL. set DTC 31. In this case the DTC 31 chart can be used.
Figure 35. Chart B-3 Check Governor System
74
2200 YRM 1017 Fuel System Components Repair
CHECK PCV SYSTEM With the PCV system, crank case fumes are sent into
the air filter and into the engine intake manifold.
CAUTION
An engine that is operated without any crankcase
ventilation can be damaged. Therefore, it is impor-
tant to replace the PCV valve at intervals shown in
the Periodic Maintenance section.
A restriction in PCV valve or hose can cause:

• Rough idle, slow idle speed, oil leaks, or oil in the air
cleaner.
A PCV valve or hose that leaks can cause:

• Rough idle, high idle speed, or engine stalls.
1. CHECK VALVE NEEDLE
If engine has a rough idle, check for a restriction in PCV
valve or hose. See Figure 36. Replace parts as de- Figure 36. PCV Valve
scribed in PCV System Repair.
Fuel System Components Repair

GENERAL – Cover for fuel meter body
– Ball bearings
WARNING – Governor assembly
To reduce the risk of fire and personal injury, relieve
the fuel system pressure before servicing fuel sys-
FUEL PRESSURE RELIEF PROCEDURE
tem components. 1. Disconnect negative battery terminal to avoid fuel
leakage if an accidental attempt is made to start
After relieving system pressure, a small amount of
engine.
fuel may be released when servicing fuel lines or
connections. To reduce the chance of personal in- 2. The internal relief in TBI unit relieves fuel pump
jury, cover fuel line fittings with a shop towel before pressure when engine is OFF. Therefore, no addi-
disconnecting to catch any fuel that may leak out. tional pressure relief procedure is required.
Place towel in an approved container when discon-
nect is completed. FUEL PUMP REPLACEMENT
NOTE: The following is general information to be used
when working on fuel system: WARNING
To reduce the risk of fire and personal injury, do not
• Always use new O-rings on fuel line fittings. operate the fuel pump outside of the fuel tank. The
• All steel tubing on fuel system must be replaced with pump can make sparks and cause an explosion.
original equipment parts.
• All fuel hoses must be replaced with original equip- 1. Disconnect negative cable at battery.
ment parts.
• Do not replace any steel fuel tubing with fuel hose. 2. Disconnect fuel lines at access plate on fuel tank.
Do not replace any steel fuel tubing with copper or Disconnect wiring harness from TBI.
aluminum tubing. 3. Remove capscrews holding access plate to fuel
• Some parts of Throttle Body Injector (TBI) can be tank. Remove access plate, fuel pump, and send-
cleaned in a cleaner such as Yale Carburetor Cleaner ing unit, if attached. See Figure 37.
or its equivalent. DO NOT clean the following parts:
– Throttle Position Sensor (TPS) 4. Inspect fittings and fuel lines that are inside fuel
– IAC valve tank for damage. Inspect screen for damage.
– Fuel injectors
75
Fuel System Components Repair 2200 YRM 1017
5. Install fuel pump and fittings on access plate. Install

float assembly.
6. Use a new seal ring and install access plate on tank.

Tighten capscrews for access plate.
7. Connect fuel lines to fittings. Connect wire connec-

tors.
1. DAY OF YEAR 4. SHIFT

2. YEAR IDENTIFICATION
1. SHUTOFF VALVE 3. ASSEMBLY PLANT 5. SOURCE CODE
2. ELECTRICAL CODE
TERMINAL
3. SENDER UNIT Figure 38. TBI Identification 3.0L Engine
4. PLATE
6. Disconnect fuel pressure and fuel return lines at
Figure 37. Fuel Pump Arrangement TBI. Hold fittings in TBI to keep them from turning
when fuel lines are disconnected.
THROTTLE BODY INJECTION UNIT (TBI)
Remove WARNING
NOTE: See Parts Manual for repair kits for components the fuel system pressure before servicing fuel sys-
of the Throttle Body Injection (TBI) unit. To make sure tem components.
the replacement part has the correct part number, ver-
ify the actual part. See Figure 38. The TBI is made of After relieving system pressure, a small amount of
many separate components. See Figure 39 and Fig- fuel may be released when servicing fuel lines or
ure 40. The TBI can be replaced as a complete unit, connections. To reduce the chance of personal in-
or parts of the TBI can be replaced while the TBI is injury, cover fuel line fittings with a shop towel before
stalled on engine. Replacement of individual compo- disconnecting to catch any fuel that may leak out.
nents is described in the following procedures. Place towel in an approved container when discon-
nect is completed.
1. Disconnect negative cable at battery.
7. Remove fasteners that hold TBI to manifold. Re-
2. Disconnect and remove parts that connect TBI to move TBI. Cover opening in manifold to prevent dirt
air filter. from entering engine.
3. Disconnect wires to IAC valve, TPS, governor mo- Clean and Inspect
tor, and fuel injector. Remove wiring harness grom-
met for fuel injector. See the cleaning instructions in the NOTE under Gen-
eral at the beginning of this section. Clean gasket from
4. Disconnect throttle cable at throttle crank. manifold and TBI. Be careful to prevent damaging ma-
5. Disconnect vacuum hoses. chined surfaces and check all machined surfaces for
damage. Check manifold for loose parts.
76
Install 3. Disconnect electrical connector at fuel injector. Re-

move grommet and wires from body. See Figure 39
1. Use a new gasket and install TBI on manifold. and Figure 40.
Tighten fasteners for TBI to 25 N•m (18 lbf ft).
2. Use new O-rings and washers on fuel lines. Con- WARNING

nect fuel pressure and fuel return lines. Tighten fuel To reduce the risk of fire and personal injury, relieve
line nuts to 27 N•m (20 lbf ft). the fuel system pressure before servicing fuel sys-
tem components.
3. Connect vacuum hoses.
4. Connect throttle cable at throttle cam. Check ad- fuel may be released when servicing fuel lines or
justment of throttle cables as described in Governor connections. To reduce the chance of personal in-
System 3.0L Engine Repair and Governor System jury, cover fuel line fittings with a shop towel before
4.3L Engine Repair. disconnecting to catch any fuel that may leak out.
5. Install wiring harness grommet for fuel injector. Place towel in an approved container when discon-
Connect wires to IAC valve, TPS, and fuel injector. nect is completed.
6. Connect negative cable at battery. 4. Disconnect fuel lines at fuel meter body. Hold fit-
tings in fuel meter body to keep them from turning
7. Turn key switch ON (do not start the engine) and when fuel lines are disconnected.
check for fuel leaks.
5. For 4.3L engine, remove fuel line fitting from inlet
8. Use a new gasket and connect air filter to TBI. port in fuel meter body.
9. Set position of pintle valve of IAC as follows: 6. Remove screws that hold fuel meter body to throttle
body.
a. Depress throttle pedal a small amount.
a. For 3.0L engine, remove fasteners that hold TBI
b. Start and run engine for 3 seconds. to manifold.
c. Turn key switch OFF for 10 seconds. b. For 4.3L engine, remove fuel meter body and
gasket.
d. Start engine and check for correct idle opera-
tion.
WARNING
FUEL METER BODY Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning sol-
Remove vents, always follow the recommendations of the
manufacturer.
7. Clean gasket surfaces on fuel meter body and throt-
2. Disconnect and remove parts that connect air filter tle body with cleaning solvent.
to TBI.
77
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 39. Throttle Body Injection (TBI) Unit for 3.0 Liter Engine
78
Figure 40. Assembly View of Throttle Body Injection (TBI) Unit for 4.3 Liter Engine
79
Legend for Figure 40

1. FUEL INJECTOR 7. INLET FUEL FITTING
2. FUEL PRESSURE REGULATOR 8. FUEL RETURN FITTING
3. THROTTLE POSITION SENSOR 9. GASKET (TBI TO MANIFOLD)
4. IDLE AIR CONTROL VALVE 10. O-RING
5. GOVERNOR MOTOR AND THROTTLE DRIVE 11. GASKET
ASSEMBLY 12. FUEL METER BODY
6. VACUUM PORTS
Install
1. Use new gasket and install fuel meter body on throt-
tle body. See Figure 39 and Figure 40.
2. Use thread-locking adhesive (Loctite® 262) on

screws for fuel meter body. Install screws and
tighten them to 4.0 N•m (35 lbf in).
3. Use a new gasket and install TBI on manifold.

Tighten fasteners for TBI to 25 N•m (18 lbf ft).
4. Use new gasket and install fuel line fittings. Tighten 1. FUEL INJECTOR (TOP VIEW)
fittings to 40 N•m (30 lbf ft). 2. PART NUMBER
3. MONTH, 1 TO 9 (JAN. TO SEPT.)
5. Use new O-rings and washers on fuel lines. Con- O, N, D (OCT., NOV., DEC.)
nect fuel pressure and fuel return lines. Tighten fuel 4. DAY
5. YEAR
line fittings to 27 N•m (238 lbf in). 6. BUILD DATE CODE
7. • = INDICATES HIGH DYNAMIC RANGE
6. Install wiring harness grommet for fuel injectors.
Connect wires at fuel injector. Figure 41. Fuel Injector Identification
7. Connect negative cable at battery. Turn key switch 3. Disconnect electrical connector at fuel injector.
to START position. (Do not start engine.) Ignition
On function will cycle the fuel pump for a few sec- 4. Remove screws and retainer for fuel injector.
onds, pressurizing the fuel system. Visually inspect
fuel system (fittings, fuel pump, and fuel lines) for WARNING
leaks.
8. Use new gasket and connect air filter to TBI. the fuel system pressure before servicing fuel sys-
tem components.
FUEL INJECTOR
Remove
connections. To reduce the chance of personal in-
NOTE: The fuel injector must be replaced as a complete jury, cover fuel line fittings with a shop towel before
unit. To make sure the replacement part has the correct disconnecting to catch any fuel that may leak out.
part number, see Figure 41. Place towel in an approved container when discon-
nect is completed.
5. To remove fuel injector, use a screwdriver as shown
2. Disconnect and remove parts that connect air filter in Figure 42. Remove and discard O-rings on fuel
to TBI. injector.
80
2. Install fuel injector into bore of fuel meter body.

Push fuel injector until it is against its seat. Turn
fuel injector so that electrical connector is toward
notch.
3. Use thread-locking adhesive (Loctite 262) on

screws for retainer. Install retainer and screws.
Tighten screws to 3.0 N•m (27 lbf in).
4. Connect negative cable at battery. Turn key switch

to START position. (Do not start engine.) Ignition
1. FUEL INJECTOR 3. FULCRUM On function will cycle the fuel pump for a few sec-
2. SCREWDRIVER 4. FUEL METER onds, pressurizing the fuel system. Visually inspect
BODY
fuel system (fittings, fuel pump, and fuel lines) for
Figure 42. Fuel Injector Removal leaks.
Install 5. Use a new gasket and connect air filter to TBI.
1. Lubricate new O-rings with engine oil. See Fig- PRESSURE REGULATOR
ure 43. Install lower (small) O-ring so that it is
against fuel filter. Install upper (large) O-ring on fuel Remove
injector.
2. Disconnect and remove parts that connect air filter

to TBI. See Figure 44.
WARNING
the fuel system pressure before servicing fuel sys-
tem components.

connections. To reduce the chance of personal in-
jury, cover fuel line fittings with a shop towel before
disconnecting to catch any fuel that may leak out.
Place towel in an approved container when discon-
nect is completed.
3. Hold pressure regulator to compress spring. Re-

move screws holding pressure regulator to fuel me-
ter body. Remove pressure regulator assembly.
Remove diaphragm.
Inspect
Inspect valve seat in fuel meter body for damage. Re-
place fuel meter body if there is any damage.
1. FUEL INJECTOR 5. SCREW
2. UPPER O-RING 6. COVER/RETAINER Install
3. LOWER O-RING 7. FUEL VAPOR
4. FUEL METER BLOCK
1. Install a new diaphragm. See Figure 44. Make sure
BODY
diaphragm fits in groove of fuel meter body.
Figure 43. Fuel Injector Installation (4.3L Engine
Shown)
81
1. COVER 4. SPRING
2. SCREW 5. DIAPHRAGM
3. SPRING SEAT 6. FUEL METER
BODY
1. THROTTLE BODY ASSEMBLY
Figure 44. Pressure Regulator 2. THROTTLE POSITION SENSOR
3. SCREW
2. Install seat for spring and spring in cover, then in- 4. THROTTLE SHAFT
stall cover. Use thread-locking adhesive (Loctite
262) on screws for cover. Install screws and tighten Figure 45. Throttle Position Sensor (TPS)
to 2.4 N•m (21 lbf in).
IDLE AIR CONTROL (IAC) VALVE
3. Connect negative cable at battery. Turn key switch
to START position. (Do not start engine.) Ignition Remove
On function will cycle the fuel pump for a few sec-
onds, pressurizing the fuel system. Visually inspect
CAUTION
fuel system (fittings, fuel pump, and fuel lines) for
leaks. If the IAC valve has been in service, DO NOT push
or pull on pintle. Moving pintle can damage internal
4. Use a new gasket and connect air filter to TBI. parts of IAC valve.
THROTTLE POSITION SENSOR (TPS) 1. Disconnect and remove parts that connect TBI to
air filter. See Figure 46.
Remove 2. Disconnect electrical connector from IAC valve.
1. Disconnect and remove parts that connect TBI to
3. Remove screws for IAC valve and valve.
air filter. See Figure 45.
2. Disconnect electrical connector from TPS.
3. Remove screws for TPS and remove TPS.
Install
1. With throttle valve closed, install TPS on throttle
shaft. See Figure 45. Rotate TPS to align screw
holes. Use thread-locking adhesive (Loctite 262)
on screws. Install screws and tighten to 2.0 N•m
(18 lbf in). A. DISTANCE OF PINTLE EXTENSION
B. DIAMETER OF PINTLE
2. Connect electrical connector to TPS. Use a new
gasket and connect air filter to TBI. 1. SCREW 3. O-RING
2. IAC VALVE BODY 4. PINTLE
Figure 46. Idle Air Control Valve
82
2200 YRM 1017 Governor System 3.0L Engine Repair
Clean and Inspect 1. Lubricate O-ring for IAC valve with engine oil and
install it on valve.
NOTE: If IAC valve must be replaced, make sure re-
placement part has correct part number and that the 2. Install IAC valve on throttle body. Tighten screws to
shape and diameter of pintle is made for this applica- 3.0 N•m (27 lbf in).
tion.
3. Connect electrical connector to IAC valve.
See cleaning instructions in NOTE under General at
beginning of this section. Use a carburetor cleaner to 4. Use a new gasket and connect air filter to TBI.
clean carbon from valve seat for pintle, air passage, and
5. Do the following procedures to reset position of pin-
surface for O-ring. Inspect O-ring for damage.
tle:
Install a. Depress throttle pedal a small amount.
NOTE: When installing a new IAC valve, measure dis- b. Start and run engine for 5 seconds.
tance between tip of pintle and flange (dimension A in
Figure 46). If distance is more than 28 mm (1.1 in.), use c. Turn key switch to OFF for 10 seconds.
your finger to retract pintle slowly. This procedure will
not damage a NEW IAC valve. DO NOT do this proce- d. Start engine and check for correct idle opera-
dure if IAC valve has been in service. tion.
Governor System 3.0L Engine Repair

GOVERNOR MODULE, REPLACE 5. Install governor assembly on bracket.
NOTE: The governor module is installed on inside of 6. Install and adjust throttle cables as described in
cowl, under plastic panel. Throttle Cables, Install and Adjust.
1. Disconnect negative battery cable. 7. Connect electrical connector at governor.
2. Disconnect electrical connector. Remove mounting 8. Connect negative battery cable.

screws and remove module.
THROTTLE CABLES, INSTALL AND
3. Inspect electrical connectors and terminals for ADJUST
damage.
1. Connect throttle cables to governor actuator as
4. Install governor module with screws. Connect con- shown in Figure 47. Only the two pulleys closest
nector at module. to governor motor are used. Install lockwashers
5. Connect negative battery cable. and flat washers on cable housings. Slide each
cable housing to end of slot. Each cable will align
GOVERNOR MOTOR, REPLACE with a groove in a pulley. The pulley closest to
governor motor is for cable that goes to TBI unit.
1. Disconnect negative battery cable. Install cable ends into pulley, making sure cables
fit in grooves. Check for free operation of cables
2. Remove cover from governor assembly. on pulleys. Tighten nuts on cable housings to 18
to 20 N•m (12 to 15 lbf ft).
3. Disconnect throttle cables at TBI and throttle pedal.
Disconnect cables at governor. 2. Connect cable to pedal as shown in Figure 48.
4. Remove governor assembly from bracket.
83
Governor System 3.0L Engine Repair 2200 YRM 1017
6. Adjust pedal return stop (see Figure 48) to ensure

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

CHECK
Slowly move Foot Directional Control pedal pad
from FORWARD to REVERSE and REVERSE to
FORWARD. See Figure 48. There must be some
movement of pedal pad before pedal frame moves and
throttle opens.
1. GOVERNOR 4. ACTUATOR
MOTOR ASSEMBLY
2. COVER 5. CABLE TO
3. CABLE TO TBI ACCELERATOR
UNIT PEDAL
Figure 47. Throttle Cables
3. Push on throttle pedal and hold it against floor

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

lever on TBI unit. Install cable housing in bracket
that is fastened to TBI adapter. Adjust cable hous- 1. PEDAL PAD 5. CAPSCREW
ing at bracket to get full throttle at TBI. Tighten jam 2. PEDAL FRAME 6. CRANK
3. PEDAL RETURN 7. GAS ENGINE
nuts at bracket when adjustment is correct. STOP THROTTLE
4. LINK CONNECTION
5. Install cover on governor assembly.
Figure 48. Foot Directional Control Pedal
84
Governor System 4.3L Engine Repair

GOVERNOR THROTTLE DRIVE
ASSEMBLY
Remove
1. Disconnect and remove parts connecting TBI to air
filter. See Figure 49, Figure 50, and Figure 51.
2. Disconnect electrical connector at drive motor.
1. THROTTLE DRIVE ASSEMBLY

2. SCREW
Figure 49. Governor Throttle Drive Assembly
Figure 50. Governor Motor and Throttle Drive Assembly
85
Legend for Figure 50

1. THROTTLE DRIVE ASSEMBLY COVER PLATE 5. GOVERNOR MOTOR LEVER
2. DC GOVERNOR MOTOR 6. SHAFT TO THROTTLE PLATES
3. THROTTLE DRIVE CAM 7. THROTTLE DRIVE ASSEMBLY HOUSING
4. THROTTLE DRIVE LEVER
GOVERNOR DRIVE MOTOR
CAUTION
The spring for the throttle lever has tension. Hold Remove
throttle valves closed; then rotate cam for throttle
lever clockwise. Rotate cam until ball joint for throt- 1. Remove governor motor and throttle drive assem-
tle cable is in 11-o’clock position. See Figure 51. bly. See Figure 52.
This procedure will prevent damage to throttle drive
assembly.
3. Remove screws that hold throttle drive assembly to

throttle body. Remove throttle drive assembly.
Inspect
Check for worn or damaged parts.
Install
1. Hold throttle valves closed. Rotate throttle drive
cam until ball joint for throttle cable is in 11-o’clock
position. See Figure 51.
1. THROTTLE DRIVE ASSEMBLY COVER PLATE
2. MOTOR DRIVE LEVER
3. SHOCK ABSORBER
4. SPRING
5. MOTOR DRIVE LEVER
Figure 52. Governor Drive Motor Arrangement
CAUTION
The spring for the throttle lever has tension. Hold
throttle valves closed; then rotate cam for throttle
lever clockwise. Rotate cam until ball joint for throt-
1. THROTTLE VALVES
2. CAM tle cable is in 11-o’clock position. See Figure 51.
This procedure will prevent damage to throttle drive
Figure 51. Align Governor Throttle Drive assembly.
2. Put throttle drive assembly in position. Use a thread 2. Disconnect spring from motor lever so that motor
locking adhesive (Loctite® 262) on screws and in- lever will be free when drive motor is removed. See
stall screws for throttle drive assembly. Tighten Figure 52.
them to 4.5 N•m (40 lbf in). Check that cam for throt-
tle valves and throttle valves rotate freely. 3. Remove four screws that hold drive motor to cover
plate. Remove screw under throttle lever cam last.
3. Connect electrical connector at drive motor. Move throttle lever cam clockwise from drive motor
to prevent release of spring tension. See Figure 53.
4. Use a new gasket and connect air filter to TBI.
4. Remove drive motor.
5. Remove shock absorber(s) only if damaged. See

Figure 55.
86
Clean and Lubricate Inspect

Some parts of the governor throttle drive need to be Check that motor drive lever rotates freely. See Fig-
lubricated with a special grease (Mobil No. 28 or equiv- ure 52. Make sure spring returns drive lever to position
alent). Clean and lubricate these parts only if new parts against shock absorber.
are used or there is no grease on parts. Lubricate parts
as shown in Figure 54.
Install
1. If replaced, install shock absorber parts as shown
in Figure 55.
2. Align motor lever with cover plate. See Figure 52.

Put straight end of spring in detent area in cover
plate. Put motor drive lever against shock absorber.
3. Wind spring for motor drive lever to engage motor

drive lever as shown in Figure 52.
4. Rotate cam until ball joint for throttle cable is in 11

o’clock position. See Figure 51 and Figure 53.
1. THROTTLE LEVER 3. DRIVE MOTOR
® CAM
5. Use a thread locking adhesive (Loctite 262) on 2. SCREW
screws and install screws for governor drive motor.
Tighten screws to 3.2 N•m (28 lbf in). Figure 53. Governor Throttle Drive Assembly
1. LEVER AND BEARING ASSEMBLY 5. COVER PLATE

2. THROTTLE-TO-MOTOR LINK 6. LUBRICATION POINTS
3. SHOCK ABSORBER 7. THROTTLE DRIVE CAM
4. THROTTLE DRIVE LEVER
Figure 54. Lubricate Governor
87
1. SUPPORT PIN 4. RETAINER RING

2. SHOCK (HERE ONLY)
ABSORBER 5. LEVER AND
3. COVER PLATE BEARING
ASSEMBLY
Figure 55. Shock Absorber
FOOT DIRECTIONAL CONTROL PEDAL,

CHECK
NOTE: The Foot Directional Control pedal check in-
formation contained below applies only to GC070-
120LJ/MJ (C818) lift truck models.
Slowly move Foot Directional Control pedal pad

from FORWARD to REVERSE and REVERSE to
FORWARD. See Figure 56. There must be some
movement of pedal pad before pedal frame moves and
throttle opens.
1. PEDAL PAD 6. CRANK

2. PEDAL FRAME 7. GAS ENGINE
3. PEDAL RETURN THROTTLE
STOP CONNECTION
4. LINK 8. SWITCH
5. CAPSCREW CONNECTOR
Figure 56. Foot Directional Control Pedal

GC070-120LJ/MJ Model Units
88
2200 YRM 1017 Ignition System Components Repair
Ignition System Components Repair

ECM REPLACEMENT 5. Remove bolt and clamp that hold distributor in en-
gine. Make a note of positions of rotor to distrib-
1. Disconnect negative battery cable. utor housing and distributor to engine. Slowly pull
distributor from engine until rotor just stops turning
2. Disconnect connectors from ECM.
counterclockwise and make a note of position of ro-
3. Remove capscrews that hold ECM to mounting tor. This position must be used when distributor is
plate on frame. installed again.
NOTE: To prevent Electrostatic Discharge damage to Disassemble

ECM, DO NOT TOUCH connector pins of ECM.
1. Remove rotor. See Figure 57. Make a match mark
4. Install ECM in position and install capscrews. Con- on gear and shaft so they can be assembled in the
nect connectors to ECM. same position.
5. Connect negative battery cable. 2. Use a punch to remove roll pin from shaft.
FUNCTION CHECK
1. Turn ignition key ON.
2. Connect SCAN Tool to Diagnostic Connector and

check for DTC 12. Check that no other DTCs are
present. This indicates that ECM functions cor-
rectly.
Let DTC 12 flash four times in a row to check that no

other DTCs are present. This indicates that ECM func-
tions correctly.
DISTRIBUTOR
Remove
CAUTION
Carefully lift and release lock tabs on connectors
to distributor. Lock tabs can be easily broken if too
much force is applied with screwdriver or other tool.
Never permit TACH CONN. terminal to touch

ground. Ignition module or ignition coil can be
damaged.
1. Disconnect battery negative (ground) cable.
2. If removal of spark plug wires are not required for

repairs, leave them connected to distributor cap. 1. CAP 7. SEAL
Remove two capscrews that fasten distributor cap 2. ROTOR 8. HOUSING
3. SHAFT/TIMER 9. MODULE
to distributor. Move distributor cap away from work CORE 10. ALIGNMENT PIN
area. 4. RETAINER 11. POLE PIECE
5. PIN 12. COIL
3. Disconnect distributor four-terminal connector. 6. DRIVE GEAR
4. Disconnect ignition coil connector. Figure 57. Distributor (3.0L Shown)
89
Ignition System Components Repair 2200 YRM 1017
3. Remove gear. 7. Align marks on gear and shaft. Install roll pin. Turn
shaft assembly and make sure teeth of timer core
4. Remove shaft with timer core from housing. on shaft assembly do not touch pole piece.
5. Remove retainer from housing. Use a screwdriver 8. Install rotor on shaft.
as a prybar.
Install
6. Disconnect sensing coil from ignition module.
1. Put rotor and distributor in same position as it was
CAUTION removed from engine.
Carefully lift and release lock tab on connector to If engine has been rotated after distributor was re-
sensing coil. Lock tab can be easily broken if too moved, the following procedure must be used be-
much force is applied with screwdriver or other tool. fore distributor is installed again:
7. Use a screwdriver to lift lock tab. Remove sensing a. Remove No. 1 spark plug.
coil.
b. Put a finger over No. 1 spark plug hole and
8. Remove two screws that hold ignition module in slowly rotate engine until pressure is felt on
housing. Remove ignition module. compression stroke.
Inspect c. Align timing mark on crankshaft pulley to 0

(TDC) on engine timing indicator.
Inspect shaft for a loose fit between shaft and its bush-
ing in housing. If bushing or shaft is worn so that shaft d. Turn distributor rotor to point near position on
moves from side to side in bushing, replace shaft or distributor cap for No. 1 spark plug lead.
housing.
e. Install distributor in engine. Rotor and shaft will
Inspect housing for cracks or damage. rotate a few degrees when gear on distributor
shaft engages drive gear on engine cam. Tim-
Assemble ing is correct if rotor points at position on dis-
tributor cap for No. 1 spark plug lead.
NOTE: Yale Part No. 504069721 is a silicon bearing
grease used between electronic components and their 2. Install clamp and bolt. Tighten bolt with your hand.
heat sinks. A small container of silicon grease is en-
closed in package with a new ignition module. 3. Install distributor four-terminal connector.
1. Apply silicon grease to bottom of ignition module. 4. Install ignition coil connector.
See Figure 57. Install ignition module into housing
and tighten two screws. 5. Install distributor cap and two capscrews. If spark
plug wires were removed, install them in correct
2. Install sensing coil. Tab on bottom of sensing coil sequence.
fits into anchor hole in housing.
6. Connect battery negative cable.
3. Connect sensing coil to ignition module. Make sure
lock tab on connector is fastened. 7. Start engine and check engine timing. See Distrib-
utor, Ignition Timing below for more information on
4. Install retainer. Ignition Timing.
5. Install shaft assembly into housing. 8. Tighten bolt for distributor clamp to 43 N•m
(25 lbf ft).
6. Install seal on housing. Install gear on end of shaft.
90
2200 YRM 1017 Ignition Module Repair
Firing Order 3. Connect a timing light to No. 1 spark plug wire.
The firing order for the GM 3.0L engine is 1-3-4-2.

WARNING
The firing order for the GM 4.3L engine is 1-6-5-4-3-2. Do not touch moving parts (fan, belt, shafts, pul-
See Figure 58. leys).
4. Start engine and check initial timing. Set SCAN

Tool to Field Service Mode. Correct setting for initial
timing set point is 8 BTDC on 3.0L engine and 0
BTDC on 4.3L engine.
5. If timing is not correct, loosen clamp that holds dis-

tributor housing. Rotate housing right or left to get
Figure 58. Firing Order for GM 4.3L V-6 correct timing. Tighten clamp when timing is cor-
rect.
Ignition Timing
6. Disconnect timing light. Disconnect SCAN Tool.
1. Start and run engine until it is at normal operating Put cover on Diagnostic Connector.
temperature. Turn key switch OFF.
2. Connect SCAN Tool to Diagnostic Connector con-

nector.
Ignition Module Repair

TEST FOR FAULT 3. Use a jumper to connect pin D (EST) to pin C (REF-
ERENCE) at distributor. Apply 12 volts through test
NOTE: The ignition module can be checked in the dis- light to pin B (BYPASS) as described in Step 2.
tributor. A test light and three jumper wires are needed Start engine. If engine starts, this step checks that
to perform the tests. The battery in the vehicle must be EST circuit in ignition module is good.
fully charged so that starter rotates engine at normal
speed. 4. Remove test light from pin B (BYPASS) while en-
gine is running. If engine stops, this check shows
1. Disconnect four-terminal connector from distributor. that ignition module internally changes EST circuit
See Figure 59. Use two jumper wires between dis- to ground. Since there is a jumper wire between pin
tributor and four-terminal connector to connect the D (EST) to pin C (REFERENCE), the REFERENCE
following circuits: signal is also sent to ground and engine stops.
REFERENCE Circuit 435
GROUND Circuit 650 5. If any tests described in Step 2, Step 3, or Step 4
do not work as indicated, check wiring harness for
2. Connect test light to a 12-volt positive source. Start a short circuit or an open circuit. If wiring harness
engine. Touch probe of test light to pin B in four-ter- is good, replace ignition module.
minal connector on distributor. When 12 volts are
applied through test light to pin B (BYPASS), ig- 6. When tests are complete, connect system for nor-
nition module changes to EST mode. EST con- mal operation.
nection (pin D) is open and engine will normally
stop. This step checks BYPASS operation of igni-
tion module.
91
Ignition Module Repair 2200 YRM 1017
Figure 59. Ignition Module Test
REPLACE 7. Install distributor cap and rotor.
1. Remove distributor cap and rotor. See Figure 57. SENSING COIL
2. Remove 2 screws that hold ignition module in dis- Test
tributor.
NOTE: Also see A-7 Ignition System Troubleshooting.
3. Lift ignition module and disconnect connections.
Make a note of connections so that they can be This test checks the resistance of the sensing coil for the
correctly connected again. Remove ignition mod- ignition module. The distributor can stay on the engine
ule from distributor. for this test.
NOTE: Do not remove silicon grease from ignition mod- Do the following procedure to check the sensing coil:
ule or distributor if same ignition module will be installed • Connect an ohmmeter to either sensing coil connec-
again. If a new ignition module is installed, a small con- tion and housing as shown in Step 1 of Figure 60. If
tainer of silicon grease is in package. Clean old sili- reading is not infinity (∞), replace sensing coil.
con grease and apply a new layer of silicon grease to • Connect an ohmmeter to both connectors of sensing
both ignition module and distributor housing. This sili- coil as shown in Step 2 of Figure 60. Move connec-
con grease is necessary for cooling ignition module. tors at sensing coil and at connector to find any open
circuits that are not constant. Ohmmeter will correctly
4. Connect connectors in distributor to ignition mod- indicate 500 to 1500 ohms. If indication is not con-
ule. Make sure connectors are the same as when stant or is not within resistance range, replace sens-
they were removed. ing coil.
5. Install ignition module in distributor.
6. Install two screws that fasten ignition module in dis-

tributor.
92
2200 YRM 1017 Ignition Module Repair
A. CLEAN METAL FOR GOOD GROUND

CONNECTION
Figure 61. Test Ignition Coil
3. Connect an ohmmeter as shown in Step 2 of Fig-

ure 61. Use low scale. Indication will be very low or
1. SENSING COIL 2. OHMMETER approximately zero. If indication is not low, replace
CONNECTIONS 3. IGNITION MODULE
ignition coil.
Figure 60. Test the Sensing Coil
4. Connect an ohmmeter as shown in Step 3 of Fig-
ure 61. Use high scale. Reading must not be infinity
Replace (∞). If reading is infinity, replace ignition coil.
Remove and disassemble distributor as described in re-
5. Connect distributor lead and wiring to ignition coil.
pairs for Distributor.
Remove
IGNITION COIL
1. Turn key switch to OFF. Apply parking brake.
Test
2. Disconnect negative battery cable.
NOTE: Also, see A-7 Ignition System Troubleshooting.
3. Put tags for identification on connectors and discon-
This procedure tests for open circuits and short circuits nect them from coil.
in ignition coil. Ignition coil can stay on engine for this
test.
CAUTION
1. Disconnect distributor wire and control wires from Do not damage high-voltage wires (spark plug
ignition coil. wires) during removal. Hold wire by boot near end
of wire. Rotate boot before pulling it and connec-
2. Connect an ohmmeter as shown in Step 1 of Fig- tion from terminal.
ure 61. Use high scale. Correct indication is infinity
(∞). If a short circuit is indicated, replace ignition 4. Remove high voltage wire.
coil.
93
Sensors Repair 2200 YRM 1017
5. Remove nuts (or capscrews) that fasten bracket for 2. Install ignition coil assembly on engine with nuts (or
ignition coil to engine. capscrews).
6. Remove ignition coil and bracket assembly from en- 3. Install control wire connectors and high voltage wire
gine. on ignition coil.
7. Use a drill and punch to remove two rivets that fas- 4. Connect negative (ground) battery cable.
ten bracket to coil.
Install
1. Install original bracket on replacement coil using
screws (supplied with replacement coil).
Sensors Repair
ENGINE COOLANT TEMPERATURE (ECT) 2. Remove mounting screws and disconnect vacuum
SENSOR, REPLACE hose.
3. Inspect electrical connectors and terminals for

WARNING damage.
The coolant can be very hot. Use caution to prevent
personal injury. 4. Install sensor on bracket.
1. Disconnect battery negative cable. Disconnect 5. Connect electrical connector. Connect vacuum
connector at ECT sensor. See Figure 62. hose from MAP sensor to fitting at TBI unit.
2. Use a wrench and carefully loosen ECT from

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

its hole in coolant manifold. Tighten ECT carefully
to 30 N•m (22 lbf ft).
4. Connect connector at ECT. Connect battery nega-

tive cable.
5. Fill radiator with coolant as required.

1. TEMPERATURE SENSOR
2. ELECTRICAL CONNECTOR
MAP SENSOR, REPLACE 3. LOCK TAB
1. Disconnect negative battery cable. Disconnect Figure 62. Engine Coolant Temperature Sensor
electrical connector. (ECT)
94
2200 YRM 1017 Wiring
PCV System Repair

REPLACE
1. Remove PCV valve from rocker arm cover. See
Figure 63.
2. Run engine at idle speed.
3. Put your thumb over end of PCV valve to check

for vacuum. If there is no vacuum at PCV valve,
check for restrictions in hoses, manifold port, or
PCV valve. Replace damaged parts.
4. Turn OFF engine and remove valve. Shake valve

and listen for movement of needle inside valve. If
needle does not move, replace valve. Connect 1. PCV VALVE 3. VALVE COVER
hose between PCV valve and fitting on intake man- 2. GROMMET
ifold.
Figure 63. PCV System
Wiring
NOTE: The most common fault that occurs in an elec- circuit. Always use a fused jumper between connec-
tronic engine control system is caused by a bad con- tors when checking circuits. Never damage insulation
nection in the wiring. Work carefully and make sure that or a seal on a connector when making a check or doing
connectors are not damaged during troubleshooting. troubleshooting. The Connector Test Adapter Kit has a
variation of adapters and connectors that can be used
The ECM wiring harness electrically connects the ECM when troubleshooting a circuit.
to solenoids, switches, and sensors in the engine com-
partment. A wiring harness must be replaced with a When troubleshooting, open circuits are often difficult
wire harness that has the same part number. If a repair to see because of dirt, corrosion, or a terminal that is
(wire splice) must be made to a wiring harness, replace- not in alignment in its socket. When troubleshooting
ment wire must have a high-temperature insulation. for an open circuit, always check for loose connections
and a terminal that can have corrosion. A fault that is
The signal wires in the electronic control system have neither regular nor constant can also be caused by a
a low voltage and low current. All wire splices must be loose connection or a terminal that has corrosion.
high quality so that a fault is not made in the circuit by
the wire splice. Use solder on the wire splices when If a connector must be repaired, be sure to replace it
possible. with the correct connector type. Some of the smaller
connectors can look similar but have a different con-
Some connectors are made as a one-piece unit. A dam- struction.
aged one-piece connector must be replaced with a wire
splice into the wiring harness. Some connectors can be Micro-Pack® 100W Connector is shown in Figure 64.
replaced, or a terminal within the connectors can be re- This connector is normally used to connect the wire har-
placed. These connectors are described in Connectors ness to the ECM.
and Terminals.
CONNECTORS AND TERMINALS

Be careful when using a probe to check voltages on ter-
minals in a connector. It is easy to cause a short circuit
between two terminals with opposite voltages. Elec-
tronic components can be easily damaged by a short
Figure 64. Micro-Pack 100W Connector
95
Wiring 2200 YRM 1017
Metri-Pack® Connectors, shown in Figure 65, come in

several sizes and types that are used on the wire har-
ness. These connectors are made by Packard Electric
Company. The typical connectors used on lift trucks
are 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 connector is correctly identified
before it is changed. Terminals can be damaged if they
are removed or installed wrong.
1. PICK 4. CONNECTOR
2. LOCK TAB BODY
3. TERMINAL
Figure 66. Metri-Pack Pull-to-Seat Connector
4. Use removal tool to move lock tab and release ter-

minal from its seat.
Push-To-Seat - Gently pull wire to remove terminal

from back of connector. See Figure 66.
Pull-To-Seat - Gently push wire to remove terminal

through front of connector. See Figure 67.
1. PICK 3. TERMINAL
2. LOCK TAB 4. CONNECTOR
BODY
Figure 65. Metri-Pack Push-to-Seat Connector
NOTE: Not all Metri-Pack connectors have a seal.
Do the following procedures to remove and install a ter-

minal:
1. Open any secondary locks that hold wires and

seals in their positions. Slide seals along wires
from ends of connector.
2. Hold wire and use it to push terminal to its forward

position in connector body. Hold terminal in this
position.
3. Find lock tab for terminal in connector channel.

Push a removal tool (pick) of correct size into con-
nector channel. See Figure 64 and Figure 66.
1. FEMALE TERMINAL
2. LOCK TAB
3. HYSTER TOOL KIT HYS1004
4. CONNECTOR BODY
96
5. SEAL 8. Push seals into their position and install any sec-
ondary locks.
Figure 67. Metri-Pack Series 150 Pull-to-Seat
Terminal Removal Weather-Pack® Connectors all have a rubber seal at
rear end of connector. All Weather-Pack Connectors
CAUTION have a round barrel shape around the terminal. This
connector is used in the engine compartment to pro-
Work carefully and do not use enough force to dam-
tect against moisture and dirt, which can cause corro-
age terminal or connector.
sion and a fault in the voltage signal. These connectors
5. Inspect terminal and connector for damage. Make normally have the low voltage and current used by the
repairs as necessary. See Figure 68. electronic control system. The repair of this type of con-
nector is shown in Figure 69 and Table 34.
Use a remover tool to remove pin and sleeve termi-

nals. These terminals can easily be damaged during
removal if correct tool is not used. Terminal must then
be replaced. When making repairs on these connec-
tors, make sure that terminals are all in their seats cor-
rectly and sealing rings are installed. These connectors
must be correctly installed and in good condition so that
electronic engine control operates correctly.
NOTE: THE GREATER THE DISTANCE D, A FAULT

CAN OCCUR IN THE CONNECTION.
A. D = 0 B. D = GREATER
THAN 0
1. CONTACT TAB
Figure 68. Metri-Pack Series Terminal Inspection A. PUSH-TO-SEAT TERMINAL, MALE
6. If terminal will be used again, make sure lock tab 1. TERMINAL 4. SEAL
2. LOCK TAB 5. REMOVAL TOOL
is correctly bent so that terminal will be locked in 3. WIRE 6. CONNECTOR
connector again. BODY
7. Push terminal into connector channel. Make sure Figure 69. Weather-Pack Terminal and Connector
that lock tab correctly locks terminal in position.
97
Table 34. Weather-Pack Terminal Repair PROCEDURES FOR SPARK PLUGS,

SPARK PLUG WIRES, AND BOOTS
1. Open secondary lock hinge on connector.
NOTE: Use a silicon grease on inside of spark plug
boots to make a better weather seal and make spark
plug boot easier to remove. The following silicon
greases are approved for use:
• General Electric® GE627
• Packard® PM776
• Wacker® Silicones G47
1. FEMALE CONNECTOR NOTE: The condition of spark plugs removed from en-
2. MALE CONNECTOR gine can show engine operating problems. See Spark
3. SECONDARY LOCK HINGE Plugs Troubleshooting.
2. Remove terminal using tool.
1. Do not damage spark plug wires during removal.
Hold wire by boot near end of wire. Rotate boot a
half-turn before pulling it and connection from spark
plug. Do not use pliers or other tools that can dam-
age boot. Do not pull wires to disconnect spark plug
wires. Pull boot, or use a tool made for this purpose.
A. PUSH TO RELEASE 2. Do NOT put a hole in boot or insulation of spark plug

1. TERMINAL wire. Do NOT try to insert a wire between boot and
2. TOOL connector of spark plug wire.
3. Cut wire behind cable seal. 3. Make sure spark plug wires are installed in same
locations using original clips. Spark plug wires can
be damaged or cause poor engine operation if they
are not correctly installed.
4. Special care must be used when spark plug boots

are installed. Make sure that metal terminal within
1. SEAL boot is fully connected to spark plug terminal. Make
2. WIRE sure that boot has not moved on wire. If there is
4. Replace terminal. boot-to-wire movement, boot can appear to be in-
stalled fully when it is not.
a. Put new seal on wire.
b. Remove 5 mm (0.2 in.) of insulation from wire. 5. Make sure to install insulator in shield at boot of all
spark plug wires.
c. Install terminal over wire and seal.
WIRING DIAGRAM
The wiring diagram for the electronic control module is
shown in Figure 70. The wiring diagram is followed by
tables of pinouts for the ECM connectors J1 and J2.
See Table 35 and Table 36.
1. SEAL
5. Push terminal and connector until they are
engaged.
6. Close secondary lock hinge.
98
Figure 70. Wiring Connections (Sheet 1 of 2)
Figure 70. Wiring Connections (Sheet 2 of 2)
99
Table 35. ECM Connector J1 Identification
Pin No. Ckt No. Function To Pin

1 Not Used
2 358 Diagnostic Test Terminal F
3 Not Used
4 Not Used
5 Not Used
6 651 Fuel Pump Relay Control
7 Not Used
8 Not Used
9 Not Used
10 Not Used
11 423 Fuel Injector 2 Driver
12 Not Used
13 642 ECM Ground
14 Not Used
15 424 Idle Air Control (IAC) Coil "B" Low A
16 427 Idle Air Control (IAC) Coil "A" High D
17 Not Used
18 Not Used
19 Not Used
20 Not Used
21 Not Used
22 Not Used
23 431 Governor
24 Not Used
25 Not Used
26 422 Fuel Injector 1 Driver
27 420 Malfunction Indicator Lamp E
28 643 ECM Ground
29 642 ECM Ground
100
Table 35. ECM Connector J1 Identification (Continued)

30 425 Idle Air Control (IAC) Coil "B" High B
31 426 Idle Air Control (IAC) Coil "A" Low C
32 440 Fuel Pressure Relay Sense
Table 36. ECM Connector J2 Identification

1 358 Battery Feed
2 428 5 Volt Reference
3 649 Sensor Ground
4 Not Used
5 Not Used
6 Not Used
7 430 Engine Coolant Temperature
8 429 Manifold Absolute Pressure (MAP)
9 Not Used
10 439 Serial Data
11 Not Used
12 Not Used
13 Not Used
14 Not Used
15 437 Bypass B
16 435 Reference High C
17 Not Used
18 650 Reference Low A
19 112 Ignition Feed
101
Spark Plugs Troubleshooting 2200 YRM 1017
Table 36. ECM Connector J2 Identification (Continued)

20 Not Used
21 Not Used
22 Not Used
23 433 Throttle Position Sensor (TPS) C
24 Not Used
25 Not Used
26 Not Used
27 Not Used
28 Not Used
29 Not Used
30 Not Used
31 436 Electronic Spark Timing D
32 Not Used
Spark Plugs Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Brown to gray or tan deposits Normal wear. Clean the spark plugs, set the elec-
and some electrode wear. trode clearance, and install.
Dry, black carbon deposits. Poor ignition output. Check distributor to coil connections.
Wet, oily deposits with mini- Break-in of new or recently overhauled Clean and install spark plugs.
mum electrode wear. engine.
Clearances too large between valve See Engine section for your engine.
stem and valve guide.
Worn seals on inlet valves. Replace seals.
102
2200 YRM 1017 Spark Plugs Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Red, brown, yellow, and white Byproducts of combustion. Clean spark plugs, set electrode clear-
colored coatings on insulator. ance, and install.
Engine operation is not con-
stant during difficult operating
conditions.
Heavy deposits on part of plug Valve seals have leaks if condition is Check seals. Replace if necessary.
that go into chamber and on found in only one or two cylinders. Clean, set electrode clearance, and in-
side facing intake valve. stall spark plugs.
Yellow glaze coating on insu- Melted by-products of combustion. Avoid sudden acceleration with full
lator of spark plug. throttle after long periods of low-speed
driving. Replace spark plugs.
Insulator tips are burned or Overheating. Check cooling system.

electrodes worn. Lean air-fuel mixture.
Check heat range of spark plugs for too
hot.
Check ignition timing.
Check torque value of spark plugs to
make sure they are correctly installed.
Spark plugs have broken or Heat shock from sudden rise in tip tem- Replace spark plugs. Set electrode
cracked insulator tips. perature under severe operating con- clearance to correct value.
ditions. Electrode clearance not cor-
rect.
103
Special Tools 2200 YRM 1017
Special Tools
SCAN Tool
Reads problem codes from the ECM memory. Used to
analyze and Troubleshoot components and the ECM
operation of the electronic engine control system.
SCAN Tool will also record data stream information
when the engine is operating. This procedure will
record information that is not regular nor constant or
that only occurs during some conditions.
Available from:
Rinda Technologies Inc.
4563 North Elston Ave.
Chicago, IL 60630
Spark Tester
Used to check secondary ignition voltage. Also called
an ST125.
OTC Part No. 3320 Tester for Idle Air Control and Idle Speed Control
The TBI units do not have external adjustments for
idle speed nor idle air control. This tester is required
to set the idle air control and the idle speed control
electronically.
OTC Part No. 3053 Signal Test Lights for Idle Air Control and Idle
Speed Control
Signal test lights that can be used with the Tester for
Idle Air Control and Idle Speed Control Part No. 3320.
Vacuum Pump, Hand Operated
Use gauge to check engine manifold vacuum and to
test vacuum sensors, valves, and solenoids.
104
2200 YRM 1017 Special Tools
Digital Multimeter
Voltmeter - A minimum impedance of 10 Megohms is
required so that the electronic circuit being measured
is accurate.
Ammeter - Can be used to measure current flow in
electronic circuits.
Ohmmeter - Some Ommeters will automatically change
ranges. Other Ohmmeters have range switches.
Many of the multimeters available will also operate as a
tachometer, a distributor dwell, and a diode tester.
Tachometer
Use a tachometer with an inductive trigger sensor to
check the engine speed.
Test Light (Without Internal Battery)

Used to check for open circuits, short circuits, and
signal voltages in a circuit.
Adjustment Wrench for Minimum Idle Speed

Used to adjust the throttle stop screw on the TBI unit.
Injector Harness Test Light

A specially designed light used to visually indicate
injector electrical pulses from the ECM.
105
NOTES
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106
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
2200 YRM 1017 10/04 (7/02) Printed in U.S.A.

Control Electronico Del Motor GM 3

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Maintenance

PART NO. 524162463 2200 YRM 1017

• 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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2004 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

Malfunction Indicator Lamp (MIL)

It lets the operator know that a problem has occurred

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

Legend for Figure 3

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

Legend for Figure 4

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

Figure 5. Diagnostic Trouble Code 12 Example

ECM DIAGNOSTIC CODES AVAILABLE

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

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

Field Service Mode

SCAN TOOL INFORMATION

Test under following conditions:

Table 3. TECH 1 SCAN Tool Information

Table 3. TECH 1 SCAN Tool Information (Continued)

Table 3. TECH 1 SCAN Tool Information (Continued)

ON-BOARD DIAGNOSTIC (OBD) SYSTEM 2. Is there a Diagnostic Trouble Code? If there is a

Table 4. On-Board Diagnostic System Checks

Step Action Value Yes No

Figure 6. Current Flow Test for Test Light

Table 5. Voltage and Pressure Chart

ATMOSPHERIC 5-VOLT REFERENCE

Table 5. Voltage and Pressure Chart (Continued)

ATMOSPHERIC 5-VOLT REFERENCE

TROUBLESHOOTING CHART DESCRIPTION SUMMARY

Table 6. Troubleshooting Chart Description Summary

Chart Malfunction Indicator

A-1 No Malfunction Indicator Lamp

Figure 7. No Malfunction Indicator Lamp

DIAGNOSTIC AIDS TEST DESCRIPTION

Table 7. No Malfunction Indicator Lamp (GM 3.0L Engine Only)

Step Action Value Yes No

Is Malfunction Indicator Light on?

Is test light on for all circuits?

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

Figure 8. No Scan Data, No DTC-12, Malfunction Indicator Lamp ON

DIAGNOSTIC AIDS • If DTC 12 does flash, be sure Scan Tool is working

Table 8. No Scan Data, No DTC-12, Malfunction Indicator Lamp ON

Step Action Value Yes No

Does MIL come on?

A-3 Engine Cranks but Does Not Run

Figure 9. Engine Cranks but Does Not Run

DIAGNOSTIC AIDS Failure to do so may result in DTCs not properly being

Table 9. Engine Cranks but Does Not Run

Step Action Value Yes No

Does fuel pump run?

Table 9. Engine Cranks but Does Not Run (Continued)

Step Action Value Yes No