2011 Emission Certified LPG Fuel System 3.0L GM Engine: Including Labor Time Guide

2011 Emission Certified
LPG Fuel System

3.0L GM Engine
Parts & Service Manual

Including Labor Time Guide
Revision A/March, 2011
Downloaded from www.Manualslib.com manuals search engine

2011 Emission Certified
LPG Fuel System
3.0L GM Engine for
Parts & Service Manual
Table of Contents
General Information ................................................................................................ 5

An overview of this Service Manual
Maintenance ............................................................................................................ 9
General maintenance and maintenance interval information
Fuel System ........................................................................................................... 17

An overview of the LPG fuel system and its components
LPG Fuel System Diagnosis ................................................................................ 27

How to identify a general problem
LPG Symptom Diagnostics .................................................................................. 35

How to correct a specific problem
Electrical Section .................................................................................................. 51
Diagnostic Scan Tool ...................................................................................... 53

Using the DST for testing and trouble shooting

Wire Schematic ...................................................................................................81
Engine wiring schematics
Engine Wire Harness Repair .............................................................................85

Repairing a wire harness on the vehicle
Diagnostic Trouble Codes (DTCs) ....................................................................89

Application, schematic and DTC specific code information
Servicing the Fuel System .................................................................................... 237

Step by step instructions on how repair and/or replace fuel related Components
LPG Parts Diagram ................................................................................................ 255

Illustrations and part views
Labor Time Guide .................................................................................................. 299

The labor reimbursed by IMPCO for warrantable service and repairs
Definitions .............................................................................................................. 317

Definitions of phrases and acronyms used throughout this Service Manual
Appendix ................................................................................................................ 323

Supplemental charts and tables

4

General Information

INTRODUCTION Fuel other than HD-5 or HD-10 may cause harm
to the engine’s emission control system and a
This service manual supplement has been devel- warranty claim may be denied on this basis if op-
oped to provide the service technician with the erators can readily find the proper fuel.* Use of
basic understanding of the IMPCO certified fuel any other fuel may result in your engine no longer
and emission systems for the 3.0L GM engine. operating in compliance with CARB or EPA emis-
This manual should be used in conjunction with sions requirements.
the base engine manual and the OEM service
manual when diagnosing fuel or electrical prob- *Not Applicable in the state of California.
lems.
FUEL LINE CONNECTIONS
HOW TO IDENTIFY THE ENGINE YEAR
Loctite® 567 is recommended for all NPT connec-
The emission label on the engine will identify the tions.
specific model year.
SERVICING YOUR EMISSIONS

CERTIFIED ENGINE
Any maintenance and repair should be performed Do not use Teflon tape to seal any fuel fit-
by trained and experienced service technicians. tings. Fragments of the tape may enter into
Proper tools and equipment should be used to the fuel system, causing damage or mal-
prevent injury to the servicing technician and function of critical fuel system components.
damage to the vehicle or components. Service
repairs should always be performed in a safe envi-
AIR FILTRATION REQUIREMENTS
ronment and the technician should always wear
protective clothing to prevent injury.
Dry filtration is required with maximum recom-
mended 4” W.C. restriction @ 75 cfm. IMPCO
For parts or labor to be reimbursed under the
strongly recommends the use of OEM or factory
IMPCO Technologies Inc. emission warranty, only
replacement parts.
work performed by IMPCO or OEM trained techni-
cians using only IMPCO specified parts will qualify
WASHING
for reimbursement. Refer to the IMPCO Labor
Caution should be used when pressure washing
Time Guide for additional information.
near or on an engine’s electrical system. Avoid
direct pressure spray on the system electrical
For parts or labor not reimbursed under warranty, connectors. The electrical connectors are splash
a repair shop or person of the owner’s choosing resistant, but if high pressure water or steam is
may maintain, replace, or repair emission-control sprayed directly at the connectors, moisture can
devices and systems. It is highly recommended become trapped behind the connector seal and
that any replacement parts used for maintenance cause serious system problems, many of them
or for the repair of emission control systems be showing up as intermittent.
new OEM replacement parts. The use of other
than genuine IMPCO replacement parts may im-
pair the effectiveness of emission control systems,
therefore, the owner should assure that such parts
are warranted by their manufacturer to be equiva-
lent to genuine IMPCO OEM parts in performance
and durability.
FUEL QUALITY
LPG engines and fuel systems are designed to

operate on HD-5 or HD-10 specification LPG fuel.
6

FUEL SYSTEM CAUTIONS
Unlike gasoline or propane vapors that

sink downward. Highly flammable
Do not use Teflon tape to seal any fuel air/fuel mixtures may be present and
fittings. Fragments of the tape may en- can be ignited causing personal injury.
ter into the fuel system, causing Always work in well ventilated areas.
damage or malfunction of critical fuel
system components.
WARNINGS, CAUTIONS AND NOTES
This manual contains several different Warnings,
Cautions, and Notes that must be observed to
prevent personal injury and or damage to the en-
Do not smoke, carry lighted tobacco or gine, the fuel system or personal property.
use a lighted flame of any type when
working on or near any fuel related A “WARNING“ is an advisement that by perform-
component. Highly flammable air-fuel ing a process or procedure listed in this manual
mixtures may be present and can be improperly may result in serious bodily injury,
ignited causing personal injury. death and/or serious damage to the engine or
property.
Typical Warning Label:
Do not allow LPG to contact the skin.

LPG is stored in the fuel tank as a liq-
uid. When LPG contacts the
atmosphere, it immediately expands in- A “WARNING” is an advisement that
to a gas, resulting in a refrigeration by performing a process or procedure
effect that can cause severe burns to listed in this manual improperly may
the skin. result in serious bodily injury, death
and/or serious damage to the engine
or property.
A “CAUTION” label or statement is used when it

Do not allow LPG to accumulate in has been determine that by performing a process
areas below ground level such as in a or procedure defined in the manual improperly a
service pit or underground ventilation less severe result may occur. It could however,
systems. LPG is heavier than air and result in serious bodily injury, and or serious dam-
can displace oxygen, creating a dan- age to the engine or property damage.
gerous condition.
Less severe than WARNING but has

the potential to cause injury or dam-
Do not make repairs to the fuel system age. Also used to notify of situations
if you are not familiar with or trained to that could lead to eventual failure, in-
service Propane fuel systems. Contact jury or damage.
the dealer who sold you the engine to
locate a repair facility with trained
technicians to repair your fuel system. This caution label may also appear in area of this
manual that applies to service and repair proce-

dures. In addition it may also be used to indicate
a failure to observe which may influence the terms
of the warranty.
An “IMPORTANT” statement generally denotes a Always leak check any fuel system con-
situation that requires strict adherence to the as- nection after servicing! Use an
sembly, tightening, or service procedure. Failure electronic leak detector and/or a liquid
to observe this procedure could result in an un- leak detection solution. Failure to leak
safe condition or improper performance of the check could result in serious bodily in-
engine or a component. jury, death, or serious property damage.
A “NOTE” statement applies to a specific item or

procedure that is to be followed during the servic-
ing of the engine or its components.
PROPER USE OF THIS SERVICE MANUAL,

TOOLS AND EQUIPMENT
To reduce the potential for injury to the technician
or others and to reduce damage to the engine dur-
ing service repairs the technician should observe
the following Steps:
 The service procedures defined in this ma-

nual, when followed, have been found to be a
safe and efficient process to repair the fuel
system. In some cases special tools may be
required to perform the necessary procedures
to safely remove and replace a failed compo-
nent.
 Tools identified in this manual with the prefix
“J” or “BT” can be procured through SPX in
Warren, Michigan.
 IMPCO tools identified in this manual with a
prefix “ITK” can be acquired through OEM
Parts Distribution.
IMPORTANT
It is important to remember that there may be a
combination of Metric and Imperial fasteners used
in the installation of the IMPCO fuel system.
Check to insure proper fit when using a socket or
wrench on any fastener to prevent damage to the
component being removed or injury from “slipping
off” the fastener.
The fuel system utilizes fuel lines and hoses with
high pressure connectors. Always use a wrench
of the proper size and torque to the correct value.
For hoses with swivel fittings, be sure not to turn
the fixed fitting which may cause a twisting or
kinking of the hose, possibly resulting in fuel line
restriction and/or leak.

Maintenance

MAINTENANCE
SERPENTINE BELT SYSTEM
The maintenance of an engine and related com-
ponents are critical to its operating performance Serpentine belts utilize a spring-loaded tensioner
and lifespan. Industrial engines operate in envi- to keep the belt properly adjusted. Serpentine
ronments that often include hot and cold belts should be checked according to the main-
temperatures and extreme dust. The recom- tenance schedule in this section.
mended maintenance schedule is listed in this
section, however, environmental operating condi- IMPORTANT:
tions and additional installed equipment may The use of “belt dressing” or “anti-slipping
require more frequent inspection and servicing. agents” on belts is not recommended.
The owner and/or service agent should review the
operating conditions of the equipment to deter- COOLING SYSTEM
mine the inspection and maintenance intervals.
It is important that the cooling system of the en-
gine be maintained properly to ensure proper
performance and longevity.
When performing maintenance on the engine,

turn the ignition OFF and disconnect the bat-
tery negative cable to avoid injury or damage
to the engine. Alcohol or Methanol based anti-freeze or
plain water are not recommended for use
ENGINE BELTS in the cooling system at anytime.
The engine installed in this equipment uses a ser-

pentine drive belt configuration that drives the
water pump, alternator and additional pumps or
devices. It is important to note that the drive belt
is an integral part of the cooling and charging sys- Do not remove the cooling system pres-
tem and should be inspected according to the sure cap (radiator cap) when the engine is
maintenance schedule in this section. When in- hot. Allow the engine to cool and then
specting the belts check for: remove the cap slowly to allow pressure
to vent. Hot coolant under pressure may
 Cracks discharge violently.
 Chunking of the belt
 Splits NOTE that the LPG vaporizer is connected to the
 Material hanging loose from the belt cooling system and the fuel system may be ad-
 Glazing, hardening versely affected by low coolant levels and
restricted or plugged radiator cores. Therefore,
If any of these conditions exist the belt should be the cooling system must be maintained according
replaced with the recommended OEM replace- to the recommend maintenance schedule in this
ment belt. section and also include:
 The regular removal of dust, dirt and debris

from the radiator core and fan shroud.
 Inspection of coolant hoses and components
for leaks, especially at the radiator hose con-
Alcohol or Methanol based anti-freeze or
nections. Tighten hose clamps if necessary.
plain water are not recommended for use in
the cooling system at anytime.  Check radiator hoses for swelling, separation,
hardening, cracks or any type of deterioration.
10

If any of these conditions exist the hose  Verify that any additional electrical services
should be replaced with a recommended OEM installed by the owner are properly installed in
replacement part. the system.
 Inspect the radiator cap to ensure proper seal-  Verify that the MIL, charging, and oil pressure
ing. lights illuminate momentarily during engine start.
COOLANT ENGINE CRANKCASE OIL

Check coolant level in coolant recovery tank and OIL RECOMMENDATION
add coolant as required. Add 50/50 mixture of
GM Dexcool antifreeze and water or coolant per Select an engine oil viscosity that will best match
engine manufacturer’s instructions. Do not add the prevailing daytime temperature:
plain water. Replace coolant per the recommend-
ed schedule.
IMPORTANT:
The manufacturers of the engine and fuel system
do not recommend the use of “stop leak” additives
to repair leaks in the cooling system. If leaks are
present the radiator should be removed and re-
paired or replaced.
ENGINE ELECTRICAL SYSTEM MAINTNANCE
The engine’s electrical system incorporates com-

puters to control various related components. The
electrical system connections and ground circuits
require good connections. Follow the recom-
mended maintenance schedule in this section to
maintain optimum performance. When inspecting
the electrical system check the following:
The oil must meet GM specification 9986231. Mo-
 Check Positive and Negative cables for corro- tor oils meeting this spec receive the API
sion, rubbing, chafing, burning and to ensure (American Petroleum Institute) starburst symbol:
tight connections at both ends.
 Check battery for cracks or damage to the
case and replace if necessary.
 Inspect engine wire harness for rubbing, chaf-
ing, pinching, burning, and cracks or breaks in
the wiring.
 Verify that engine harness connectors are cor-
rectly locked in by pushing in and then pulling
the connector halves outward.
 Inspect ignition coil wire for hardening, crack-
ing, arcing, chafing, burning, separation, split
boot covers. ILSAC GF-4 oils are highly recommended. Oils
 Check spark plug wires for hardening, crack- meeting the SL-4 spec are improved over the pre-
ing, chafing, arcing or burning, separation, and vious generation GF-3 oils in many ways
split boot covers.
 Replace spark plugs at the required intervals  Reduced Phosphorous levels (20%) for re-
per the recommended maintenance schedule. duced catalyst poisoning
 Verify that all electrical components are se-  Improved oxidation resistance (4X oxidation
curely mounted to the engine or chassis. inhibitor treat level = 100% improvement)
11

 Improved hi temp deposit control (1.5X deter-
gents = 25% improvement)
It is noted that the GF-4 oils are also “backward

compatible” and are equal or better than previous
grades of oil in all aspects.
OEM’s may opt for higher viscosity oils based on

their application experience however GF-4 oils
may not be available in these viscosity ranges. In
this case it is recommended the OEM utilize high
quality oil (API rating SM).
Engine Oil Dip Stick (Typical)
CAUTION: Do not to operate your engine with an
oil level below the normal operating range. Se- 5. If the oil level is below the “ADD” mark reinstall
vere engine damage could occur. the dipstick into the dipstick tube and proceed
to Step 6.
SYNTHETIC OILS 6. Remove the oil filler cap from the valve cover.
7. Add the required amount of oil to bring the
Synthetic oils have been available for use in in- level up to, but not over, the “FULL” mark on
dustrial engines for a relatively long period of the dipstick. Reinstall the oil filler cap to the
time and may offer advantages in cold and hot valve rocker arm cover and wipe any excess
temperatures. However, it is not known if syn- oil clean.
thetic oils provide operational or economic
benefits over conventional petroleum-based oils CHANGING THE ENGINE OIL
in industrial engines. Use of synthetic oils does
not permit the extension of oil change intervals. IMPORTANT:
When changing the oil, always change the oil
CHECKING/FILLING ENGINE OIL LEVEL filter.
IMPORTANT: 1. Start the engine and run until it reaches nor-

Care must be taken when checking engine oil lev- mal operating temperature.
el. Oil level must be maintained between the
“ADD” mark and the “FULL” mark on the dipstick.
To ensure that you are not getting a false reading,
make sure the following steps are taken before
checking the oil level.
An overfilled crankcase (oil level being too
high) can cause an oil leak, a fluctuation
1. Stop engine.
or drop in oil pressure. When overfilled,
2. Allow approximately five minutes for the oil to
the engine crankshafts splash and agitate
drain back into the oil pan.
the oil, causing it to aerate or foam.
3. Remove the dipstick. Wipe with a clean cloth
or paper towel and reinstall. Push the dipstick
all the way into the dipstick tube. IMPORTANT:
4. Remove the dipstick and note the amount of Change oil when engine is warm and the old oil
oil on the dipstick. The oil level must be be- flows more freely.
tween the “FULL” and “ADD” marks.
2. Stop engine
12

When refueling or exchanging the fuel cylinder,
check the quick fill valve for thread damage. Also
verify O-ring is in place and inspect for cracks,
Engine oil will be hot. Use protective chunking or separation. If damage to the o-ring
gloves to prevent burns. Engine oil con- is found, replace prior to filling. Check the ser-
tains chemicals which may be harmful to vice line quick coupler for any thread damage.
your health. Avoid skin contact.
IMPORTANT:
When refueling the fuel cylinder, wipe both the
3. Remove drain plug and allow the oil to drain. female and male connection with a clean rag prior
4. Remove and discard oil filter and its sealing to filling to prevent dust, dirt and debris from being
ring. introduced to the fuel cylinder.
5. Coat sealing ring on the new filter with clean
engine oil, wipe the sealing surface on the filter INSPECTION OF THE FUEL FILTER
mounting surface to remove any dust, dirt or
debris. Tighten filter securely (follow filter man- The LPG system on this emission certified engine
ufacturer’s instructions). Do not over tighten. utilizes an in-line replaceable fuel filter element.
6. Check sealing ring on drain plug for any dam- This element should be replaced, at the intervals
age, replace if necessary, wipe plug with clean specified in the recommended maintenance sche-
rag, wipe pan sealing surface with clean rag dule. When inspecting the fuel filter check the
and re-install plug into the pan. Tighten to the following:
OEM specification.
7. Fill crankcase with oil.  Check for leaks at the inlet and outlet fittings,
8. Start engine and check for oil leaks. using a soapy solution or an electronic leak
9. Dispose of oil and filter in a safe and respon- detector and repair if necessary.
sible manner.  Check to make sure filter is securely mounted.
 Check filter housing for external damage or
FUEL SYSTEM INSPECTION AND distortion. If damaged replace fuel filter.
MAINTENANCE
LPG FUEL SYSTEM AIR FUEL MIXER/THROTTLE CONTROL
DEVICE MAINTENANCE AND INSPECTION
The LPG fuel system installed on this industrial
engine has been designed to meet the emission IMPORTANT:
standard applicable for the 2011 model year. To The Air Fuel Mixer components have been
ensure compliance to these standards, follow the specifically designed and calibrated to meet the
recommended maintenance schedule contained in fuel system requirements of the emission certified
this section. engine. The mixer should not be disassembled or
rebuilt. If the mixer fails to operate or develops a
INSPECTION AND MAINTENANCE OF THE leak the mixer should be replaced with the OEM
FUEL STORAGE CYLINDER recommended replacement parts.
The fuel storage cylinder should be inspected When inspecting the mixer check for the following
daily or at the beginning of each operational shift items:
for any leaks, external damage, adequate fuel
supply and to ensure the manual service valve is  Leaks at the inlet fitting.
open. Fuel storage cylinders should always be  Fuel inlet hose for cracking, splitting or chaff-
securely mounted, inspect the securing straps or ing, replace if any of these condition exist.
retaining devices for damage ensure that all lock-  Ensure the mixer is securely mounted.
ing devices are closed and locked. Check to
 Inspect air inlet hose connection and clamp.
ensure that the fuel storage cylinder is positioned
Also inspect inlet hose for cracking, splitting or
with the locating pin in the tank collar on all hori-
chafing. Replace if any of these conditions ex-
zontally mounted cylinders this will ensure the
ist.
proper function of the cylinder relief valve.
13

 Inspect Air cleaner element according to the The measurement of oxygen in the exhaust
Recommended Maintenance Schedule found stream is measured in voltage and sent to the
in this section. ECM. The ECM then makes corrections to the
 Check Fuel lines for cracking, splitting or chaf- fuel air ratio to ensure the proper fuel charge and
ing. Replace if any of these conditions exist. optimum catalytic performance. Therefore, it is
 Verify Throttle body return action to ensure important that the exhaust connections remain
throttle shaft is not sticking. Repair if neces- secured and air tight.
sary.
 Check for leaks at the throttle body and intake
manifold.
PRESSURE REGULATOR MAINTENANCE AND Contamination of the HEGO sensor can re-
INSPECTION sult from the use of an inappropriate RTV
sealer or silicone spray products. Do not use
IMPORTANT: silicone sprays or hoses which are assem-
The Pressure Regulator components have been bled using silicone lubricants. Always use
specifically designed and calibrated to meet the “oxygen sensor safe” RTV sealant for repair
fuel system requirements of the emission certified procedures. Silicon contamination will cause
engine. a high but false HEGO signal voltage (rich
exhaust indication). The ECM will then re-
If the Regulator fails to operate or develops a duce the amount of fuel delivery to the
leak, it should be repaired or replaced with the engine, causing a severe driveability prob-
OEM recommended replacement parts. When lem. If silicone contamination is suspected,
inspecting the regulator check for the following remove and visually inspect the sensor ele-
items: ment. If contaminated, the portion of the
sensor exposed to the exhaust stream will
 Check for any fuel leaks at the inlet and outlet have a white powdery coating. Always be
fittings. sure to eliminate the cause of contamination
 Check for any fuel leaks in the regulator body. before replacing the sensor.
 Check the inlet and outlet fittings of the coo-
lant supply lines for water leaks. When inspecting the Exhaust system check the
 Check the coolant supply lines for hardening, following:
cracking, chafing or splits. If any of these con-
ditions exist replace coolant lines.  Exhaust manifold at the cylinder head for
 Check coolant supply hose clamp connec- leaks and that all retaining bolts and shields (if
tions, ensure they are tight. used) are in place.
 Check to ensure the Regulator is securely  Manifold to exhaust pipe fasteners to ensure
mounted and the mounting bolts are tight. they are tight and that there are no exhaust
 Check the Regulator for external damage. leaks repair if necessary.
 Check the Regulator electrical connections to  HEGO electrical connector to ensure connec-
ensure the connector is seated and locked. tor is seated and locked, check wires to
ensure there is no cracking, splits chafing or
EXHAUST SYSTEM AND CATALYTIC “burn through. Repair if necessary.
CONVERTER INSPECTION AND  Exhaust pipe extension connector for leaks
MAINTENANCE tighten if necessary.
 Visually inspect converter to ensure muffler is
IMPORTANT: securely mounted and tail pipe is properly
The exhaust system on this emission certified en- aimed.
gine contains Heated Exhaust Gas Oxygen  Check for any leaks at the inlet and outlet of
Sensors (HEGOs) which provide feedback to the the converter.
ECM on the amount of oxygen present in the ex-
haust stream after combustion.
14

LPG CERTIFIED ENGINE MAINTENANCE REQUIREMENTS
For maintenance or other work that is not performed under warranty, maintenance, replacement, or repair of
the emission control devices and systems may be performed by any engine repair establishment or individual.
Perform the following maintenance on the engine at the hours indicated and at equivalent hour intervals thereafter.
This maintenance schedule represents the manufacturer’s recom- Interval Hours
mended maintenance intervals to maintain proper engine/equipment
function. Federal, State, or Local regulations may require additional or
more frequent inspection or maintenance intervals than those speci- Daily 1000 1500 2000 2500 3000 3500 4000 4500 5000
fied above. Check with the authority having jurisdiction for details.
General Maintenance Section
Visual check for fluid leaks X
Check engine oil level X
Check coolant level X
Change engine oil and filter Every 100 hours or 60 days of operation
Check LPG system for leaks Prior to any service or maintenance activity
Inspect accessory drive belts for cracks, breaks, splits or glazing X X X X X
Inspect electrical system wiring for cuts, abrasions or corrosion X X
Inspect all vacuum lines and fittings for cracks, breaks or hardening X X
Engine Coolant Section
Clean debris from radiator core Every 100 hours or 60 days of operation
Change coolant--GM 6277M specification (Dexcool) 50-50
Every 5000 hours or five years
mixture with distilled water
Inspect coolant hoses for cracks, swelling or deterioration X X X X X
Replace coolant hoses and accessory drive belt Every 2,000 hours or two years, whichever occurs first
Engine Ignition System
Inspect Battery case for leaks or damage X X X X X
Inspect battery cables for damage corrosion or contamination X X X X X
Check all electrical connector retainer locks X X X X X
Replace spark plugs X X X
Inspect crank sensor timing wheel for debris or damage Every 100 hours or 60 days of operation
Clean ignition coil X X X X X
Check spark plug wires for cuts abrasions or hardening X
Replace distributor cap and rotor X
Replace spark plug wires X
Fuel System Maintenance
Inspect air cleaner Every 200 hours, or every 100 hours in dusty environment
Replace fuel filters X X X X X
Inspect Shut-off Valve for leaks and closing X X
Leak check fuel lines, regulator, fuel rail and injectors X X
Check air induction and intake manifold for leaks X X
Check manifold for vacuum leaks X X
Drain Regulator oil build up Every 100 hours or 60 days of operation
Engine Exhaust System
Inspect exhaust manifold for leaks X X
Inspect exhaust piping for leaks X X
Check HEGO sensor connectors and wires for burns, cuts or damage X X
Inspect catalyst for mechanical damage X X
Note that propane engines are designed to operate on HD–5 or HD–10 specification LPG fuel. Fuel other than HD–5 or HD–
10 may cause harm to the engine’s emission control system and a warranty claim may be denied on this basis if operators
can readily find the proper fuel*. Use of any other fuel may result in your engine no longer operating in compliance with CARB
or EPA emissions requirements. * Not Applicable in the state of California.
15

16

LPG Fuel System
17

LPG FUEL SYSTEM OPERATION
18

DESCRIPTION AND OPERATION OF THE FUEL
SYSTEMS
LPG FUEL SYSTEM

The primary components of the LPG fuel system
are the fuel storage tank, regulator, throttle control
device, fuel injectors, engine control module (ECM), Typical LPG Cylinder
catalytic converter and Heated Exhaust Gas Oxy-
gen (HEGO) Sensor. 1. Liquid Outage Fill Check Valve
2. Pressure Relief Valve
LPG FUEL TANK 3. Liquid Outage valve w/quick disconnect coupl-
ing
LPG is stored in the fuel tank as a liquid. The ap- 4. Filler Valve
proximate pressure of the fuel in the tank is 16.5 5. Fuel Gauge
bar (240 psi) when the tank is full at an ambient 6. Vapor Withdrawal Tube (when applicable)
temperature of 27° C (81°F). The boiling point, 7. 80% Limiter Tube
(temperature at which the liquid fuel becomes va- 8. Fuel Level Float
por) is approximately -40° C (-40° F). When the 9. Liquid Withdrawal Tube
fuel changes from liquid to vapor the fuel expands
and creates pressure inside the tank. When the SERVICE LINE
tank service valve is opened the pressure inside
the tank forces the liquid fuel out though the pickup
LPG flows from the fuel tank to the Regulator via
tube located near the bottom of the fuel cylinder.
the service line connected to the tank utilizing a
quick coupler. The other end of the service line is
connected to a bulkhead connector, allowing for a
safe means of passing through the sheet metal
and into the engine compartment. The service
line is made of high pressure hose with special
material or possibly tubing which is compatible
with the LPG fuel and should always be replaced
with an OEM supplied part.
The service valve mounted in the end of the cylind-

er controls the flow of fuel from the tank. By turning
the handle to its “open” position, fuel flows out of
the tank and into the service line. The service The bulkhead assembly should never be
valve is also equipped with a safety feature called removed. Never run a service line through
an excess flow check valve. This feature reduces the sheet metal.
the flow from the service valve in the event of a rup-
ture of the fuel line or any downstream fuel
FUEL FILTER
transport components. A safety valve is built into
the tank. Normally set at 25.8 bar (375 psi), it will
LPG, fuel like all other motor fuels is subject to
release pressure to prevent tank rupture due to
contamination from outside sources. Refueling of
over-pressurization of the cylinder
the equipment tank and removal of the tank from
the equipment can inadvertently introduce dirt,
rust and other foreign matter into the fuel system.
It is therefore necessary to filter the fuel prior to
entering the fuel system components downstream
19

of the tank. A replaceable, high pressure, inline connection with the throttle and there is no direct
fuel filter is built into regulator and another is in mechanical (cable) connection between the pedal
line between the regulator and fuel rail. Mainten- and the throttle shaft.
ance of the filters is critical to proper operation of
the fuel system and should be replaced according The ECM monitors the foot pedal position sensor
to the maintenance schedule or more frequently when the engine is running. When the operator
under severe operating conditions. depresses or releases the foot pedal, the ECM
sends an electrical signal to the motor on the
REGULATOR electronic throttle to increase or decrease the an-
gle of the throttle blade thereby increasing or
The Regulator is a combination vaporizer and pres- decreasing the volume of air delivered to the en-
sure regulating device with a built-in LPG shut-off gine. Two internal Throttle Position Sensors
solenoid valve. The fuel shutoff is a normally (TPSs) provide feedback to the ECM indicating
closed valve on the vaporizer, controlled by the the position of the throttle shaft and blade. De-
ECM. The valve is opened is opened momentarily faults programmed into the ECM software ensure
when the ignition is first turned on to allow the sys- correct speed, load and emission control for all
tem to pressurize and when the engine is running. throttle ranges.
When open, LPG passes into the regulator and any
liquid LPG is vaporized by heat provided by the en-
gine coolant. The fuel vapor pressure is then
reduced to approximately 88 kPa (12.6 psi) and
delivered to the fuel rail and fuel injectors. The out-
let fuel pressure is referenced to the manifold
pressure for a more stable idle.
A throttle related failure will cause a “LIMP

HOME” mode of operation, where the engine has
no response to the pedal.
THREE WAY CATALYTIC CONVERTER
The Catalytic Converter is a component of the

emissions system which is designed and cali-
brated to meet the emission standards in effect
for 2011 model year.
Regulator
The exhaust gases pass through the honeycomb
The regulator and some of components are servi- catalyst which is coated with a mixture of metals
ceable. (such as platinum, palladium, and rhodium) to
oxidize and reduce CO, HC and NOx emission
THROTTLE CONTROL DEVICE—DRIVE BY gases.
WIRE
Speed control is maintained by the amount of pres-

sure applied to the foot pedal located in the engine
compartment, however, in this Drive By Wire
(DBW) application, the foot pedal has an electronic
20

Engine Control Module (ECM)
Three Way Catalytic Converter
The ECM also performs diagnostic functions on
ENGINE CONTROL MODULE the fuel system and notifies the operator of en-
gine malfunctions by turning on a Malfunction
To obtain maximum effect from the catalyst and Indicator Light (MIL) mounted in the dash. Mal-
accurate control of the air fuel ratio, the emission functions in the system are identified by a
certified engine is equipped with an onboard Diagnostic Trouble Code (DTC) number. In addi-
computer or Engine Control Module (ECM). The tion to notifying the operator of the malfunction in
ECM is a controller which receives input data the system, the controller also stores the informa-
from sensors mounted to the engine and fuel sys- tion about the malfunction in its memory. A
tem and then outputs various signals to control technician can than utilize a computerized diag-
engine operation. nostic scan tool to retrieve the stored diagnostic
code and by using the diagnostic charts in this
manual to determine the cause of the malfunc-
tion. In the event a technician does not have the
computerized diagnostic tool.
HEATED EXHAUST GAS OXYGEN SENSOR
The Heated Exhaust Gas Oxygen (HEGO) Sen-

One specific function of the controller is to main- sor is mounted in the exhaust system to measure
tain a closed loop fuel control which is the amount of oxygen present in the exhaust
accomplished by use of the Heated Exhaust Gas stream. The ECM continuously monitors the
Oxygen Sensors (HEGOs) mounted in the ex- HEGO measurement to determine whether the
haust system. The HEGO sensors send a fuel air ratio is too rich, too lean and richen or
voltage signal to the ECM which then changes lean the mixture of fuel delivered to the engine. If
the amount of fuel being delivered from the injec- the ECM determines that a rich or lean condition
tors to the engine. is present for an extended period of time which
cannot be corrected, the ECM will set a diagnos-
tic code and turn on the MIL light in the dash.
21

The Heated Exhaust Gas Oxygen Sensor
(HEGO) is an emissions control compo-
nent. In the event of a failure, the HEGO
should only be replaced with the recom-
mended OEM replacement part. The
HEGO is sensitive to silicone based prod-
ucts and can become contaminated.
Avoid using silicone sealers or air or fuel
hoses treated with a silicone based lubri-
The Heat Exhaust Gas Oxygen (HEGO) Sensor
cant.
TMAP SENSOR
The Air Temperature/Manifold Absolute Pressure

or TMAP sensor is a combination of two sensors:
1) A variable resistor used to monitor the differ-

ence in pressure between the intake manifold
and outside or atmospheric pressure. The
ECM monitors the resistance of the sensor to
determine engine load (the vacuum drops
when the engine is under load or at wide
open throttle) and may alter the fuel mixture
to improve performance and emissions.
HEGO voltage output.
2) The Manifold Air Temperature (MAT or IAT)
sensor is a variable resistance thermistor lo-
cated in the air intake passage which
measures the temperature of the incoming air.
The ECM uses the resistance value to monitor
incoming air temperature and calculate the en-
gine’s airflow requirement. The ECM provides
a voltage divider circuit so that when the air is
cool, the signal reads a higher voltage, and
lower when warm. On cold starts, the ECM ri-
chens the fuel/air mixture.
22

IGNITION SYSTEM
TMAP Sensor
COOLANT TEMPERATURE SENSOR
The Engine Coolant Temperature sensor or ECT is

a variable resistance thermistor that changes resis-
The ignition system spark system uses a Crank
tance as the engine's coolant temperature
Position and Camshaft Position sensor for engine
changes. The sensor's resistance is monitored by
timing. A coil assembly contain an ignition coil
the ECM to determine a cold start condition and to
regulate various fuel and emission control functions and an ignition module supplies the ignition spark
via a closed loop emission system. for the system. The coil is fired for each cylinder
over two engine revolutions. The distributor
routes each spark event to the appropriate cy-
linder spark plug. The plug is fired near the top of
the compression stroke to ignite the fuel and air
mixture.
CAM SENSOR
In the 2011 engine the CAM sensor and a cam

Coolant Temperature Sensor signal wheel are incorporated into the ignition dis-
tributor mounted on the side of the engine block.
OIL PRESSURE SENDER
CRANK SENSOR
The Engine Oil Pressure Sender is designed to en-
sure adequate lubrication throughout the engine. It
is monitored by the ECM. If the pressure drops, a
MIL will occur.
Crank Sensor
The crank position sensor is a Hall effect sensor

that is triggered by a reluctor wheel on the crank-
Oil Pressure Sender shaft. Two missing teeth are used to determine
23

engines rotational position. The crank sensor is the stage, pilot actuated principal. When the coil is ac-
source of all other ECU functions if this sensor is tuated it pulls the primary seal off the primary orifice
not functioning the ECU will not see an engine against the force of the flat return spring. This al-
speed and will not provide fuel or spark to the en- lows gas to flow out of the upper chamber of the
gine. injector. Because the orifice supplying the upper
chamber is smaller than the primary orifice which is
now allowing fuel to flow out of the upper chamber,
the pressure drops in this chamber and the now
higher pressure in the lower chamber pushes the
main secondary seal off the secondary orifice and
allows full flow of the injector (this occurs in about 1
to 2 ms). When the coil is de-energized the primary
seal is returned to cover the primary orifice by the
force of the flat spring and pressure builds in the
upper chamber forcing the secondary seal down to
seal the secondary orifice and shutting off all flow of
gas.
Fuel Rail Assembly and LPG Injectors.
The gaseous LPG flows into the fuel rail where it is

distributed to the four LPG injectors. At the oppo-
site end of the fuel rail to the inlet port there is a
Fuel Absolute Pressure (FAP) sensor (also known
as a Fuel Rail Pressure Sensor) this sensor allows
the ECU to lengthen or shorten the fuel injector
pulse width to compensate for variations in the ab-
solute fuel pressure supplied to the injectors. This
injector assembly has one end inserted into the
manifold ports and the other end inserted into the
fuel rail ports. There is an o-ring seal on the mani-
fold side and an o-ring and split spacer seal on the
fuel rail side. The fuel rail holds the injectors in
place.
A Spectrum IV Gaseous Fuel Injector
The 2011 saturated drive injectors operate on a two
24

LPG Closed Loop Schematic
25

26

LPG System Diagnosis
27

LPG FUEL SYSTEM DIAGNOSIS
Regulator Assembly
FUEL SYSTEM DESCRIPTION  Verify the manual shut off valve on the
LPG tank is fully opened.
The Engine Control Module (ECM) receives  Verify that the excess flow valve has not
information from various engine sensors in been activated.
order to control the operation of the engine.  Inspect fuel tank to ensure it is properly
mounted and rotated to the correct posi-
LPG is stored in the tank as a liquid and deli- tion.
vered under pressure up to 21.5 BAR (312  Inspect the hoses leading from the tank
psi). At Key ON the Regulator allows LPG to ensuring they are properly connected and
flow from the tank through the fuel filter and do not have any kinks or damage.
inside, where fuel is vaporized and reduced in
pressure. TOOLS REQUIRED:
DIAGNOSTIC AIDS  7/16” Open end wrench (for test port

plugs)
This procedure is intended to diagnose a ve-  Test port adapter
hicle operating on LPG. If the vehicle will not
continue to run refer to Hard Start for prelimi-
DST
nary checks. Before starting this procedure,
complete the following tasks to verify that liq-
uid fuel is being delivered to the EPR:  Diagnostic Scan Tool (DST)
PRESSURE GAUGES
 Inspect fuel tank to verify it has a sufficient
amount of fuel.
 0-15 PSI Gauge
28

FUEL SYSTEM DESCRIPTION
The Engine Control Module (ECM) receives information from various engine sensors in
order to control the operation of the Pressure Regulator and Shut-Off Valve. The Shut-
Off Valve solenoid prevents fuel flow unless the engine is cranking or running.
LPG is stored in the tank as a liquid and delivered under pressure of up to 21.5 BAR
(312 psi). At Key ON the Regulator allows LPG to flow from the tank through the fuel
filter and inside, where fuel is vaporized and reduced in pressure.
DIAGNOSTIC AIDS
This procedure is intended to diagnose a vehicle operating on LPG. If the vehicle will not
continue to run on LPG, refer to Hard Start for preliminary checks. Before starting this
procedure, complete the following tasks to verify that liquid fuel is being delivered to the
Regulator:
 Inspect fuel tank to verify it has a sufficient amount of fuel.

 Verify manual Shut Off valve on the LPG tank is fully opened.
 Verify that the excess flow valve has not been activated.
 Inspect fuel tank to ensure it is properly mounted and rotated to the correct position.
 Inspect the hoses leading from the tank ensuring they are properly connected and do
not have any kinks or damage.
29

LPG FUEL SYSTEM DIAGNOSTICS
Step Action Value(s) Yes No
Were you referred to this procedure by a DTC diagnostic Go to Step Go to
1
Chart? (3) Step (2)
Connect the Diagnostic Scan Tool (DST) to the ECM Data Link
Go to appli-
Connector (DLC) and check for any DTCs. Go to
2 cable DTC
Step (3)
Table
Are any DTCs present in the ECM?
Perform the following visual and physical preliminary checks:
 Check all ECM system fuses and circuit breakers (refer to
Engine Wiring Schematic).
 Check the ECM grounds for being clean, tight and in their
proper locations (refer to Engine Wiring Schematic).
 Check the vacuum hoses for damage, splits, kinks and prop-
er connections.
 Check the fuel system for any type of leak or restriction from
the supply tank.
 Check for air leaks at all mounting areas of the intake mani-
fold sealing surfaces.
 Check for air leaks at all intake ducting between intake mani-
fold and air cleaner. Correct
 Check air cleaner and all vehicle intake ducting for restric- the faulty
Go to
3 tions. condition
Step (4)
 Check exhaust system for flow obstructions or leaks. and Go to
Step 20
Check the ignition wires for the following conditions:
 Cracking or hardening
 Proper routing
 Bare or shorted wires
 Carbon tracking
Check the wiring harness for the following conditions:

 Proper connections
 Pinches
 Cuts or abrasions
Were any faulty conditions found in the preliminary checks?

Go to Step Go to
4 Does the vehicle start and run?
(9) Step (5)
Check the fuel system for the following conditions:
 Verify the LPG fuel tank is at least ¼ full.
 Verify the manual fuel shut-off valve is open and operating
Correct
correctly.
the faulty
 Verify the high-flow valve has not tripped. Go to
5 condition
 Verify the quick disconnect is fully engaged and there are no Step (6)
and Go to
kinks or obstructions in the high pressure LPG supply hose. Step 20
 Verify the LPG fuel filter is clean and unobstructed.
Were any faulty conditions found in the fuel supply system?
30

 Connect a calibrated 0-5” PSI pressure gauge to the pri- If NO
mary pressure test port of the Regulator. pressure
 Make sure the manual shut-off valve is open and turn the was indi-
ignition to ON. cated, Go
 Crank the engine and observe the pressure gauge. to Step
(14)
Does the pressure gauge indicate the proper primary fuel 2.0–4.0 Go to Step
6 pressure? If LOW
PSI (7)
or HIGH
pressure
was in-
dicated,
Go to
Step
(15)
LPG is a gaseous fuel and requires higher secondary igni-
tion voltages than gasoline fueled engines. Check the
ignition system for proper ignition secondary voltage output
with J 26792 or equivalent.
Remove the spark plugs and check for the following: Correct
 Correct plug type for LPG application. the faulty
 Wet electrodes (oil fouling) condition Go to
7
 Cracks and Step (8)
 Wear Go to Step
 Improper gap (20)
 Burned electrodes
 Heavy deposits
Were any faulty conditions found in the ignition system

check?
Perform a leak-down test on the engine. Repair
Are all cylinder leak-down test results within specification? the en-
gine as
<10% Go to Step neces-
8
leakage (12) sary and
Go to
Step
(20)
 Turn OFF the manual fuel shut-off valve.
 Start the engine and let it run until it dies.
 Remove the LPG Temperature Sensor from the Regula-
tor (DO NOT disconnect the electrical connector). Go to
Go to Step
9  Inspect the inside of the low-pressure fuel supply hose Step
(16)
for heavy-end deposits. (10)
Are there any deposits built-up in the low-pressure fuel

supply hose?
31

Step Action Values Yes No
 Remove the FAP sensor from the Fuel Rail and insert the
Pressure Test Adapter and connect to 103 kPa (15 PSI)
10 pressure gauge.
 Connect the DST to the vehicle DLC connector and open the
DST software.
 Turn the manual shut-off valve ON. Start the engine and
allow it to reach operating temperature.
Compare the gauge secondary pressure reading to the actual +/-15 kPa Go to Step Go to
11
pressure on the DST. (2.2 PSI) 19 Step (11)
Is the gauge secondary pressure within the specified percen-

tage of the actual pressure indicated on the DST?
 Turn OFF the manual shut-off valve and let the engine run
Go to Step Go to
12 until it dies.
(14) Step (13)
 Turn the ignition OFF.
 If turned OFF, turn ON the manual shut-off valve.
13
 Disconnect the Lock-off valve electrical connector.
 Apply 12V to the lock-off valve terminals and observe the
pressure gauge. Above Go to Step Go to
14
1.0 PSI 17 Step 18
Does the pressure gauge indicate pressure?
Repair or replace the Shut Off Valve (refer to Repair Instruc-
tions). Go to Step
15 NA
20
Is the action complete?
32

Inspect the following for heavy-end deposits:
 Pressure Regulator. Inspect, clean and/or repair as neces- Go to Step

16 NA
sary (refer to Regulator Repair Instructions). 20
Are all actions complete?

Replace the ECM.
Go to Step
17 NA
20
Replace the Shut Off Valve.
Go to Step
18 NA
20
 System working correctly at this time. Vehicle may have
intermittent electrical connection conditions.
 Return vehicle to original condition (but leave the diagnostic
equipment connected).
Go to Step
19  Start the engine and wiggle test the harness while observing NA
20
the DST Faults Screen and the pressure gauge readings.
 Repair any conditions encountered.

 Clear any active or historic DTCs (DST Service or Faults
Screen).
 Clear Adaptive from memory (DST Service Screen).
 Return the vehicle to original condition.
 Operate the vehicle under all load and driving conditions for
at least 10 minutes.
 Park the vehicle with the engine running and connect the -15% to Go to Step Go to
20
DST to the vehicle’s DLC connector. +15% 21 Step 24
 Open the DST software and switch to the Faults Screen.
 Let the vehicle idle with no load for at least 30 seconds and
observe the Adaptive 1 fuel correction.
Did the Adaptive 1 fuel correction remain within the specified

values?
With engine still idling, apply a load with the hydraulic system
for at least 10 seconds and observe the Adaptive 1 value.
-15% to Go to Step Go to
21
+15% 22 Step 24
Did the Adaptive 1 fuel correction remain within the specified
values?
Raise the engine rpms to 75-90% of maximum full governed
speed with no load for at least 10 seconds and observe the
Adaptive 1 fuel correction. -15% to Go to Step Go to
22
+15% 23 Step 24
Did the Adaptive 1 fuel correction remain within specified val-
ues?
 With the engine still running at 75-90% of full governed
speed, apply a moderate load with the hydraulic system.
 Observe the Adaptive 1 fuel correction. -15% to Go to Step Go to
23
+15% 29 Step 24
Did the Adaptive 1 fuel correction remain within specified val-
ues?
33

Go to Step Go to
24 Was the Adaptive 1 fuel correction less than -15%?
(26) Step (25)
Go to Step
25 Was the Adaptive 1 fuel correction more than +15%? NA
(27)
Engine is running RICH (system is trying to compensate by de-
creasing the amount of fuel). Check the following for any
condition which may cause the engine to run RICH:
 Ignition system (See Step 7).
 Air cleaner and intake system (including vehicle intake Go to Step
26 NA
ducting) for airflow obstructions. (28)
 Exhaust system for flow obstructions.
 HEGO for correct switching characteristics.

Engine is running LEAN (system is trying to compensate by
increasing the amount of fuel). Check the following for any
condition which may cause the engine to run LEAN:
 Intake manifold for leaks.
 All throttle body gaskets or o-rings for leaks.
 All vacuum hoses and fittings for leaks.
 Exhaust system for leaks
Go to Step
27 NA
NOTE: Exhaust system leaks allow for excess O2 to dilute the (28)
HEGO sensor giving a false reading. Engine may exhibit signs
of a rich running condition but the Adaptive 1 corrections will
indicate an excessive positive fuel adjustment.
 HEGO for correct switching characteristics.

28 Repeat Step 20. NA NA
 Remove all test equipment except the DST.
 Connect any disconnected components, fuses, etc.
 Using the DST clear DTC information from the ECM.
 Turn the ignition OFF and wait 30 seconds.
 Start the engine and operate the vehicle to full operating
29 temperature NA NA
 Observe the MIL
 Observe engine performance and driveability
Does the engine operate normally with no stored codes?

Remove all diagnostic equipment and return vehicle to original
condition. Return vehicle to customer.
34

Fuel Symptom Diagnostics
35

FUEL SYMPTOM DIAGNOSTICS
Checks Action
Before using this section, you should have performed On Board Diagnostic
(OBD) Check and determined that:
1. The ECM and MIL are operating correctly.

Before Using This 2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists
Section but without a MIL.
Several of the following symptom procedures call for a careful visual and
physical check. These checks are very important as they can lead to prompt
diagnosis and correction of a problem.
1. Verify the customer complaint.

2. Locate the correct symptom table.
3. Check the items indicated under that symptom.
4. Operate the engine under the conditions the symptom occurs. Verify
Fuel System Check HEGO switching between lean and rich (cycling of voltage).
IMPORTANT! Normal HEGO switching indicates the fuel system is
in closed loop and operating correctly at that time.
5. Take a data snapshot using the DST under the condition that the symp-
tom occurs to review at a later time.
 Check all ECM system fuses and circuit breakers.

 Check the ECM ground for being clean, tight and in its proper location.
 Check the vacuum hoses for splits, kinks and proper connections.
 Check thoroughly for any type of leak or restriction.
 Check for air leaks at all the mounting areas of the intake manifold sealing
surfaces.
 Check for proper installation and leakage around the Regulator and Throt-
tle body.
Check the ignition wires for the following conditions:

Visual and Physical
Checks  Cracking
 Hardening
 Proper routing
 Carbon tracking
 Check the wiring for the following items: proper connections, pinches or
cuts.
 The following symptom tables contain groups of possible causes for each
symptom. The order of these procedures is not important. If the DST read-
ings do not indicate a problem, then proceed in a logical order, easiest to
check or most likely to cause the problem.
36

INTERMITTENT
Checks Action
DEFINITION: The problem may or may not turn ON the (MIL) or store a Diagnostic Trouble Code
(DTC).
Do not use the DTC table if a fault is an intermittent, the use of the DTC
Preliminary Checks
tables with this condition may result in the replacement of good parts.
Faulty electrical connections or wiring can cause most intermittent problems.

Check the suspected circuit for the following conditions:
 Faulty fuse or circuit breaker, connectors poorly mated, terminals not fully
seated in the connector (backed out). Terminals not properly formed or
damaged.
 Wire terminals poorly connected.
Faulty Electrical Con-
 Terminal tension is insufficient.
nections or Wiring
 Carefully remove all the connector terminals in the problem circuit in or-
der to ensure the proper contact tension.
 If necessary, replace all the connector terminals in the problem circuit in
order to ensure the proper contact tension (except those noted as “Not
Serviceable”). See section Wiring Schematics.
 Checking for poor terminal to wire connections requires removing the
terminal from the connector body.
If a visual and physical check does not locate the cause of the problem, op-
Operational Test erate the engine with the DST connected. When the problem occurs, an
abnormal voltage or scan reading indicates a problem circuit.
The following components can cause intermittent MIL and no DTC(s):
 A defective relay.
 Switch that can cause electrical system interference. Normally, the prob-
lem will occur when the faulty component is operating.
Intermittent MIL
 The improper installation of add on electrical devices, such as lights, 2-
Illumination
way radios, electric motors, etc.
 The ignition secondary voltage shorted to a ground.
 The MIL circuit or the Diagnostic Test Terminal intermittently shorted to
ground.
 The MIL wire grounds.
To check for the loss of the DTC Memory:
1. Disconnect the TMAP sensor.

Loss of DTC Memory 2. Run engine under no load until the MIL illuminates.
3. The ECM should store a TMAP DTC which should remain in the memory
when the ignition is turned OFF. If the TMAP DTC does not store and
remain, the ECM is faulty.
37

NO START
Checks Action
DEFINITION: The engine cranks OK but does not start.
Preliminary Checks None
Use the DST to :
 Check for proper communication with both the ECM

 Check all system fuses engine fuse holder. Refer to Engine Controls
ECM Checks
Schematics.
 Check battery power, ignition power and ground circuits to the ECM. Re-
fer to Engine Control Schematics. Verify voltage and/or continuity for
each.
 Check the TMAP sensor.
 Check the cam/crank sensors for output (rpm). This can be verified by an
Sensor Checks
RPM signal on the DST.
 Check the cam angle sensor for output (rpm).
 Verify proper operation of the Shut-off solenoid Valves.
Important: A closed Gas supply valve will create a no start condition.

Fuel System Checks
 Check for air intake system leakage around the Regulator and throttle
body.
 Check the fuel system pressures.
 Refer to the Fuel System Diagnosis.
NOTE: Natural Gas and Propane require higher secondary ignition system
voltages for the equivalent gasoline operating conditions.
1. Check for the proper ignition voltage output with J 26792 or the equiva-
lent.
2. Verify that the spark plugs are correct.
Check the spark plugs for the following conditions:

Ignition System Checks
 Wet plugs (Oil Fouling)
 Cracks.
 Wear.
 Improper gap.
 Burned electrodes.
 Heavy deposits.
 Check for bare or shorted ignition wires.
 Check for loose ignition coil connections at the coil.
38

Checks Action
Important: The LPG Fuel system is more sensitive to intake manifold lea-
kage than the gasoline fuel system.
Check for the following:
 Manifold vacuum leaks.

Engine Mechanical  Venturi vacuum leaks.
Checks  Engine Vacuum leaks.
 Improper valve timing.
 Low compression.
 Improper valve clearance.
 Worn rocker arms.
 Broken or weak valve springs.
 Worn camshaft lobes.
Check the exhaust system for a possible restriction:
Exhaust System Checks  Inspect the exhaust system for damaged or collapsed pipes.
 Inspect the muffler for signs of heat distress or for possible internal fail-
ure.
39

HARD START
Checks Action
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run,
or may start but immediately dies.
Preliminary Checks Make sure the engine’s operator is using the correct starting procedure.
 Check the Engine Coolant Temperature sensor with the DST. Compare
the engine coolant temperature with the ambient air temperature on a
cold engine. If the coolant temperature reading is more than 10 degrees
greater or less than the ambient air temperature on a cold engine, check
Sensor Checks
for high resistance in the coolant sensor circuit. Check the cam/crank
sensors.
 Check the Throttle Position (TPS) and Foot Pedal Position (FPP) sensor
connections.
Important: A closed LPG manual fuel shut off valve will create a no start
condition.
 Check Venturi assembly for proper installation and leakage.

Fuel System Checks  Verify proper operation of the Shut-off solenoid Valves.
 Verify proper operation of the system low pressure Regulator.
 Check for air intake system leakage between the Throttle Body and Air
Filter Assembly. Check the fuel system pressures. Refer to the Fuel
System Diagnosis.
NOTE: LPG requires higher secondary ignition system voltages for the
equivalent gasoline operating conditions.
 Check for the proper ignition voltage output with J 26792 tool or the
equivalent.
 Verify that the spark plugs are the correct type and properly gapped.
Check the spark plugs for the following conditions:
 Wet plugs (oil fouling).

 Cracks.
Ignition System Checks  Wear.
 Heavy deposits.
 Check for bare or shorted ignition wires.
 Check for moisture in the distributor cap.
 Check for loose ignition coil connections.
Important:
1. If the engine starts but then immediately stalls, check the cam/crank sen-
sor.
2. Check for improper gap, debris or faulty connections.
40

Checks Action
Important: The LPG Fuel system is more sensitive to intake manifold lea-
kage than the gasoline fuel supply system.
Check for the following:
 Engine vacuum leaks

Engine Mechanical  Manifold vacuum leaks.
Checks  Venturi Vacuum Leaks
 Improper valve timing-how?
 Low compression
 Worn rocker arms
 Broken or weak valve springs
 Inspect the exhaust system for damaged or collapsed pipes.

Exhaust System Checks  Inspect the muffler for signs of heat distress or for possible internal fail-
ure.
Check for possible plugged catalytic converter. Refer to Restricted Exhaust
System Diagnosis.
41

CUTS OUT, MISSES
Checks Action
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load
increases, but normally felt below 1500 rpm. The exhaust has a steady spitting sound at low speed, or
hard acceleration for the fuel starvation that can cause the engine to cut-out.
Preliminary Checks None
1. Start the engine.
2. Check for proper ignition output voltage with spark tester J 26792.
3. Check for a cylinder misfire.
4. Verify that the spark plugs are the correct type and properly gapped.
Remove the spark plugs and check for the following conditions:
 Insulation cracks.
 Wear.
Ignition System Checks
 Improper gap.
 Heavy deposits.
Visually/Physically inspect the secondary ignition for the following:
 Ignition wires for arcing and proper routing.

 Cross-firing.
 Ignition coils for cracks or carbon tracking.
Perform a cylinder compression check. Check the engine for the following:

Engine Mechanical  Improper valve clearance.
Checks  Worn rocker arms.
 Check the intake and exhaust manifold passages for casting flash.
Check the fuel system:
Fuel System Checks  Plugged fuel filter (if equipped).

 Low fuel pressure, etc. Refer to Fuel System Diagnosis.
 Check the condition of the wiring to the Shut-off Valves.
Check for Electromagnetic Interference (EMI), which may cause a misfire con-
dition. Using the DST, monitor the engine rpm and note sudden increases in
Additional Check rpm displayed on the scan tool but with little change in the actual engine rpm.
If this condition exists, EMI may be present. Check the routing of the second-
ary wires and the ground circuit.
42

HESITATION, SAG, STUMBLE
Checks Action
DEFINITION: The engine has a momentary lack of response when accelerating the engine. The condi-
tion can occur at any engine speed. The condition may cause the engine to stall if it’s severe enough.
Preliminary Checks None.
 Check the fuel pressure. Refer to Fuel System Diagnosis.
 Check for low fuel pressure during a moderate or full throttle accelera-
tion. If the fuel pressure drops below specification, there is possibly a
faulty low pressure regulator or a restriction in the fuel system.
Fuel System Checks
 Check the TMAP sensor response and accuracy.
 Check Shut-Off electrical connections.
 Check the Regulator, Venturi and Throttle body for proper installation
and leakage.
NOTE: Natural Gas and Propane require higher secondary ignition system
voltages for the equivalent gasoline operating conditions.
Ignition System Checks  Check for the proper ignition voltage output with J 26792 or the equiva-
lent. Verify that the spark plugs are the correct type and properly gapped.
 Check for faulty spark plug wires.
 Check for oil fouled spark plugs.
 Check for manifold vacuum or air induction system leaks.

Additional Check
 Check the alternator output voltage.
43

BACKFIRE
Checks Action
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping
noise.
Preliminary Check None.
NOTE: LPG requires higher secondary ignition system voltages for the
equivalent gasoline operating conditions.
 Check for the proper ignition coil output voltage using the spark tester
J26792 or the equivalent.
 Check the spark plug wires by connecting an ohmmeter to the ends of
each wire in question. If the meter reads over 30,000 ohms, replace the
wires.
 Check the connection at ignition coil.
Ignition System Checks  Check for deteriorated spark plug wire insulation.
Remove the plugs and inspect them for the following conditions:

 Cracks.
 Wear.
 Improper gap.
 Heavy deposits.
Important! The LPG Fuel system is more sensitive to intake manifold
leakage than a gasoline fuel supply system.
Check the engine for the following:

Engine Mechanical  Engine compression.
Check
 Manifold vacuum leaks.
 Intake manifold gaskets.
 Sticking or leaking valves.
 Exhaust system leakage.
 Check the intake and exhaust system for casting flash or other restric-
tions.
Fuel System Checks Perform a fuel system diagnosis. Refer to Fuel System Diagnosis.
44

LACK OF POWER, SLUGGISHNESS, OR SPONGINESS
Checks Action
DEFINITION: The engine delivers less than expected power. There is little or no increase in speed
when throttling the engine.
 Refer to the Fuel system OBD System Check.
 Compare the customer’s engine with a similar unit to verify customer has
an actual problem. Do not compare the power output of the engine op-
erating on Natural Gas and Propane to one operating on gasoline as the
Preliminary Checks
fuels do have different performance characteristics.
 Remove the air filter and check for dirt or restriction.
 Check the vehicle transmission.
 Refer to the OEM transmission diagnostics.
 Check for a restricted fuel filter, contaminated fuel, or improper fuel pres-
sure. Refer to LPG Fuel System Diagnosis.
 Check for the proper ignition output voltage with the spark tester J 26792
or the equivalent.
 Check the Regulator and Throttle body for proper installation and lea-
Fuel System Checks
kage. Check all air inlet ducts for condition and proper installation.
 Check all air inlet ducts for condition and proper installation.
 Check for fuel leaks in supply lines.
 Verify that the Fuel Supply Valve on the supply line is open.
 Verify that liquid fuel (not vapor) is being delivered to the Regulator.
 Check the Heated Exhaust Gas Oxygen Sensor (HEGO) for contamina-
Sensor Checks tion and performance. Check for proper operation of the TMAP sensor.
 Check for proper operation of the TPS and FPP sensors.
 Inspect the exhaust system for damaged or collapsed pipes.

Exhaust System Checks  Inspect the muffler for signs of heat distress or for possible internal fail-
ure.
 Check for possible plugged catalytic converter.
Check the engine for the following:
Engine Mechanical  Engine compression.

Check  Valve timing.
 Improper or worn camshaft.
 Refer to Engine Mechanical in the Service Manual.
 Check the ECM grounds for being clean, tight, and in their proper loca-
tions.
If all procedures have been completed and no malfunction has been found,
Additional Check
review and inspect the following items:
 Visually and physically, inspect all electrical connections within the sus-
pected circuit and/or systems.
 Check the DST data.
45

POOR FUEL ECONOMY
Checks Action
DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected.
Also, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by
refueling records.
 Check the air cleaner element (filter) for dirt or being plugged.
 Visually check the vacuum hoses for splits, kinks, and proper connec-
tions.
 Properly inflated tires.
Check the operators driving habits for the following:

Preliminary Checks
 Excessive idling or stop and go driving.
 Carrying of very heavy loads.
 Rapid acceleration.
 Suggest to the owner to fill the fuel tank and to recheck the fuel economy
and/or suggest that a different operator use the equipment and record the
results.
 Check the Regulator fuel pressure. Refer to Fuel System Diagnosis.
Fuel System Checks
 Check the fuel system for leakage.
Sensor Checks  Check the TMAP sensor.
Verify that the spark plugs are the correct type and properly gapped.

 Cracks.
 Wear.
 Improper gap.
Ignition System
Checks
 Heavy deposits.
Check the ignition wires for the following items:
 Cracking.
 Hardness.
 Proper connections.
Cooling System Check the engine thermostat to see if it is stuck open or for the wrong heat
Checks range.
46

ROUGH, UNSTABLE, OR INCORRECT ENGINE SPEED, STALLING
Checks Action
DEFINITION: The engine runs unevenly at under no load. If severe enough, the engine may shake.
The engine speed may vary in rpm. Either condition may be severe enough to stall the engine.
Preliminary Check None.
Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance:
 Check for silicone contamination from fuel or improperly used sealant. If

contaminated, the sensor may have a white powdery coating result in a high
but false signal voltage (rich exhaust indication). The ECM will reduce the
Sensor Checks
amount of fuel delivered to the engine causing a severe performance prob-
lem.
Check the Temperature Manifold Absolute Pressure (TMAP) sensor response

and accuracy.
 Check for rich or lean symptom that causes the condition.
 Run the engine at the speed of the complaint.
 Monitoring the oxygen sensor will help identify the problem.
 Verify proper operation of the Regulator.
Fuel System Checks  Perform a cylinder compression test. Refer to Engine Mechanical in the
Service Manual.
 Check the Regulator fuel pressure. Refer to the Fuel System Diagnosis.
 Check the Regulator, Venturi and Throttle body for proper installation and
leakage.
 Check for the proper ignition output voltage using the spark tester J26792 or
the equivalent.

Ignition System  Cracks.
Checks  Wear.
 Improper gap.
 Blistered insulators.
 Heavy deposits.
Check the spark plug wires by connecting an ohmmeter to the ends of each
wire in question. If the meter reads over 30,000 ohms, replace the wires.
Important: The LPG Fuel system is more sensitive to intake manifold leakage
than the gasoline fuel supply system.
 Check for vacuum leaks. Vacuum leaks can cause poor engine perfor-
Additional Checks mance.
 Check the ECM grounds for being clean, tight, and in their proper locations.
Check the battery cables and ground straps. They should be clean and se-
cure. Erratic voltage may cause all sensor readings to be skewed resulting
in poor engine performance.
47

Checks Action
Check the engine for:
 Broken motor mounts.

Engine Mechani-
 Low compression.
cal Check
 Worn rocker arms.
48

SURGES/CHUGGLES
Checks Action
DEFINITION: The engine has a power variation under a steady throttle. The engine feels as if it speeds
up and slows down with no change to the throttle.
Preliminary Checks None.
Sensor Checks Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance.
 Check for Rich or Lean symptom that causes the condition.
 Run the engine at the speed of the complaint. Monitoring the oxygen sen-
sor will help identify the problem.
 Check the fuel pressure while the condition exists. Refer to Fuel System
Fuel System Checks
Diagnosis.
 Verify proper fuel control solenoid operation.
 Verify that the LPG manual shut-off valve is fully open.
 Check the in-line fuel filter for restrictions.
 Check for the proper ignition output voltage using the spark tester J26792 or
the equivalent.
Ignition System  Wet plugs (oil fouling).

Checks  Cracks.
 Wear.
 Improper gap.
 Heavy deposits.
Check the Crankshaft Position (CKP) sensor.
 Check the ECM grounds for being clean, tight, and in their proper locations.
Additional Check
 Check the vacuum hoses for kinks or leaks.
 Check Transmission
49

CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS
RESULTS OF INCORRECT OPERATION
A plugged positive crankcase ventilation (PCV) orifice or hose may cause the following conditions:
 Rough or unstable engine speed

 Stalling or low idle speed
 Oil leaks
 Oil in the air cleaner
 Sludge in the engine
A leaking PCV orifice or hose may cause the following problems:
 Rough or unstable engine speed.

 Stalling
 High idle speed
Functional check:
Any blow-by in excess of the system capacity, from a badly worn engine, sustained heavy load, etc., is exhausted
into the air cleaner and is drawn back into the engine.
Proper operation of the crankcase ventilation system depends on a sealed engine. If irregular oil flow or dilution is
noted and the crankcase ventilation system is functioning properly, check the engine for another possible cause.
Correct any of these problems first.
If an engine is idling rough, inspect for a clogged PCV orifice, a dirty vent filter, air cleaner element, or plugged
hose. Replace any faulty items found. Use the following procedure:
 Remove the PCV hose (positive side) from the rocker arm cover.
 Operate the engine at idle.
 Place your thumb over the end of the hose in order to check for vacuum. If there is no vacuum at the hose end,
inspect for the following items:
 Plugged hoses
 The manifold vacuum port
 Turn the engine OFF.

 Inspect the PCV orifice in the valve cover for debris or blockage.
50

Electrical Section
51

52

DST (Diagnostic Scan Tool)
53

DST (Diagnostic Scan Tool)
Software Installation Instructions
 Installation of the USB to CAN adapter driver and utility.

 Installation of the Spectrum series IV DST software program.
 Software login and password functionality.
DST INSTALLATION INSTRUCTIONS
Before installing the DST software, please be sure your computer meets the minimum system re-
quirements.
Supported operating systems are:
 Windows 7 (32 bit)

 Windows Vista (32 bit)
 Windows XP (32 bit)
Minimum processor speed:
 Pentium III 1.0 GHz
Minimum RAM requirement:
 Windows 7 1 GB
 Windows Vista 512 MB
 Windows XP 256 MB
Additional:
 Display capable of at least 1024 x 768 screen resolution and one available USB port.
Examples and snapshots used in this manual are based off of the initial DST tool release as of Au-
gust, 2011 using the Windows 7 operating system. This tool is used for multiple fuel systems and is
frequently updated. Snapshot illustrations may vary depending on the installed operating system
and changes included in any updated DST display Interface. This software has the ability to auto-
matically detect functions that may or may not be used in any one particular fuel system. In this
instance unused or irrelevant values and graphic displays will be shaded in gray on the DST display
screens. Terms, names and descriptions of systems and other servicing procedures may be up-
dated periodically with new DST installation software.
54

Ifak Driver and Utility Installation:
NOTE: Close any open applications prior to installing the DST.
Insert the Ifak CD included with your USB to CAN adapter and open the file folder.
For users with restricted rights using Windows 7 or Windows Vista, select Run as administrator as shown above.
For all others, select the Setup file. You may receive a Windows message asking you to confirm the installation
request by an unknown publisher. You must select Yes to continue the installation.
55

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

Click the Finish box to complete the installation. It is now recommended you re-boot your computer.
Connect the Ifak adapter to an available USB port. You may see a message confirming you wish to make changes
to the computer from an unknown publisher. If so, you must select the Yes box to continue the installation. Win-
dows will now install the Ifak driver to your computer. You should see a message confirming the driver was
successfully installed as shown above.
57

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

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

When the Ifak device serial number is shown, click the Select box, then click the OK box. The Ifak driver and utility
installation is now complete. If you had problems during this installation please see the additional information and
test instructions for your Ifak adapter included with your service test kit.
60

Spectrum Series IV DST Software Installation:
In most instances the OEM manufacturer will have supplied you the DST software installation files. The instal-
lation files may have been provided to you by internet download, CD or other media storage. Regardless of the
delivery system, please follow the instructions to install the DST software below. If the files were supplied to you in
a .zip file format it is strongly recommended that the files are first unzipped before proceeding with the DST soft-
ware installation.
Insert the CD, USB flash drive, other storage media or find the location where the DST software has been saved on
your computer.
Open the Spectrum_Series_IV_DST file folder.
61

For users with restricted rights using Windows 7 or Windows Vista, it may be necessary to select the Run as
administrator box similar to the Ifak USB driver installation. For all others, click the Spectrum Engine Moni-
tor.msi file. You may receive a Windows message asking you to confirm the installation request by an unknown
publisher. If so, you must select the Yes box to continue the installation.
Click the Next box.
62

Follow the on screen prompts that will guide you through the installation.
The Spectrum 4 logo shortcut is placed on the desktop confirming the installation is complete. It is now recom-
mended that you re-boot your computer.
63

Connecting the DST:
Connect the Diagnostic Link Connector or DLC to the Ifak adapter’s connector. Connect the other end of the DLC
connector to the engine harness (3 pin connector).
Click on the Spectrum 4 shortcut to open the DST software program. Turn the engine ignition power ON.
64

Click on the S3000 tab at the lower left of the Spectrum Engine Monitor page.
On the S3000 data stream page, pull down the Settings menu and click on Connection Settings
65

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

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

Using the Spectrum DST
The Spectrum IV DST is the next generation all CAN (Controller Area Network) enabled diagnostic tool. This is
a new tool for emission year 2011. It is designed to be compatible for all 2011 Spectrum fuel systems that use both
the MEFI (industrial) and S3000 (mobile) ECM applications. The DST operates on an expandable platform and its
functions are planned to increase in the future. The functions are listed below:
 Updating the ECM calibration using the .s37 calibration file.

 Provide graphical display interface for engine and sensors parameters
 Display DTC (Diagnostic Trouble Codes)
 Provide data stream information from engine sensors and actuators
 Plot data.
 Record Data
68

Updating the ECM Calibration
In field updates (or reflashing) are possible with the S3000 ECM using the DST. Always check first to be sure
the ECM has been programmed with the latest calibration before attempting any diagnostic or service repair proce-
dure. Calibration files are supplied in the .s37 file format. These files may be supplied to you by the OEM along
with a password unique to that particular s.37 file. You will need the password to complete the re-programming
procedure. Before re-programming the ECM, shut down any other programs running on your PC including wireless
and e-mail programs. The PC must be dedicated to the re-programming process at this time. Be sure your PC bat-
tery is adequately charged. Failure to follow these instructions may render the ECM not usable in the field.
Under the Tools drop down menu, select Reprogram S3000 Engine Control Unit. Turn ignition power ON.
The S3000 Flash Upgrade Wizard dialog box will appear. Select the Next box.
69

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

Select the Next box.
The progress bar shows the status updating.
Any interruption during the re-programming

process may render the ECM unusable in
the field.
71

Please wait until you receive a message confirming the update is complete.
Turn the ignition power OFF. Wait 10 seconds and select Finish.
Turn the ignition ON. Verify the calibration updated with the new file number in the ECM Part Number data stream
shown above. The reprogramming process is now complete.
72

Graphic Display Interface
Shown as the monitor page in the DST, the above page is the default entry page that opens with the DST pro-
gram. It provides a graphical interface for important engine parameters. Graphics shown in gray are not available
for the specific application the DST may be connected to as shown above. This function is controlled by the ECM
calibration file and cannot be changed by the service technician.
73

Display DTC (Diagnostic Trouble Codes)
DTC codes can be read by clicking on the Diagnostics tab at the bottom of the monitor page. The source of
the DTC stream can be set manually for the MEFI ECM or the S3000 ECM, or left in the default All position for auto
detection of the DTC codes from either MEFI or the S3000 ECM. Codes that can be viewed are set in two catego-
ries, active and historic. Active codes are codes that are set and the fault that is causing the code to set is
constant. Historic codes are codes that have set in the past, but the fault that caused them has been corrected
such as with an intermittent problem. This function is selectable by choosing the Active or Historic, as shown in
the above image. Codes can be cleared by clicking the Clear box. The DTC set code list may also be saved by
clicking the Save box shown above. The file will be saved in a convenient HTML file compatible with Windows In-
ternet Explorer and will provide a browse function to save the file to a location of choice for the service technician.
74

Data Stream:
The fuel and emissions service manual will refer to the DST and asked that it be connected in the data stream
mode. This simply means it is first connected and that data is shown on the S3000 data stream page as shown
above. The data stream page can be accessed by selecting the S3000 tab shown at the lower left above.
Plot Data:
Data stream information may also be selected for a trace plot. This page is available by clicking the Plot tab at the
lower page center as shown above.
75

The custom parameters of the plot can be selected by clicking on the plot icon just below the Settings menu item
at the top left of the page shown above. To save the custom settings select OK.
76

Diagnosing Intermittent Problems
Intermittent fuel system problems can prove to be the most challenging to diagnose. It is of the upmost
important when diagnosing intermittent problems to operate the engine system while monitoring with the
DST and pressure gauge set. An example of this would be if the DST showed a lean fuel mixture at full
load. One of the first things to look at would be the fuel pressure. The fuel pressure would need to be mo-
nitored while the engine is operating at full load, not at low or no load because the leaning effect does not
occur until full load. Electrical problems should be treated in a similar same way. One excellent tool for
finding intermittent electrical problems is the DST plot function. Set up the plot for the sensor code that
sets. An example of this would be if an intermittent IAT code set, tag the IAT voltage and watch the plot.
While watching the plot, agitate the electrical wire connection at the sensor and ECM connector. The reso-
lution of the plot screen is such that you will be able to see any unstable voltages that you may not see with
a standard DVOM.
Caution should be used when pressure washing the under hood of any electrical system. Avoid direct
pressure spray on the system electrical connectors. The connectors are splash proof but if high pressure
water or steam is sprayed directly at the connector moisture can become trapped behind the connector
seal and cause serious system problems, many of them showing up as intermittents. Extra care must be
taken when probing electrical pins and terminals. Do not bend or spread these terminals as this can also
be a source of intermittent problems cause by improper handling of these low voltage connectors and ter-
minals. When running electrical diagnostics avoid back probing the wire connectors as this may damage
the wire seal. When running the continuity checks use a wire probe to only touch the wire terminal. Forc-
ing the electrical probe into the terminal may cause the terminal to spread leading to permanent damage.
More Intermittent diagnostic information can be found on the Fuel Symptom Diagnostics, Intermittent Diag-
nostic Charts.
Fuel System Checks
This system has OBD (Onboard Diagnostics) for many sensors, relays and monitors, but not all mal-
functions have a DTC code available to alert the service technician to a problem. A good example of this
would be the engine ignition system. If a spark plug, cap, rotor or wire fails a DTC code may not be set.
The DST provides advanced diagnostic capabilities, but some items are still left to the basics of general
engine mechanics. Following the recommended maintenance schedule is the best way to prevent this type
of problem for which a DTC code does not exist. Many times the basics are overlooked and can be attri-
buted to improper maintenance. Some general rules to follow are:
 Check to be sure the ECM is programmed with the latest calibration file
 Check general engine tune up items such as spark plugs, distributor cap and rotor, spark plug wires,
air, and fuel filters if equipped with such.
 Check that the charging system is working correctly.
 Check block heaters, battery heaters, battery terminals and fuel supply systems for proper operation.
77

78

INTERMITTENT PROBLEMS
Intermittent fuel system problems can prove to be the most challenging to repair. It is most important to
remember when looking to find the cause of these problems, to operate the system in the condition when
and where the problem occurs. An example of this would be, if the DST showed a lean fuel mixture at full
load, one of the first things to look at would be the fuel pressure. The fuel pressure would need to be
monitored while the machine is operating at full load, not at idle because the leaning effect does not oc-
cur at idle. Electrical problems should be treated the same way. One excellent tool for finding
intermittent electrical problems is the DST plot/log function. Set up the plot for the code that sets. An ex-
ample of this would be if an intermittent IAT code set, tag the IAT voltage and watch the plot. While
watching the plot, agitate the electrical wire connection at the sensor and ECM connector. The resolution
of the plot screen is such that you will be able to see any unstable voltages that you would otherwise not
see with a standard DVOM.
Caution should be used when pressure washing the under hood of any electrical system. Avoid direct
pressure spray on the system electrical connectors. They are splash proof, but if water is sprayed direct-
ly at the connector moisture can become trapped behind the connector seal and cause serious system
problems.
Extra care must be taken when probing electrical pins and terminals. Do not bend or spread these ter-
minals as this can also be a source of intermittent problems cause by improper handling of these
connectors.
79

80

Engine Wire Schematic
81

2011 3.0L GM Engine IMPCO Emission Certified LPG Fuel System
82

83

84

Engine Wire Harness Repair
85

ON-VEHICLE SERVICE REPAIRING TWISTED/SHIELDED CABLE
WIRE HARNESS REPAIR
The ECM harness electrically connects the

ECM to a various components in both the en-
gine and passenger compartments.
Wire harnesses should be replaced with proper 1. Remove outer jacket

part number harnesses. When wires are spliced
into a harness, use wire with high temperature 2. Unwrap aluminum/Mylar tape. Do not re-
insulation only. move Mylar.
Low current and voltage levels are used in the

system, so it is important that the best possible
bond at all wire splices be made by soldering the
splices.
3. Untwist conductors, strip insulation as ne-
CONNECTORS AND TERMINALS cessary.
Use care when probing a connector or replacing

terminals in them to prevent shorting opposite
terminals and damage certain components. Al-
ways use jumper wires between connectors, for
circuit checking. Do not probe through the 4. Splice wire using splice clips and rosin
Weather-Pack seals with oversized wire probes. core solder. Wrap each splice to insulate.
Use tachometer adapter J 35812 (or equivalent)
which provides an easy hook up of the tach lead. 5. Wrap with Mylar and drain wire (uninsu-
The connector test adapter kit J 35616 (or lated) wire.
equivalent), contains an assortment of flexible
connectors used to probe terminals during diag-
nosis. Fuse remover and test tool BT 8616, or
equivalent, is used for removing a fuse and to
adapt fuse holder, with a meter, for diagnosis.
Do not solder oxygen sensor wire terminals as 6. Tape over entire juncture and secure.
these wire ends are used for the sensors oxygen
reference.
Open circuits are often difficult to locate by sight

due to dirt, oxidation, or terminal misalignment.
Merely wiggling a connector on a sensor, or in
the wiring harness, may correct the open circuit
condition. This should always be considered,
when an open circuit, or failed sensor is indi-
cated. Intermittent problems may also be caused
by oxidized or loose connections.
Before making a connector repair, be certain of

the type of connector. Weather-Pack and Com-
pact Three connectors look similar, but are
serviced differently.
86

REPAIRING TWISTED LEADS METRI-PACK
Some connectors use terminals called Metri-

Pack Series 150. They are also called “Pull-To-
Seat” terminals because of the method of instal-
lation. The wire is inserted through the seal and
connector, the terminal is crimped on the wire
1. Locate Damaged Wire. and then pulled back into the connector to seat it
2. Remove insulation as required. in place.
3. Splice two wires together suing splice

clips and rosin core solder.
4. Cover splice with tape to insulated from

other wires.
5. Retwist as before and tape with electrical
tape and hold in place.
MICRO-PACK
Refer to Figure 2 and repair procedure for re-

placement of a Micro-Pack terminal. Metri-Pack Series 150 Terminal Removal
1. Slide the seal back on the wire.

2. Insert tool BT-8518, or J 35689, or equiva-
lent, as shown in insert “A” and “B” to release
the terminal locking tab (2).
3. Push the wire and terminal out through the
connector. If reusing the terminal, reshape
the locking tab (2).
WEATHER-PACK
A Weather-Pack connector can be identified by a

rubber seal, at the rear of the connector. The
connector is used in the engine compartment to
protect against moisture and dirt that may oxid-
ize and/or corrode the terminals. Given the low
Micropack Connector voltage and current levels found in the electronic
system, this protection is necessary to ensure a
1. Cable good connection.
2. Terminal
3. Locking Tang
4. Tool J33095/BT8234-A
87

WEATHER-PACK TERMINAL REPAIR backup, or secondary locking feature for the
connector. They are used to improve the con-
nector reliability by retaining the terminals, if the
small terminal lock tabs are not positioned prop-
erly.
Weather-Pack connections cannot be replaced

with standard connections. Additional instruc-
tions are provided with Weather-Pack connector
and terminal packages.
1. Open secondary lock hinge on connector.
2. Remove terminal using tool.
3. Cut wire immediately behind cable seal
4. Replace terminal.
a. Slip new seal onto wire
b. Strip 5 mm (.2”) of insulation from wire.
c. Crimp terminal over wire and seal.
5. Push terminal and connector and engage

locking tangs.
6. Close secondary lock hinge.
Use tool J M28742, or BT8234-A or equivalent to

remove the pin and sleeve terminals. If the re-
moval is attempted with an ordinary pick, there is
a good chance that the terminal will be bent, or
deformed. Unlike standard blade type terminals,
these terminals cannot be straightened once
they are bent.
Verify that the connectors are properly seated

and all of the sealing rings in place, when con-
necting leads. The hinge type flap provides a
88

Diagnostic Trouble
Codes (DTCs)
89

Ignition Control System Diagnostics
Before using the Ignition Control Diagnostic chart be sure to check the following items:
Spark plug wires:

Be sure spark plug wires are in good condition. Check for cuts, breaks, burns, hardness or swelling.
LPG fuel requires much higher peak firing voltages compared to gasoline. Check spark plug electrical
continuity using a DVOM. Wires should ohm out to no more than 1,000 ohms per foot of wire length.
Distributor cap and rotor:

Check the cap and rotor assembly for moisture, corrosion or carbon tracking. The ignition timing is not
adjustable. Turning the distributor assembly will not change the ignition timing, but will alter the rotor
phase. Wipe away dust and debris from the ignition coil tower.
System power fuses:

Check the system power fuses. These sources supply the ignition coil and module system power.
Check that the power and ground terminals are clean and in the proper location.
90

Ignition Control System Diagnostic Chart
Did you perform the On-Board (OBD) System Go to OBD Sys-
Go to Step
1 Check? - tem Check
(2)
Section
 DST connected and in the system data mode.
 Crank the engine and observe the engine
Go to Step
2 speed signal on the DST ~125 RPM Go to Step (3)
(5)
Is the value greater than the specified value?
 Check the DST for historical code sets.
(Always diagnose and repair codes with the
Go to Step
3 lowest numerical value first). Go to Step (4)
(16)
Did you find and correct the problem?
 Run the diagnostic chart for DTC 522752 Go to Step
4 Go to Step (5)
Did you find and correct the problem? (16)
 Disconnect the ignition module connector
C035
 Using an LED type test lamp check for a sig-
nal between the ignition module connector
5 pin B and battery positive Go to Step(6) Go to Step (10)
 Crank the engine
Does the LED test lamp flash while cranking the

engine?
 Using a DVOM check for power between the Repair the sys-
ignition module connector pin A and engine tem power
ground System vol- Go to Step circuit. Check
6
tage (7) all system fuses
Do you have power? and power relay
connections
 Disconnect the ignition coil connector C035
 Using a digital LED test lamp check for a sig-
nal between the ignition coil connector pin B
and battery positive Go to Step
7 Go to Step (13)
 Crank the engine (8)
Does the LED test lamp flash while cranking the

engine?
 Using a DVOM check for voltage between the Repair the sys-
ignition coil connector pin A and engine tem power
ground System vol- Go to Step circuit. Check
8
tage (9) all system fuses
Does the DVOM show voltage? and power relay
connections
 Replace the ignition coil
Go to Step
9 _
(16)
Is the replacement complete?
91

 Key OFF
 Disconnect the connector ECU-C Repair the open
 Using a DVOM check for continuity between ignition control
Go to Step
10 ignition module connector pin B and ECM circuit. See wir-
(11)
connector pin K1 ing harness
repair section.
Do you have continuity between them?
 Using a DVOM check for continuity between Repair the
ignition module connector pin B and engine shorted to
ground ground igni-
11 tion control Go to Step (12)
Do you have continuity between them? circuit. See
wiring harness
repair section.
 Replace ECM
Go to Step
12 -
(16)
 Disconnect coil. Using a DVOM check for Repair the open
continuity between the ignition module con- ignition module
Go to Step
13 nector pin C and engine ground ground circuit.
(14)
See wiring har-
Do you have continuity? ness repair.
 Using a DVOM check for continuity between Repair the open
the ignition module connector pin D and igni- ignition module
Go to Step
14 tion coil connector pin B circuit. See wir-
(15)
ing harness
Do you have continuity? repair.
 Replace the ignition module.
Go to Step
15 -
(16)
 Connect any disconnected components, fus-
es, etc.
 Using the DST clear DTC information from
the ECM.
 Start the engine and operate the vehicle to
Go to OBD Sys-
16 full operating temperature System OK
tem Check
 Observe the MIL
 Observe engine performance and driveability
 After operating the engine check for any
stored codes.
Does the engine operate normally with no stored

codes?
92

93

DTC 51 ETC TPS 1 Range
Conditions for Setting the DTC
 Electronic Throttle Control

 Check Condition-Ignition ON
 Fault Condition-TPS 1 voltage below 0.2 TPS 2 voltage greater than 4.95
 MIL-On during active fault
Circuit Description
The electronic throttle body has two throttle position sensors TPS1 and TPS2. The voltage from these
sensors is used to determine the percentage throttle opening. The TPS sensors have a nominal output
range of 0.2 to 4.95 volts. From the throttle body itself TPS1 ranges from 0.2 to 4.95 volts as the throttle is
opened, TPS2 ranges from 4.95 to 0.2 volts for this same closed to open travel. The ECM rectifies TPS2
signal so both signals on the diagnostic monitor read from 0.2 to 4.95 as the throttle is opened. The travel
of the throttle plate from the fully closed to the fully open mechanical stops may not use this entire range of
voltages. The ECM learns the actual range of voltages used and adjusts the THROTTLE POSITION read-
ing to range from 0 to 100% over this used range of voltages. The system looks at both TPS signals and if
the readings are outside of the upper and lower limits or do not agree with each within limits a code will be
set. The following failure combinations and resulting outcomes are possible:
a) TPS1 fails open or shorted: MIL illuminated, ECM uses TPS2, normal engine operation
b) TPS2 fails open or shorted: MIL illuminated, ECM uses TPS1, normal engine operation
c) TPS1 & 2 fail open or shorted: MIL illuminated, ECM stops controlling throttle, throttle goes to limp
home position and is non- responsive, engine will high idle or allow truck to move slowly.
d) TPS1 & 2 do not match: MIL illuminated, ECM will use the higher of the two TPS readings resulting in
normal or less than normal engine power.
94

Typical TPS and Throttle Position Readings (assumes 5.00 supply voltage):
Actual TPS1 TPS2 TPS1 TPS2 Throttle

Throttle reading at reading at reading reading Position
Position Throttle Throttle on Moni- on Moni- on Moni-
tor tor tor
Fully
0.32 4.70 0.32 0.30 0
closed
¼ Open 1.32 3.70 1.32 1.30 25
¾ Open 3.32 1.70 3.32 3.30 75
Fully Open 4.32 0.70 4.32 4.30 100
CONDITIONS FOR SETTING THE DTC
DTC 51 will set if TPS1 and TPS2 disagree by greater than 5.96%
 A short circuit code will set if the TPS1 (as shown on the diagnostic monitor) is greater than 99.02%
of the 5 Volt Power Supply 1 (approx. 4.95 volts)
 A short circuit code will set if the TPS2 (as shown on the diagnostic monitor) is greater than 99.8% of
the 5 Volt Power Supply 1 (approx. 4.99 volts)
 An open circuit code will set if the TPS1 (as shown on the diagnostic monitor) is less than 4% of the 5
Volt Power Supply 1 (approx. 0.2 volts)
95

 Did you perform the On-board diagnostics
(OBD) system check? Go to On-
Board Diag-
NOTE: If the 5 volt reference Supply 1 is shorted nostics
Go to Step
1 to ground, various codes may set, including System
(2)
Throttle, Pedal 1, Oil Pressure, Cam and 5 Volt Check/Malfun
Power Supply Codes. If multiple codes are set, ction indicator
refer to diagnostics for codes 524261 to verify 5 lamp.
volt reference.
 With the monitor connected, Key ON, read
both throttle position sensors 1 and 2 voltag-
es.
 Is either reading below 0.2 volts
 Is the TPS 1 voltage above 9.95 volts or is Intermittent
TPS 1
TPS 2 voltage above 4.99 problem. Go
<0.2V Go to Step
2 to Preliminary
TPS 2 (3)
Is the higher voltage minus the lower voltage di- and Intermit-
>4.99V
vided by 5 then multiplied by 100 greater than 6. tent Checks
NOTE: this is the formula the ECU uses to de-

termine if the TPS readings are within the
specifications
 Key OFF, disconnect C017 from the throttle
body.
 Key ON, measure the voltage from C017 pin Between Go to Step
3 Go to Step (4)
6 to pin 2 4.8-5.2V (5)
Is the voltage between 4.8 and 5.2 volts?

 Key OFF, disconnect ECU-B
Verify that
 Measure the resistance from C017 pin 2 to
there are no
ECU B pin G2 Repair the
codes for the
 Measure the resistance from C017 pin 6 to circuit as ne-
5 volt supply
ECU B pin G4 cessary. Refer
4 before pro-
 Is the resistance less than 5Ω? to Wire Har-
ceeding.
ness Repair.
Replace the
NOTE: Do not probe wires without proper ser- Go to Step (9)
ECU. Go to
vice tool. Permanent harness damage may Step (9)
result.
96

 With C017 disconnected, measure the resis-
tance from pin 6 to pin 1 of the throttle body.
 Push the throttle plate to the fully closed posi-
tion, and then observe the resistance sweep
while moving the throttle to the fully open
Replace the
position
Go to Step throttle body
5  Repeat the test across pin 6 to pin 4. (6) assembly. Go
to Step (7)
Is the resistance change smooth with no ob-
served glitches, and does the resistance vary
from 800 to 1500Ω for pin 6 to 1 and from 1400
to 300 for pin 6 to 4 as the throttle is moved from
fully closed to fully open?
 Key OFF, disconnect ECU-B NOTE: Verify
 Measure the resistance from C017 pin 1 to that there are Repair the
ECU-B pin G3 no codes for circuit as ne-
 Measure the resistance from C017 pin 4 to the 5 volt cessary. Refer
6 ECU-B pin D3 <5 Ω supply before to Wire Har-
proceeding. ness Repair.
Is the resistance less than 5Ω? Replace the Go to Step
ECU. Got to (7).
step 7
 Remove all test equipment except the moni-
tor.
 Using the monitor, reset the adaptive learn.
es, etc.
 Using the monitor, clear DTC information
from the ECM. Go to On-Board
 Turn the ignition OFF and wait 30 seconds. Diagnostics
 Start the engine and operate the vehicle to System
7 System OK.
full operating temperature. Check/Malfuncti
 Observe the MIL. on Indicator
 Observe engine performance and driveability. lamp.
 After operating the engine within the test pa-
rameters of code, check for any stored
codes.

codes?
97

Pedal Position Voltage Table

Code Definition Condition Limit Comment
Pedal Sensor 1 to Pedal Sensor 2 Differ by more 12 to Varies with Pedal
91-2
Coherence Then 25 % Position
522712-3 Pedal Sensor 1 Short to Ground Less then 0.09 volts
522712-4 Pedal Sensor 1 Short to High Greater Then 4.97 volts
Circuit Description
There are two pedal position sensors on the electronic foot pedal to signal to the ECU exactly how much
throttle the driver has requested. The sensors are Hall Effect type not variable resistance sensors. The two
sensors are provided as a safety feature in case one sensor fails. While the system looks at both sensors,
sensor 1 is used to operate the system. The diagnostic tool allows the technician to monitor three signals
which relate to the foot pedal. The first is pedal position, the system automatically scales the full travel of
the pedal to equal 0 to 100 percent pedal position. The second and third signals are sensor 1 and sensor 2
voltages. Sensor 1 voltage can range from 0.66 to 4.95 volts but will usually be in the range of 1.0 to 3.6
volts. Sensor 2 voltage can range from 0.33 to 2.48 volts but will usually be in the range of 0.5 to 1.8 volts.
(Sensor 2 should read ½ of sensor 1).
98

Did you perform the On-board diagnostics (OBD) Go to On-
system check? Board
Diagnostics
Go to Step
System
1 (2).
Check/
Malfunction
indicator
lamp.
 With the monitor connected, Key ON, read If there is a
both pedal position sensor voltages. glitch in the
Intermittent
 See Pedal Position Voltage Table sweep, re-
problem. Go
 Slowly depress the pedal while observing the place the
2 to Preliminary
monitor pedal position
and Intermit-
sensor. Oth-
tent Checks.
Are the readings within the specifications and is erwise, go to
the sweep smooth without any glitches? Step (3).
 Check pedal position sensor
 Disconnect VIC 1
 Key ON, measure voltage from VIC 1 pins S
and R. Go to Step
3 Go to Step (4)
 Key ON, measure voltage from VIC 1 pins M (5)
and L.

 Key ON, measure the voltage from VIC 1 Refer to the
pins S and M to ground vehicle wiring
diagram and
Is the voltage between 4.8 and 5.2 volts? repair the
power supply
Refer to the
problem be-
vehicle wiring
tween here
diagram and
Between 4.8 and ECU.
4 check ground
and 5.2V Check for
back to ECU,
possible ECU
repair as ne-
5 volt prob-
cessary.
lem. Refer to
codes 524260
and 524261
for diagnostic
aids.
99

 Check pedal sensor
 Key OFF, disconnect VIC 1. Remove pins K
and J from the connector.
 Reconnect VIC 1. Key ON.
 Measure the voltage from each wire to en-
gine ground while slowly depressing the
pedal. Reinstall the
 Sweep, watch for glitch pins to the
Reinstall the
 Repeat on other side proper posi-
pins to the
tions in the
>0.09 and proper posi-
5 NOTE: Pin J will show ½ the voltage of pin K. connector.
<4.97 V tions in the
This is normal operation Replace pedal
connector.
position sen-
Go to step 6
Does the voltage sweep with no glitches from sor. Go to
greater than 0.09 volts to less than 4.97 volts on step 8.
pin A and from greater than 0.09 to less than
2.49 volts on pin B?
NOTE: Do not probe wires without proper ser-

vice tool. Permanent harness damage may
result.
 Key OFF, disconnect ECU-A
 Measure the resistance from VIC 1 pin K to Repair the
ECU-A pin H2 and VIC 1 pin J to ECU-A pin Go to Step open in the
6 <5Ω
F3. (7) harness. Go
to Step (8)
Is the resistance less than 5Ω?
 Connect the ECU-A and VIC 1 connectors.
With the monitor or DST connected, wiggle Repair or re-
Replace the
the ECU-A connector. place the
7 ECU. Go to
harness. Go
Step (8).
Are any glitches observed while wiggling the to Step (8)
connector?
100

101

DTC 100 Oil Pressure Low/High/High at Stall
The normal voltage output limits for this sensor are 0.5 volts to 4.5 volts. If at any time, the voltage output
is less than 0.46 volts or greater than 4.54 volts a DTC will be triggered. If the engine is not rotating the oil
pressure should not raise above 0 psig. Due to the nature of this sensor an open ground wire with Key ON
engine off may result in the signal voltage drifting up above 1 volt even at 0 psig oil pressure. To sense
this fault a diagnostic is triggered if at an engine speed of 0 rpm the sensor voltage is above 1.0 volts.
Circuit Description
The engine has an internal oil pump which creates oil pressure once the engine is rotating. An oil pressure
sensor monitors the pressure created by this oil pump.
102

DTC 100 Oil Pressure Low/High/High at Stall
Did you perform the On-Board (OBD) System Go to OBD
Check? Go to Step System.
1 -
(2) Check Sec-
tion
Verify that the engine has oil pressure using a
mechanical oil pressure gauge before proceed-
ing with this chart. Oil pressure must remain Go to Step Repair faulty
2 6 PSI
above 6 psi. (3) Oiling System
Does the engine have oil pressure above 6 psi?

 Ignition ON, Engine Running DST connected
in system Data Mode
 Clear DTC 100
Intermittent
 Warm the engine by idling until the ECT
Go to Step problem. Go
3 temperature is above 160 degrees F. and
(4) to Intermittent
has been running for at least one minute
section
 Increase engine speed above 500 RPM
Does DTC 100 reset?

 Clear DTC 100
 Key OFF
 Disconnect oil pressure switch connector
C012 and isolate the connector from engine Go to Step Go to Step
4
ground. (6) (5)
 Start and run the engine
Does DTC 100 reset?

Replace oil pressure switch
Go to Step
5 -
(9)
 Ignition OFF Repair the
 Disconnect C012 shorted to
 Using a DVOM check for continuity between ground oil
the oil pressure switch connector and engine pressure cir- Go to Step
6
ground cuit as (7)
necessary.
Does the DVOM show continuity? Refer to Wir-
ing Repairs.
Inspect ECU-B connector pin C1 for damage Repair the
corrosion or contamination circuit as ne-
cessary.
Go to Step
7 Did you find a problem? Refer to Wir-
(8)
ing Repairs in
Engine Elec-
trical.
103

Replace ECM
Go to Step
8 -
(9)
es, etc.
the ECM.
 Start the engine and run to full operating
Go to OBD
temperature
9 System OK System
 Observe the MIL Check
 Observe engine performance
rameters of DTC 100 check for any stored
codes.

codes?
104

105

DTC 105 MAT Short to High/Ground/Open
 Key ON
 Manifold Air Temp Short Circuit to High, MAT voltage greater than 4.95 V.
 Manifold Air Temp Short Circuit to Ground, MAT voltage less than 0.05 V
 Manifold Air Temp Open Circuit, MAT voltage greater than 4.88V but less than 4.94V
Circuit Description
The TMAP is a combined manifold air temperature (MAT) and manifold absolute pressure (MAP) sensor. A
temperature-sensitive resistor is used in the TMAP Sensor located in the intake manifold of the engine. It is
used to monitor incoming air temperature and pressure; and the output, in conjunction with other sensors,
is used to determine the airflow to the engine. The ECU provides a voltage divider circuit so that when the
air is cool, the signal reads higher voltage, and lower when warm.
106

DTC 105 MAT Short to High/Ground/Open

(OBD) system check?
NOTE: If the 5 volt reference supply 2 is shorted

Go to Step Perform OBD
1 to ground, various codes may set, including
(2) System check
Pedal 2, and 5 Volt Power Supply Codes, as well
as ignition system malfunctions. If multiple
codes are set, refer to diagnostics for code
524260 to verify 5 volt reference.
 Key ON. Intermittent
 Monitor MAT PID. problem. Go
Go to Step
2 to Preliminary
(3)
Does Monitor display MAT at the default value of and Intermit-
214 degrees? tent Checks.
 Key OFF.
 Disconnect the TMAP sensor connector J8
from the TMAP sensor.
Go to Step
 •Key ON, measure the voltage across pins 1 (5). If the 5
and 2 Between 4.8 Go to Step volt supply 2
3
and 5.2V (4) is grounded,
Is the voltage between 4.8 and 5.2 volts? an open code
will be set.
result
 Key OFF.
 Measure the resistance across the TMAP
Replace the
sensor pins 1 and 2. Replace the
TMAP sen-
4 ECU. Go to
sor. Go to
Is the resistance correct for the temperature as step last
step last
shown in the temperature/ resistance chart
above?
 Key OFF.
 Disconnect the ECU wire harness connector
ECU-B.
 Measure the resistance from TMAP sensor Repair the
Go to Step
5 connector C011 pin 2 and ECU-B pin E2. <5Ω circuit as ne-
(6)
 Measure the resistance from TMAP sensor cessary
connector pin 1 and ECU-B pin H4.

 Disconnect the ECU wire harness connector.
 Measure the resistance between TMAP sen- Repair short
Go to Step
6 sor connector ground circuit pins 1 and 2. >30MΩ circuit as ne-
(7)
cessary
Is the resistance greater than 30MΩ?
107

 Recheck wire harness and TMAP sensor
connectors for damage corrosion or contami- Repair the
Go to Step
7 nation. circuit as ne-
(8)
cessary
Were any problems found?
 Replace the ECU.
Go to Step
8
(9)
108

109

DTC 106 MAP/Low/High/Short/Open
 Key ON, engine RPM equals zero

 MAP reading less than 50 kPa absolute or greater than 108 kPa absolute
 MAP sensor signal voltage greater than 4.923 volts.
 MAP sensor signal voltage less than 0.122 volts.
 On successful engine start-up MAP value does not drop at least 9 kPa from Key ON engine off val-
ue.
Circuit Description
The Manifold Absolute Pressure sensor is a piezoelectric pressure sensor fitted to the manifold to measure
the pressure internal to the manifold. It is combined in one sensor with the manifold air temperature sensor
and referred to as the TMAP sensor. The MAP reading is used to determine the load and state of the en-
gine. Because the sensor measures absolute pressure, with the Key ON, engine off, the reading should be
atmospheric pressure, displayed as kPa (approximately 100 kPa at sea level). The sensor operates on 5
volts and sends a signal voltage on the output circuit to the ECU. The ECU uses the signal to determine
correct fueling. Voltage varies from a low voltage when the MAP is low (below atmospheric) to high when
the MAP is close to or at atmospheric pressure. If there is a failure in the 5 volt reference to the TMAP sen-
sor, a code will be set. Depending on the 5 volt failure mode, the system may go to the Limp Home mode.
110

MAP DIAGNOSTIC AID
PSIa kPa PSIa kPa PSIa kPa
5 34.47 55 379.2116 105 723.9495
10 68.94757 60 413.6854 110 758.4233
15 103.4214 65 448.1592 115 792.8971
20 137.8951 70 482.633 120 827.3708
25 172.3689 75 517.1068 125 861.8446
30 206.8427 80 551.5806 130 896.3184
35 241.3165 85 586.0543 135 930.7922
40 275.7903 90 620.5281 140 965.266
45 310.2641 95 655.0019 145 999.7398
50 344.7379 100 689.4757 150 1034.214
kPa PSIa kPa PSIa kPa PSIa

5 0.725189 55 7.977074 105 15.22896
10 1.450377 60 8.702262 110 15.95415
15 2.175566 65 9.427451 115 16.67934
20 2.900754 70 10.15264 120 17.40452
25 3.625943 75 10.87783 125 18.12971
30 4.351131 80 11.60302 130 18.8549
35 5.07632 85 12.3282 135 19.58009
40 5.801508 90 13.05339 140 20.30528
45 6.526697 95 13.77858 145 21.03047
50 7.251885 100 14.50377 150 21.75566
MAP Output Voltage
120
100
80
MAP in kPa
60
40
20
0
0 1 2 3 4 5 6
Voltage
111

DTC 106 MAP/Low/High/Short/Open
system check? Board Diag-
nostics
1 Go to Step (2) System
Check/Malfun
ction indicator
lamp.
 Key ON, engine off. Intermittent
 Monitor the MAP reading. problem. Go
2 508 kPa Go to Step (3) to Preliminary
Does the monitor display MAP reading of 508 and Intermit-
kPa on the digital display? tent Checks.
 Key OFF, disconnect C011 from the TMAP
sensor
Between
 Key ON, measure the voltage across the
3 4.8 and Go to Step (4) Go to Step (5)
C011 connector, pins 1 and 3.
5.2V
Is voltage between 4.8 and 5.2 volts?
 Replace known good MAP sensor and retest.
 Is everything OK?
4 Go to Step (7) Go to Step (5)
result.
 Check resistance between C011 pin 1 and Repair open
ECU-B pin H4, C011 pin 3 and ECU-B pin in the wiring
5 <5Ω Go to Step (6)
H2, and C011 pin 4 and ECU-B pin H3. and Go to
Step (7)
Is resistance less than 5Ω?
 Refer to diagnostics for 5 volt reference vol-
tage. See codes DTC 524260 Between Replace the
6  Retest for 5 volts at Co11 pins 1 and 3 4.8 and Go to Step (7) ECU. Go to
5.2V Step (7)
Is voltage now between 4.8 and 5.2 volts?
112

tor.
es, etc.
from the ECM. Go to On-
 Turn the ignition OFF and wait 30 seconds. Board Diag-
 Start the engine and operate the vehicle to nostics
7 full operating temperature. System OK. System
 Observe the MIL. Check/Malfun
 Observe engine performance and driveabili- ction Indicator
ty. lamp.
codes.

codes?
113

DTC 110-ECT/Low/High/Short/Open

Temp
Ohms
 ECT sensor voltage less than 0.059. (deg F)
 ECT sensor voltage greater than 4.888. 242.4 101
 ECT sensor voltage greater than 4.99. 231.9 121
 MIL - on during active fault and for 2 seconds after active fault. 211.6 175
201.4 209
Circuit Description 181.9 302
163.1 434
The Coolant Temperature Sensor is a Negative Coefficient (as the temperature ris- 144.9 625
es, the resistance drops) temperature sensitive resistor located in the Cylinder Head. 127.4 901
The ECM uses the reading to determine temperature related operating condition re- 102.4 1,556
quirements for the engine. Five volts is applied across the sensor and voltage drop is 78.9 2,689
measured to determine the temperature. 49.9 5,576
23.5 11,562
-5.7 28,770
-21.2 49,715
-30.8 71,589
-40.0 99,301
114

DTC 110-ECT/Low/High/Short/Open

 From Diagnostic tool, monitor ECT. Intermittent
 Is the displayed temperature reading esti- fault. See wir-
mated engine temperature ing
schematics
Key ON, ECT should reflect engine tempera- and check
1 Go to step2
ture? circuits from
C034 to ECU-
B for possible
short to
ground.
 Disconnect connector C034
Go to Step Go to Step
2
From monitor, does temperature read 214° C? (3) (4)
(Default)
 With C034 disconnected, measure the vol-
tage across C034 pins A and B
 Is voltage between 4.8 and 5.2 volts? Replace the
Between 4.8 Go to Step
3 sensor. Go
and 5.2 V (4)
NOTE: Do not probe wires without proper ser- to Step (5)
result.
 With C034 and ECU-B disconnected, meas-
ure the resistance from C034 pin 1 to ECU-B
pin F2, C034 pin 2 to ECU-B pin F4 and Replace the Repair fault in
<5Ω and
4 across C034 pins 1 and 2. ECU. Go to harness. Go
>30MΩ
Step (5) to Step (5)
Is the resistance less than 5 ohms from C034 to
ECU-B and greater than 30MΩ across C034?
115

DTC 135 FRP Open/Short/High
 FRP Sensor
 Check Condition-Key ON
 Fault Condition-FRP voltage greater than 4.94 volts
 Fault Condition-FRP voltage less than 0.25 volts
 MIL-ON
Circuit Description
The FRP (Fuel Rail Pressure) is a sensor that monitors the state of the LP fuel in the fuel rail. A pressure
sensor located on the fuel rail monitors the fuel pressure. The output in conjunction with other sensors is
used to determine the appropriate injector pulse to deliver the fuel. A lower output voltage indicates a low-
er pressure, and higher voltage for higher pressure. This fault will set if the signal voltage is less than 0.25
or greater than 4.94 volts.
116

DTC 135 FRP Open/Short/High
Check? Go to Step System
1
(2) Check Sec-
tion
 Key ON
 DST (Diagnostic Scan Tool) connected
with the Voltages and Service windows
Less than Go to Step Go to Step
2 displayed.
0.20 volts? (4) (3)
Does the DST display FRP (Fuel Rail Pres-
sure) voltage less than 0.20 volts?
 Key OFF
 Disconnect the FRP sensor connector
C016 from the wiring harness.
 Jump the 5 volt reference B and FRP sig- Greater
3 nal circuit C together. than 4.90
(6) (5)
 Key ON volts
Does the DST display FRP voltage greater

than 4.90 volts?
Inspect FRP connector and pins for corrosion, Repair the
contamination or mechanical damage. circuit as
necessary. Go to Step
4
Any problems found? See wire (5)
harness re-
pair section.
Replace FRP Sensor.
Go to Step
5 Is the replacement complete?
(12)
 Key ON Repair the 5

 Using a DVOM check for voltage between volt refer-
FRP connector 5 volt reference ECU-B J2 ence circuit
Greater
and sensor ground pin A. as neces- Go to Step
6 than 4.90
sary. See (7)
volts
Does the DVOM display a voltage greater wire harness
than 4.90 volts? repair sec-
tion
 Key OFF Repair the
 Disconnect ECU-B connector open signal
 Check for continuity between FRP sensor Go to Step circuit. See
7
connector C and ECM signal pin J3. (8) wire harness
repair sec-
Do you have continuity between them? tion.
117

 Using a DVOM check for continuity be- Repair the
tween FRP sensor connector signal A shorted to
and sensor ground K2. ground sig-
Go to Step
8 nal circuit.
(9)
Do you have continuity? See wire
harness re-
pair section.
 Using a DVOM check for continuity be- Repair the
tween FRP sensor connector B and shorted to
engine ground. ground sig-
Go to Step
9 nal circuit.
(10)
Do you have continuity? See wire
harness re-
pair section.
 Inspect ECM connector and wire harness Repair har-
connector terminals for corrosion, conta- ness and
mination or mechanical damage. connector as
Go to Step
10 necessary.
(11)
Any problems found? See wire
harness re-
pair section.
 Replace ECM.
Go to Step
11 Is the replacement complete?
(12)
 Remove all test equipment except the

DST.
 Connect any disconnected components,
fuses, etc.
the ECM.
 Turn the ignition OFF and wait 30
Go to OBD
seconds.
12 System OK System
 Start the engine and operate the vehicle to Check
full operating temperature
 Observe the MIL
 Observe engine performance and drivea-
bility
Does the engine operate normally with no

stored codes?
118

119

DTC 168 System Voltage Low/High
 System Voltage
 Voltage high: battery voltage above 18.5 volts with the Key ON.
 Voltage low: battery voltage below 5.29 volts while the engine is running
 MIL-On
Circuit Description
The system monitors battery voltage and will set a code if the voltage is out of range.
120

DTC 168 System Voltage Low/High

 Perform charging system diagnostics.
Was a fault found?

Repair as ne-
1 Go to step 2
cessary
result.
 Key OFF, disconnect connector ECU-B.
 Using the proper tools, ground ECU-B pin Intermittent
D4. problem. Go
Go to Step
2  Measure voltage from ECU-B M2 to M1. to Preliminary
(3)
and Intermit-
Is voltage within range? tent Checks
 Measure voltage from ECU-B M2 to engine Check all

ground. grounds and
Go to Step
3 repair as ne-
(4)
Is voltage within range? cessary. Go
to Step (7)
 Remove Component Power Relay.
 Measure voltage from pins E8 and D8 to en-
System Vol- Go to Step Go to Step
4 gine ground.
tage (6) (5)
Is voltage within range?
 Key OFF Repair open
 Disconnect ECU-B in harness as
Replace the
 Measure the resistance from: ECU-B pin M2 necessary.
power latch
6 to Component Power Relay pin C9 and ECU- Refer to Wire
relay. Go to
B pin D4 to Component Power Relay pin A9 Harness
Step (7).
Repair. Go to
Is the resistance less than 5Ω? Step (7).
121

DTC 628 Cal Memory Failure
 Engine Control Module

 Fault Condition-Internal microprocessor error
 MIL-On
Circuit Description
The ECM has several internal checks that must be satisfied each time an instruction is executed. Sev-
eral different things can happen within the microprocessor that will cause this fault. This diagnostic applies
to internal microprocessor integrity conditions within the engine control module (ECM). This diagnostic al-
so addresses if the ECM is not programmed or the program checksum does not match or has become
corrupted. Always verify that the ECM was flashed with the proper calibration files before using the follow-
ing diagnostic chat.
122

DTC 628 Cal Memory Failure
 Did you perform the On-board diagnostics Go to On-
(OBD) system check? Board Diag-
nostics
1 Go to step 2 System
Check/Malfun
ction indicator
lamp.
 Reprogram or replace the ECU as required.
Go to Step
2
(3)
Is the repair completed?
tor.
es, etc.
ty. lamp.
codes.

codes?
123

DTC 630 ECU Checksum Error

 MIL-On
Circuit Description
124

DTC 630 ECU Checksum Error
nostics
1 Go to step 2 System
Check/Malfun
ction indicator
lamp.
Go to Step
2
(3)
tor.
es, etc.
ty. lamp.
codes.

codes?
125

DTC 651 Injector Short/Open
 Short to B+
 Open Circuit
 Short to Ground
Circuit Description
The ECU injector circuit drives the LPG system.
126

nostics
Go to Step
1 System
(2)
Check/Malfun
ction indicator
lamp.
 For DTC 651-3 short to B+, Go to Step (3)
 For DTC 651-5 Open Circuit, Go to Step (5)
2
 For DTC 651-6 Short to Ground, Go to Step
(11)
 Disconnect injector connector
 Key OFF
 Disconnect ECU-B
Go to Step
3  Is resistance between pin Measure voltage >0V
(4)
from pin injector pin 2 to ground.
Is voltage greater than zero?

Repair short
 Key ON, measure voltage from pin 2 to Replace
to power in
4 ground. >0V ECU. Go to
the harness.
Step (14)
Go to step14
 For affected cylinder, disconnect injector
connector, Key ON
Battery Vol- Go to Step Go to Step
5  Measure voltage from pin 1 to ground.
tage (8) (6)
Is battery voltage present?
 With C007 disconnected, Key ON Repair open
 Measure voltage at C007 pin 2 in harness
between
Is battery voltage present? Battery Vol- C007 and in- Go to Step
6
tage jector (7)
connector.
Go to Step
(14)
 Key OFF, disconnect ECU-B. Refer to the
 Measure resistance from C007 pin 1 to ECU- wiring dia-
B pin A1 gram for your Repair open
truck and re- in the har-
7 <5 Ω
Is resistance less than 5Ω? pair power ness. Go to
supply prob- Step (14)
lem. Go to
Step (14)
 Measure resistance of affected injector. Replace in-
Go to Step
8 2Ω ± .5Ω jector. Go to
(9)
Is resistance 2Ω ± .5Ω? Step (14)
127

 Key OFF, C007 disconnected
Repair open
 Measure the resistance of the control circuit.
Go to Step in the har-
9 See table above. <5Ω
(10) ness. Go to
Step (14)
 Key OFF, ECU-B disconnected
Repair open
 Measure the resistance of the control circuit Replace
in the har-
10 from C007 to ECU-B. <5Ω ECU. Go to
ness. Go to
Step (14)
Step (14)
Is the resistance less than 5 Ω?
 With the affected cylinder disconnected,
Replace the
measure the resistance if the injector. Go to Step
11 2Ω ± .5Ω injector. Go to
(12)
Step (14)
Is resistance 2Ω ± .5Ω?
 Measure resistance from the injector connec-
Replace the
tor pin 1 of the affected cylinder to ground. Go to Step
12 >30Ω ECU. Go to
(13)
Step (14)
 Key OFF, ECU-B disconnected Repair the
 Measure the resistance from the control cir- short to Replace the
13 cuit to ground. >30Ω ground in the ECU. Go to
harness. Go Step (14)
Is the resistance greater than 30MΩ? to Step (14)
tor.
es, etc.
ty. lamp.
codes.

codes?
128

129

 Short to B+
 Open Circuit
 Short to Ground
Circuit Description
130

nostics
Go to Step
1 System
(2)
Check/Malfun
ction indicator
lamp.
2
(11)
 Key OFF
Go to Step
3  Measure voltage from injector pin 2 to >0V
(4)
ground.

 Key OFF, disconnect ECU-B Repair short
 Key ON, measure voltage from pin 2 to to power in Replace
4 ground. >0V the harness. ECU. Go to
Go to Step (14)
Is voltage greater than zero? Step(14)
connector, Key ON
tage (8) (6)
between
6
tage jector (7)
connector.
Go to Step
(14)
7 <5 Ω
lem. Go to
Step (14)
Go to Step
(9)
131

Repair open
(10) ness. Go to
Step (14)
Repair open
in the har-
10 from C007 to ECU-B pin 2. <5Ω ECU. Go to
ness. Go to
Step (14)
Step (14)
Replace the
11 2Ω ± .5Ω injector. Go to
(12)
Step(14)
Replace the
(13)
Step (14)
harness. Go Step (14).
tor.
es, etc.
ty. lamp.
codes.

codes?
132

133

 Short to B+
 Open Circuit
 Short to Ground
Circuit Description
134

nostics
Go to Step
1 System
(2)
Check/Malfun
ction indicator
lamp.
2
(11)
 Key OFF
Go to Step
(4)

Repair short
to power in
the harness.
Step (14)
Go to step14
connector, Key ON
tage (8) (6)
between
6
tage jector (7)
connector.
Go to Step
(14)
7 <5 Ω
lem. Go to
Step (14)
Go to Step
(9)
135

Repair open
9 See table above.
(10) ness. Go to
Step (14)
Repair open
in the har-
ness. Go to
Step (14)
Step (14)
Replace the
11 <5Ω injector. Go to
(12)
step14
Replace the
12 2Ω ± .5Ω ECU. Go to
(13)
Step (14)
tor.
es, etc.
14 full operating temperature. >30Ω System OK. System
ty. lamp.
codes.

codes?
136

137

 Short to B+
 Open Circuit
 Short to Ground
Circuit Description
138

nostics
Go to Step
1 System
(2)
Check/Malfun
ction indicator
lamp.
2
(11)
 Key OFF
Go to Step
(4)

Repair short
to power in
the harness.
Step (14)
Go to step14
connector, Key ON
tage (8) (6)
between
6
tage jector (7)
connector.
Go to Step
(14)
7 <5 Ω
lem. Go to
Step (14)
Go to Step
(9)
139

Repair open
(10) ness. Go to
Step (14)
Repair open
in the har-
ness. Go to
Step (14)
Step (14)
 With the affected cylinder disconnected, Replace the
Go to Step
11 measure the resistance if the injector. 2Ω ± .5Ω injector. Go to
(12)
Is resistance 2Ω ± .5Ω? step14
Replace the
(13)
Step (14)
tor.
es, etc.
ty. lamp.
codes.

codes?
140

141

DTC 1635 Code vs. Cal Version

 MIL-On
Circuit Description
142

DTC 1635 Code vs. Cal Version
1 -
(2) Check Sec-
tion
 Ignition ON
 DST (Diagnostic Scan Tool) connected in
System Data Mode Intermittent
 Clear system fault code Go to Step problem. Go
2
 Ignition OFF (3) to Intermittent
 Ignition ON section
Does DTC 1635 reset with the Ignition ON?

 Check ECM power and ground connections Repair the
at ECU-B pins M2, M1, L1 and C001. circuit as ne-
cessary.
Go to Step
3 Did the power and ground circuits check OK? Refer to Wir-
(4)
ing Repairs in
Engine Elec-
trical.
 Re-flash the ECM with the correct calibration
file
4  Repeat all in step (2).
(5) (6)
Does DTC 1635 still set?
Replace ECM
Go to Step
5 -
(5)
es, etc.
the ECM
 Turn the Ignition OFF and wait 30 seconds.
Go to OBD
temperature
6 System OK System
rameters of DTC 1635 check for any stored
codes

codes?
143

DTC 522545 MIL (Malfunction Indicator Lamp) Open
Circuit Description
The Spectrum Fuel system is equipped with OBD (On-Board Diagnostics). The system has a
dash mounted MIL (Malfunction Indicator Lamp). The MIL serves as notification of an emis-
sions related problem. It will display DTCs that have been stored due to a possible system
malfunction. The following DTC charts in this manual will instruct the technician to perform
the OBD system check. This simply means to verify the operation of the MIL. The lamp
should illuminate when the key is in the ON position, and the engine is not running. This fea-
ture verifies that the lamp is in proper working order. If the lamp does not illuminate with the
vehicle Key ON and engine OFF, repair it as soon as possible. Once the engine is in start or
run mode, the lamp should go off. If the lamp stays on while the engine is in the start or run
mode, a current diagnostic trouble code may be set or a problem may exist with the MIL elec-
trical wiring. The electrical schematic above shows the MIL power source supplied to the
lamp. The ECM completes the circuit to ground to turn the lamp ON.
144

145

DTC 522614 Throttle Failed to Enter Limp Home

 Fault Condition-Throttle return spring test
Circuit Description
Dual throttle position sensors (TPS) are used with the electronic throttle control (ETC) to determine
throttle plate position. The TPS values are used by the ECM to determine if the throttle is opening and
closing as commanded. The ECM runs several checks at ignition on to validate the working condition of
the ETC. This fault will set if the ECM detects a problem with the ETC internal return spring.
146

DTC 522614 Throttle Failed to Enter Limp Home
Go to Step
1 Check? - System Check
(2)
Section
 Ignition ON
data stream mode. Intermittent
 Clear DTC 522614 Go to Step problem. Go
2
Does DTC 522614 re-set?

Check the electronic throttle for a foreign object Remove the
in the throttle bore or damaged throttle bore or foreign object
fly assembly. or replace the
3 throttle if Go to Step (4)
Did you find damage or a foreign object in the damage is
bore? found. Go to
Step (17)
 Ignition OFF
 Disconnect electronic throttle connector
Repair the
C017
shorted to
 Disconnect ECM wire harness connector
ground TPS
ECU-B
4 circuit as ne- Go to Step (5)
 Using a DVOM check for continuity between cessary.
all electronic throttle connector pins and en- Refer to Wir-
gine ground ing Repairs
Does the DVOM show continuity?
Using a DVOM check for continuity between Repair the
electronic throttle connector pin 1 and ECU-B open circuit as
Go to Step
5 connector pin G3. necessary.
(6)
Refer to Wir-
Does the DVOM show continuity? ing Repairs.
electronic throttle connector pin 2 1 and ECU-B open circuit as
Go to Step
(7)
Refer to Wir-
Does the DVOM show continuity? ing Repairs
Go to Step
7 connector pin M3. necessary.
(8)
Refer to Wir-
147

electronic throttle connector pin 4 and ECU-B shorted TPS
connector pin D3. circuit to
Go to Step
8 ground as ne-
(9)
Does the DVOM show continuity? cessary. Refer
to Wiring Re-
pairs.
connector pin M4. circuit to
Go to Step
9 ground as ne-
(10)
to Wiring Re-
pairs.
connector pin G4. circuit to
Go to Step
10 ground as ne-
(11)
to Wiring Re-
pairs.
Replace electronic throttle
Go to Step
11 -
(12)
es, etc.
the ECM.
temperature. Go to Step
12 System OK
 Observe the MIL (13)
 Observe engine performance.
rameters of DTC 522614 check for any
stored codes.

codes?
Replace the ECM
Go to Step
13 -
(14)
148

es, etc.
the ECM.
temperature. Go to OBD
14 System OK
 Observe the MIL System Check
stored codes.

codes?
149

DTC 522616 Throttle Actual vs. Commanded Error

 Fault Condition-TPS 1 and 2 calculated values exceed 10%
Circuit Description
throttle plate position. Although the actual voltage values between them are inverse, the calculated position
values should remain very close. The TPS values are used by the ECM to determine if the throttle is open-
ing and closing as commanded. This fault will set if the ECM detects more than a 10% difference in
calculated values between TPS 1 and TPS 2.
150

DTC 522616 Throttle Actual vs. Commanded Error
Go to Step
(2)
Section
 Ignition ON
2

bore? found. Go to
Step (17)
 Ignition OFF
Repair the
C017
shorted to
ground TPS
ECU-B
Go to Step
(6)
Refer to Wir-
Go to Step
(7)
Refer to Wir-
Go to Step
(8)
Refer to Wir-
151

Go to Step
8 ground as ne-
(9)
to Wiring Re-
pairs.
Go to Step
9 ground as ne-
(10)
to Wiring Re-
pairs.
Go to Step
10 ground as ne-
(11)
to Wiring Re-
pairs.
Go to Step
11 -
(12)
es, etc.
the ECM.
12 System OK
stored codes.

codes?
Replace the ECM
Go to Step
13 -
(14)
152

es, etc.
the ECM.
14 System OK
stored codes.

codes?
153

DTC 522617 Throttle Failed to Fully Open/Close

 Fault Condition-TPS 1 and 2 calculated values exceed 10%
Circuit Description
throttle plate position. Although the actual voltage values between them are inverse, the calculated position
values should remain very close. The TPS values are used by the ECM to determine if the throttle is open-
ing and closing as commanded. This fault will set if the ECM detects more than a 10% difference in
calculated values between TPS 1 and TPS 2.
154

DTC 522617 Throttle Failed to Fully Open/Close
Go to Step
(2)
Section
 Ignition ON
Intermittent
data stream mode.
2  Clear DTC 522617
(3) to Intermittent
 Start the engine section
bore? found. Go to
Step (17)
 Ignition OFF
Repair the
C017
shorted to
ground TPS
ECU-B
Go to Step
(6)
Refer to Wir-
Go to Step
(7)
Refer to Wir-
Go to Step
(8)
Refer to Wir-
Go to Step
8 ground as ne-
(9)
to Wiring Re-
pairs.
155

Go to Step
9 ground as ne-
(10)
to Wiring Re-
pairs.
Go to Step
10 ground as ne-
(11)
to Wiring Re-
pairs.
Go to Step
11 -
(12)
es, etc.
the ECM.
12 System OK
stored codes.

codes?
Replace the ECM
Go to Step
13 -
(14)
156

es, etc.
the ECM.
14 System OK
stored codes.

codes?
157

DTC 522630 Oxygen Sensor Failure to Switch Lean, Bank 1

The short term fuel correction has a range of ± 25%. If the correction reaches the upper or lower limit, it will
then try an additional 2% change to watch for an O2 switch. If the sensor switches with the additional 2%, a
short term fuel correction code will be set. If the sensor does not switch with the additional 2% change, the
system will set a code for a sensor that fails to switch rich or lean.
Circuit Description
The system monitors the O2 sensor to ensure that the fuel control is functioning properly. The HEGO sen-
sor is mounted in the exhaust system downstream of the engine. The HEGO sensor is used to measure
the amount of oxygen present in the exhaust stream and communicates that to the ECM via an electrical
signal. The amount of oxygen present in the exhaust stream indicates whether the fuel air ratio is rich or
lean. If the HEGO sensor signal indicates that the exhaust stream is rich, the ECM will decrease or lean the
fuel mixture by reducing the short term fuel correction value which reduces the injector on-time supplying
less fuel. If the mixture is lean, the ECM will richen the mixture or increase the short term fuel correction
value which will increase the pulse width to the injectors. Under normal steady operation the short term
fuel correction value should move up and down approx. 5%. This 5% movement may range within a plus
25 to minus 25 percent window. The ECM continuously monitors the HEGO sensor output. If a rich or lean
condition is present for an extended period of time and if the ECM cannot correct the condition, the ECM
will set a diagnostic code and turn on the MIL light in the dash. NOTE: The HEGO sensor is sensitive to
silicone and silicone-based products and can become contaminated. Avoid using silicone sealers or hoses
treated with silicone lubricant in the air stream or fuel supply lines.
Diagnostic Aids
 Low fuel pressure
 Partially blocked fuel injectors
 Manifold vacuum leaks
 Defective O2 sensor
 A misfire on one or more cylinders
 Exhaust leak ahead of the O2 sensor
 Faulty MAP sensor
158

system check? Board
Diagnostics
Go to Step
System
1 (2)
Check/
Malfunction
indicator
lamp.
 With the engine at operating temperature, No problems
monitor the O2 sensor voltage and the short at this time.
term fuel trim Intermittent
problem. Go Go to Step
2
Is the O2 sensor switching from rich to lean, and to Preliminary (3)
is the short term correction less than 25%? and Intermit-
tent Checks
 Check all problems listed in the diagnostic

aids.
 For the O2 sensor, also refer to DTC 522730
diagnostics.
 For MAP diagnostics, refer to DTC 106
Repair as re-
 For ECT diagnostics, refer to DTC 110 Go to Step
3 quired. Go to
 Verify proper maintenance and condition of (4)
step last
the ignition system.
 Verify engine condition with a compression
test.
Were any faults found?

 Monitor connected with the engine running,
monitor the engine RPM.
 One at a time, disconnect each injector and
observe the drop in engine speed.
4  Do one or more injectors not drop the engine (6) (5)
speed when disconnected?
NOTE: the engine speed will only drop momen-

tarily as the ECU corrects the engine speed.
 Check the fuel pressure.
Replace the
 Is the pressure 88 kPa (12.8 PSI) above at- Go to Step
5 Regulator, Go
mospheric pressure, engine off ±15 kPa (2.2 (6)
to Step (8).
PSI) holding steady?
 Checking injectors
 One at time, connect a noid light across Replace faul- Repair circuit
each injector connector. ty injector Go to the injec-
6
 With the engine running, does the noid light to Step (8) tor. Go to
flash at the connector of the failed injector step last
connector?
159

 Check pressure drop
Replace the Verify the fil-
 Check manifold vacuum supply to regulator
7 regulator. Go ter is OK. Go
to Step (8) to Step (8).
Is the pressure within specifications?
tor.
es, etc.
Go to On-
from the ECM.
Board
Diagnostics
8 full operating temperature. System OK.
Check/
 Observe the MIL. Malfunction
 Observe engine performance and driveabili- Indicator
ty. lamp.
codes.

codes?
160

161

DTC 522631 Oxygen Sensor Failure to Switch Rich, Bank 1

Circuit Description
The system monitors the O2 sensor to ensure that the fuel control is functioning properly. The HEGO
sensor is mounted in the exhaust system downstream of the engine. The HEGO sensor is used to meas-
ure the amount of oxygen present in the exhaust stream and communicates that to the ECM via an
electrical signal. The amount of oxygen present in the exhaust stream indicates whether the fuel air ratio is
rich or lean. If the HEGO sensor signal indicates that the exhaust stream is rich, the ECM will decrease or
lean the fuel mixture by reducing the short term fuel correction value which reduces the injector on-time
supplying less fuel. If the mixture is lean, the ECM will richen the mixture or increase the short term fuel
correction value which will increase the pulse width to the injectors. Under normal steady operation the
short term fuel correction value should move up and down approx. 5%. This 5% movement may range
within a plus 25 to minus 25 percent window. The ECM continuously monitors the HEGO sensor output. If
a rich or lean condition is present for an extended period of time and if the ECM cannot correct the condi-
tion, the ECM will set a diagnostic code and turn on the MIL light in the dash. NOTE: The HEGO sensor is
sensitive to silicone and silicone-based products and can become contaminated. Avoid using silicone sea-
lers or hoses treated with silicone lubricant in the air stream or fuel supply lines.
Diagnostic Aids
162

system check? Board
Diagnostics
Go to Step
System
1 (2)
Check/
Malfunction
indicator
lamp.
2
tent Checks

aids.
diagnostics.
Repair as re-
3 quired. Go to
step last
test.


Replace the
5 vaporizer, Go
to Step (8).
PSI) and holding steady?
6
connector?
163

tor.
es, etc.
Go to On-
from the ECM.
Board
Diagnostics
Check/
ty. lamp.
codes.

codes?
164

165

DTC 522635 Short Term Fuel Lean, Bank 1

Circuit Description
Diagnostic Aids
166

system check? Board
Diagnostics
Go to Step
System
1 (2)
Check/
Malfunction
indicator
lamp.
2
tent Checks

aids.
diagnostics.
Repair as re-
3 quired. Go to
step last
test.


Replace the
5 Regulator, Go
to Step (8).
PSI) and holding steady?
6
connector?
167

tor.
es, etc.
Go to On-
from the ECM.
Board
Diagnostics
Check/
ty. lamp.
codes.

codes?
168

169

DTC 522636 Short Term Fuel Lean, Bank 1

Circuit Description
Diagnostic Aids
170

system check? Board
Diagnostics
Go to Step
System
1 (2)
Check/
Malfunction
indicator
lamp.
2
tent Checks

aids.
diagnostics.
Repair as re-
3 quired. Go to
step last
test.


 Check the fuel pressure. Replace the
 Is the pressure 88 kPa (12.8 PSI) above at- Go to Step Regulator.
5
mospheric pressure, engine off ±15 kPa (2.2 (6) Go to Step
PSI) and holding steady? (8).
6
connector?
171

tor.
es, etc.
Go to On-
from the ECM.
Board
Diagnostics
Check/
ty. lamp.
codes.

codes?
172

173

DTC 522690 Bus Failure
 CAN Rx
 Check Condition-Engine running
 Fault Condition-CAN error packets lost, not received or corrupt
 MIL-ON
Circuit description
The CAN bus (controller area network) is used by the ECM to communicate with other digital devices
used throughout the fuel system. Information is sent over the CAN bus in digital information “packets” that
contain information for various control functions. This fault will set if the ECM detects continuous CAN
communications hardware errors or CAN policy violations.
174

DTC 522690 Bus Failure
(OBD) system check? Board
Diagnostics
Go to Step
System
1 (2)
Check/
Malfunction
indicator
lamp.
Go to Step
2
(3)
tor.
es, etc.
 Turn the ignition OFF and wait 30 seconds. Board
 Start the engine and operate the vehicle to Diagnostics
full operating temperature. System
3 System OK.
 Observe the MIL. Check/
 Observe engine performance and driveabili- Malfunction
ty. Indicator
 After operating the engine within the test pa- lamp.
codes.

codes?
175

DTC 522691 Redundant Check Failure

 MIL-On
Circuit Description
176

DTC 522691 Redundant Check Failure
1 -
(2) Check Sec-
tion
 Ignition ON
2

 Check ECU-B power and ground connec- Repair the
tions at M1, L1 and M2. Also check C001, circuit as ne-
C005, C003 and C015. cessary.
Go to Step
3 Refer to Wir-
(4)
Did the power and ground circuits check OK? ing Repairs in
Engine Elec-
trical.
file
4  Repeat all in Step (2).
(5) (6)
Replace ECM
Go to Step
5 -
(5)
es, etc.
the ECM
Go to OBD
temperature
6 System OK System
stored codes

codes?
177

DTC 522692 Redundant General Conversion Failure

 MIL-On
Circuit Description
178

1 -
(2) Check Sec-
tion
 Ignition ON
2

Go to Step
3 Refer to Wir-
(4)
Engine Elec-
trical.
file
(5) (6)
Replace ECM
Go to Step
5 -
(5)
es, etc.
the ECM
Go to OBD
temperature
6 System OK System
stored codes

codes?
179

DTC 522694 Memory Checksum Error

 MIL-On
Circuit Description
180

DTC 522694 Memory Checksum Error
1 -
(2) Check Sec-
tion
 Ignition ON
2

Go to Step
3 Refer to Wir-
(4)
ing Repairs in
Did the power and ground circuits check OK? Engine Elec-
trical.
file
(5) (6)
Replace ECM
Go to Step
5 -
(5)
es, etc.
the ECM
Go to OBD
temperature
6 System OK System
stored codes

codes?
181


 MIL-On
Circuit Description
182

1 -
(2) Check Sec-
tion
 Ignition ON
2

Go to Step
3 Refer to Wir-
(4)
Engine Elec-
trical.
file
(5) (6)
Replace ECM
Go to Step
5 -
(5)
es, etc.
the ECM
Go to OBD
temperature
6 System OK System
stored codes

codes?
183

DTC 522698 Redundant Clock Failure

 MIL-On
Circuit Description
184

DTC 522698 Redundant Clock Failure
1 -
(2) Check Sec-
tion
 Ignition ON
2

Go to Step
3 Refer to Wir-
(4)
Engine Elec-
trical.
file
(5) (6)
Replace ECM
Go to Step
5 -
(5)
es, etc.
the ECM
Go to OBD
temperature
6 System OK System
stored codes

codes?
185

DTC 522699 Redundant Watchdog Failure

 MIL-On
Circuit Description
186

DTC 522699 Redundant Watchdog Failure
1 -
(2) Check Sec-
tion
 Ignition ON
2

Go to Step
3 Refer to Wir-
(4)
Engine Elec-
trical.
file
(5) (6)
Replace ECM
Go to Step
5 -
(5)
es, etc.
the ECM
Go to OBD
temperature
6 System OK System
stored codes

codes?
187

DTC 522700 Redundant SDF Timeout

 MIL-On
Circuit Description
188

DTC 522700 Redundant SDF Timeout
1 -
(2) Check Sec-
tion
 Ignition ON
2

 Check ECM power and ground connections Repair the
at C001 pins E and F, C002, C012 and C016 circuit as ne-
cessary.
Go to Step
3 Did the power and ground circuits check OK? Refer to Wir-
(4)
ing Repairs in
Engine Elec-
trical.
file
(5) (6)
Replace ECM
Go to Step
5 -
(5)
es, etc.
the ECM
Go to OBD
temperature
6 System OK System
stored codes

codes?
189


Circuit Description
a) TPS1 fails open or shorted, - MIL illuminated, ECM uses TPS2, normal engine operation
b) TPS2 fails open or shorted, - MIL illuminated, ECM uses TPS1, normal engine operation
c) TPS1 & 2 fail open or shorted, - MIL illuminated, ECM stops controlling throttle, throttle goes to limp
home position and is non-responsive, engine will high idle or allow truck to move slowly.
d) TPS1 & 2 do not match, - MIL illuminated, ECM will use the higher of the two TPS readings resulting in
190

Actual TPS1 TPS2 TPS1 TPS2 reading Throttle

Throttle reading at reading at reading on Monitor Position on
Position Throttle Throttle on Moni- Monitor
tor
Fully
0.32 4.70 0.32 0.30 0
closed
¼ Open 1.32 3.70 1.32 1.30 25
¾ Open 3.32 1.70 3.32 3.30 75
Fully Open 4.32 0.70 4.32 4.30 100
Also see DTC 51.
191

Did you perform the On-board diagnostics (OBD)
system check? Go to On-
Board Diag-
Go to Step
(2)
Power Supply Codes .If multiple codes are set, ction indicator
volt reference.
es.
Go to Step
2 to Preliminary
(3)
Is the higher voltage minus the lower voltage di- and Intermit-
vided by 5 then multiplied by 100 greater than 6? tent Checks
NOTE: this is the formula the ECU uses to de-

termine if the TPS readings are within the
specifications
body.
 Key ON, measure the voltage from C017 pin Go to Step
3 Go to Step (4)
6 to pin 2 (5)

 Measure the resistance from C017 pin 2 to Verify that
ECU B pin G2 there are no
Repair the
 Measure the resistance from C017 pin 6 to codes for the
circuit as ne-
ECU B pin G4 5 volt supply
cessary. Refer
4 before pro-
to Wire Har-
Is the resistance less than 5Ω? ceeding.
ness Repair.
Replace the
Go to Step (9)
NOTE: Do not probe wires without proper ser- ECU. Go to
result.
192

Replace the
position
to Step (7)
6 ECU-B pin D3 supply before to Wire Har-
ECU. Go to (7).
Step (7)
tor.
es, etc.
from the ECM. Go to On-Board
 Turn the ignition OFF and wait 30 seconds. Diagnostics
7 System OK.
full operating temperature. Check/Malfuncti
 Observe the MIL. on Indicator
codes.

codes?
193


Circuit Description
a) TPS1 fails open or shorted, - MIL illuminated, ECM uses TPS2, normal engine operation
b) TPS2 fails open or shorted, - MIL illuminated, ECM uses TPS1, normal engine operation
c) TPS1 & 2 fail open or shorted, - MIL illuminated, ECM stops controlling throttle, throttle goes to limp
home position and is non-responsive, engine will high idle or allow truck to move slowly.
d) TPS1 & 2 do not match, - MIL illuminated, ECM will use the higher of the two TPS readings resulting in
194

Actual TPS1 TPS2 TPS1 TPS2 reading Throttle

Throttle reading at reading at reading on Monitor Position on
Position Throttle Throttle on Moni- Monitor
tor
Fully
0.32 4.70 0.32 0.30 0
closed
¼ Open 1.32 3.70 1.32 1.30 25
¾ Open 3.32 1.70 3.32 3.30 75
Fully Open 4.32 0.70 4.32 4.30 100

 A short circuit code will set if the TPS1 (as shown on the diagnostic monitor) is greater than 99.02%
of the 5 Volt Power Supply 1 (approx. 4.95 volts)
Also see DTC 51.
195

(OBD) system check? Go to On-
Board Diag-
Go to Step
(2)
Power Supply Codes .If multiple codes are set, ction indicator
volt reference.
es.
Go to Step
2  Is the higher voltage minus the lower voltage to Preliminary
(3)
divided by 5 then multiplied by 100 greater and Intermit-
than 6. tent Checks

result.
body.
 Key ON, measure the voltage from C017 pin Go to Step
3 Go to Step (4)
6 to pin 2 (5)

 Measure the resistance from C017 pin 2 to Verify that
ECU B pin G2 there are no
Repair the
 Measure the resistance from C017 pin 6 to codes for the
circuit as ne-
ECU B pin G4 5 volt supply
cessary. Refer
4 before pro-
to Wire Har-
Is the resistance less than 5Ω? ceeding.
ness Repair.
Replace the
Go to Step (9)
NOTE: Do not probe wires without proper ser- ECU. Go to
result.
196

Replace the
position
to Step (7)
6 ECU-B pin D3 supply before to Wire Har-
ECU. Go to (7).
Step (7)
tor.
es, etc.
Go to On-
from the ECM.
Board Diag-
nostics
7  Start the engine and operate the vehicle to System OK. System
full operating temperature. Check/Malfunc
 Observe the MIL. tion Indicator
codes.

codes?
197


91-2
Circuit Description
198

system check? Board
Diagnostics
Go to Step
System
1 (2).
Check/
Malfunction
indicator
lamp.
Intermittent
problem. Go
2 to Preliminary
and Intermit-
sensor. Oth-
tent Checks.
 Key ON, measure voltage from VIC 1 pins S
Between 4.8
and R. Go to Step
3 and 5.2 Go to Step (4)
 Key ON, measure voltage from VIC 1 pins M (5)
volts?
and L.

diagram and
power supply
Refer to the
problem be-
vehicle wiring
tween here
Between 4.8 diagram and
and ECU.
4 and 5.2 check ground
Check for
volts? back to ECU,
possible ECU
repair as ne-
5 volt prob-
cessary.
lem. Refer to
codes 524260
and 524261
for diagnostic
aids.
199

Reinstall the
pedal.
pins to the
 Sweep, watch for glitch Reinstall the
proper posi-
 Repeat on other side pins to the
tions in the
 NOTE: Pin J will show ½ the voltage of pin K. proper posi-
5 connector.
This is normal operation tions in the
Replace pedal
connector.
position sen-
Does the voltage sweep with no glitches from Go to step 6
sor. Go to
greater than 0.09 volts to less than 4.97 volts on step 8.

result.
ECU-A pin H2 and VIC 1 pin J to ECU-A pin open in the
6 <5Ω? Go to step 7
F3. harness. Go
to step 8
With the monitor or DST connected, wiggle Repair or
Replace the
the ECU-A connector. replace the
7 ECU. Go to
harness. Go
Step (8).
connector?
tor.
es, etc.
Go to On-
from the ECM.
Board
Diagnostics
Check/
ty. lamp.
codes.

codes?
200

201


91-2
Circuit Description
202

system check? Board
Diagnostics
Go to Step
System
1 (2)
Check/
Malfunction
indicator
lamp.
Intermittent
problem. Go
2 to Preliminary
and Intermit-
sensor. Oth-
tent Checks.
 Key ON, measure voltage from VIC pins S
and R. Between 4.8 Go to Step
3 Go to Step (4)
 Key ON, measure voltage from VIC pins M and 5.2 volts (5)
and L.

diagram and
power supply
Refer to the
problem be-
vehicle wiring
tween here
diagram and
Between 4.8 and ECU.
4 check ground
and 5.2 volts Check for
back to ECU,
possible ECU
repair as ne-
5 volt prob-
cessary.
lem. Refer to
codes 524260
and 524261
for diagnostic
aids.
203

pedal. Reinstall the
 Sweep, watch for glitch Reinstall the pins to the
 Repeat on other side pins to the proper posi-
proper positions in the
5 NOTE: Pin J will show ½ the voltage of pin K. tions in the connector.
This is normal operation connector. Replace pedal
Go to Step position sen-
Does the voltage sweep with no glitches from (6) sor. Go to
greater than 0.09 volts to less than 4.97 volts on Step (8).

result.
ECU-A pin H2 and VIC 1 pin J to ECU-A pin Go to Step open in the
6
F3. (7) harness. Go
to Step (8)
With the monitor or DST connected, wiggle Repair or re-
Replace the
the ECU-A connector. place the
7 ECU. Go to
harness. Go
Step (8).
connector?
204

tor.
es, etc.
Go to On-
from the ECM.
Board
Diagnostics
Check/
ty. lamp.
codes.

codes?
205

DTC 522735 Oxygen Sensor Short/Open
 Heated Oxygen Sensor

 Fault Condition-Less than 30mv
 MIL-On
Circuit Description
The EGO sensor (Exhaust Gas Oxygen) sensor is used to determine if the fuel flow to the engine is
correct by measuring the oxygen content in the exhaust gas. The EGO sensor uses an internal heating
element to keep the sensor active. This fault will set if the ECM detects a short low or open in the HEGO
heater element or control circuit. NOTE: The HEGO sensor is sensitive to silicone and silicone-based
products and can become contaminated. Avoid using silicone sealers or hoses treated with silicone lubri-
cant in the air stream or fuel supply lines.
206

1 -
(2) Check Sec-
tion
 Ignition OFF
 Disconnect HEGO connector C018
 Ignition ON
System Bat- Go to Step Go To Step
2  Using a DVOM check for voltage between tery Voltage (8) (3)
EGO connector pins C and D
Does the DVOM show voltage?

 Ignition ON Repair open
 Using a DVOM check for voltage between HEGO heater
HEGO connector pin C and engine ground supply circuit
System Bat- Go to Step
3 from power
tery Voltage (4)
Do you have voltage? relay. See
wire harness
repair.
 Using a DVOM check for voltage between Repair open
HEGO connector pin D and battery positive HEGO
 Ignition ON System Bat- ground cir- Go to Step
4
tery Voltage cuit. See (5)
Do you have voltage? wire harness
repair.
 Ignition OFF
Repair the
 Disconnect ECU-C Connector
open HEGO
 Using a DVOM check for continuity between Go to Step heater
5 ECU-C connector pin L2 and HEGO connec- (6) ground. See
tor pin D wire harness
repair.
 Ignition ON Repair the
 Using a DVOM check for voltage between HEGO heater
HEGO connector pin D and battery positive ground short- Go to Step
6
ed to voltage. (7)
Does the DVOM show voltage? See wire har-
ness Repair.
 Replace ECM
Go to Step
7 -
(10)
207

Using a DVOM measure the resistance of the
HEGO heater (sensor side) between pins C and
D. Greater than Go to Step Go to Step
8
25 Ohms (9) (5)
Does the DVOM show a resistance value greater
than 25 Ohms?
Replace the HEGO sensor
Go to Step
9 -
(10)
es, etc.
the ECM.
Go to OBD
temperature
10 System OK System
stored codes.

codes?
208

209

The maximum current, current to ground, and drain voltage are monitored internally to the ECU. If the cur-
rent at the driver chip goes above 3 amps, current to ground goes above 100 micro Amps, or voltage drops
below 3 volts, a diagnostic code will be set.
Circuit Description
The system monitors the O2 sensor to ensure that the fuel control is functioning properly. The HEGO sen-
sor is mounted in the exhaust system downstream of the engine. It is used to measure the amount of
oxygen present in the exhaust stream and communicates that to the ECM via an electrical signal. The
amount of oxygen present in the exhaust stream indicates whether the fuel air ratio is rich or lean. If the
HEGO sensor signal indicates that the exhaust stream is rich, the ECM will decrease or lean the fuel mix-
ture by reducing the short term fuel correction value which reduces the injector on-time supplying less fuel.
If the mixture is lean, the ECM will richen the mixture or increase the short term fuel correction value which
will increase the pulse width to the injectors. Under normal steady operation the short term fuel correction
value should move up and down approx. 5%. This 5% movement may range within a plus 25 to minus 25
percent window. The ECM continuously monitors the HEGO sensor output. If a rich or lean condition is
present for an extended period of time and if the ECM cannot correct the condition, the ECM will set a di-
agnostic code and turn on the MIL light in the dash. The O2 sensor uses a heater circuit to bring it up to
operating temperature as quickly as possible, as well as maintaining the temperature during idle. The hea-
ter is controlled by the ECU, which will cycle the heater to prevent overheating of the sensor
210

system check? Board
Diagnostics
Go to Step
System
1 (2)
Check/
Malfunction
indicator
lamp.
 Key OFF, disconnect C018
 Key ON, measure voltage from C018 pin D
to ground. Repair open
in Component
Go to Step
2 Is battery voltage present? Power Relay
(3)
circuit. Go to
NOTE: Voltage is supplied from the Component Step (8)
Power Relay circuit and will only be present for
1 to 2 seconds when the key is first turned on.
 Measure resistance across the O2 sensor Replace the
9.6Ω, ±
heater circuit, pins C and D. Go to Step O2 Sensor.
3 1.5Ω @
(4) Go to Step
21˚C?
Is the resistance 9.6Ω, ± 1.5Ω @ 21˚C? (8)
 Measure the resistance from the O2 sensor
heater circuit pins C and D to ground
Replace the
 Is the resistance greater than 30MΩ?
Go to Step O2 Sensor.
4 >30MΩ
(5) Go to Step
(8)
result.
 Key OFF, disconnect ECU-C
Repair the
 Measure resistance from C018 pin C to
Go to Step open in the
5 ECU-C pin L2 <5MΩ
(6) circuit. Go to
Step (8)
 Measure the resistance from C018 pin C to Repair the
ground. short to
Go to Step
6 >30MΩ ground in the
(7)
Is the resistance greater than 30MΩ? harness. Go
to Step (8)
 Key ON, engine running, monitor the system
Repair or re-
for faults
place the Replace the
 Flex the connectors at the ECU while watch-
7 ECU harness. ECU. Go to
ing for faults
Go to Step Step (8)
(8)
Was a fault indicated by wiggling the wires?
211

tor.
es, etc.
Go to On-
from the ECM.
Board
Diagnostics
Check/
ty. lamp.
codes.
Does the engine operate normally with no

stored codes?
212

213

DTC 522752 Start Failure Due to Cam Signal Error
Conditions for setting the DTC
This fault will set if the ECU does not detect a cam pulse within 16 engine revolutions whenever the engine
is cranking or running.
Circuit Description
The camshaft position sensor (CMP) is a Hall Effect sensor used to synchronize the fuel and ignition sys-
tems. The sensor produces a short 5 volt square wave pulse every two engine revolutions. The signal
wire from the CAM sensor is held up at 5 volts by a pull-up resistor in the ECU. The CAM sensor pulls this
5 volt level to ground until a small hole in the end of the camshaft passes the sensor at which time the sig-
nal goes high to 5 volts for a brief period.
214

DTC 522752 Start Failure Due to Cam Signal Error
 Did you perform the On-board diagnostics Perform OBD
1 Go to step 2
(OBD) system check? System check
 Check connections at C004, ECU-B pin M1, Intermittent
M2, L1, and ECU-C pins A4 and F1. problem. Go
Go to Step
2 to Preliminary
(3)
and Intermit-
tent Checks
 Key OFF, disconnect C004 Connector.
 Key ON, measure voltage across C004 pins
Between 4.8 Go to Step Go to Step
3 A and C.
and 5.2 volts (4) (5)
Is voltage between 4.8 and 5.2 volts?
 Reconnect C004.
 Using suitable probe, back probe C004 pins
B and C.
 Connect a Multi-meter capable of measuring
Replace Cam
Duty Cycle, + to pin B, - to pin C. Go to Step
4 Sensor, Go to
 Crank the engine. (5)
Step (9)
Does the duty cycle read 90% (or 10%)? Duty
cycle can show either 90% or 10% ±5% depend-
ing on the meter.
 Wiring check
Repair the
 Key OFF, disconnect ECU-C and C004
circuit as ne-
 Measure resistance from :
cessary.
 C004 pin A to ECU-C pin A4 Go to Step
5 <5Ω Refer to Wire
 C004 pin B to ECU-C pin F1 (6)
Harness
 C004 pin C to ECU-B pin M2 Repair. Go to
Step (9)
 Key OFF, disconnect ECU-C and C004 Repair short
 Measure resistance from : to ground as
 C004 pin A to ground. necessary.
Go to Step
6  C004 pin B to ground >30MΩ Refer to Wire
(7)
 C004 pin C to ground Harness
Repair. Go to
Is resistance greater than 30MΩ? Step (9)
 Key OFF, disconnect ECU-C and C004
Repair short
 Measure resistance from :
in harness.
 C004 pin A to C004 pin B
Go to Step Refer to Wire
7  C004 pin A to C004 pin C >30MΩ
(8) Harness re-
 C004 pin B to C004 pin C pair. Go to
Step (9)
Is resistance greater than 30MΩ?
 Replace ECU computer.
Go to Step
8
(9)
Is replacement completed?
215

tor.
es, etc.
9 full operating temperature. System OK System
ty. lamp.
codes.

codes?
216

217

DTC 523821 Oil Lamp Circuit Open
 Engine Low Oil Pressure Signal

 Check Condition-Engine running for greater than 10 seconds with engine speed greater than 500 rpm.
 Fault Condition-No oil pressure signal for more than 5 seconds
 Engine shut down
Circuit Description
The Oil Pressure Switch is used to communicate a low oil pressure condition to the ECM. Engine
damage can occur if the engine is operated with low oil pressure. This fault will set if the oil pressure
switch remains closed with the engine running. The switch is set to open above 6 PSI.
Circuit Description
Never assume the fault is due to an electrical malfunction. Low oil pressure can damage the engine. Verify
oil pressure before proceeding with this diagnostic.
218

DTC 523821 Oil Lamp Circuit Open
Check? Go to Step System.
1 -
(2) Check Sec-
tion
Verify that the engine has oil and oil pressure
using a mechanical oil pressure gauge before
proceeding with this chart. Oil pressure must Go to Step Repair faulty
2
remain above 6 psi. (3) Oiling System
Does the engine have oil pressure above 6 psi?

 Ignition ON, Engine Running DST connected
in stem Data Mode
 Clear DTC 523821
Intermittent
 Warm the engine by idling until the ECT
3 temperature is above 160 degrees F. and
(4) to Intermittent
has been running for at least one minute
section
 Increase engine speed above 500 RPM
Does DTC 523821 reset?

 Clear DTC 523821
 Key OFF
 Disconnect oil pressure switch connector
C012 and isolate the connector from engine Go to Step Go to Step
4
ground. (6) (5)
 Start and run the engine
Does DTC 523821 reset?

Replace oil pressure switch
Go to Step
5 -
(9)
 Ignition OFF Repair the
 Disconnect ECM harness connector ECU-C shorted to
 Using a DVOM check for continuity between ground oil
the oil pressure switch connector pin and en- pressure cir- Go to Step
6
gine ground cuit as (7)
necessary.
Does the DVOM show continuity? Refer to Wir-
ing Repairs.
Inspect ECU-B connector pin C1 for damage Repair the
corrosion or contamination circuit as ne-
cessary.
Go to Step
7 Did you find a problem? Refer to Wir-
(8)
ing Repairs in
Engine Elec-
trical.
219

Replace ECM
Go to Step
8 -
(9)
es, etc.
the ECM.
Go to OBD
temperature
9 System OK System
rameters of DTC 523821check for any stored
codes.

codes?
220

221

DTC 524260 5 Volt Power Supply 1 Out of Spec
The voltage output of the two power supplies are compared against two range limits. The first “Out of
Spec” limits are 4.8 to 5.2 volts the second “Malfunction” limits are 4.5 to 5.5 volts. If the 5 volts supplies
are outside the “Out of Spec” limits but not outside the broader “Malfunction” limits the sensors and com-
ponents will continue to operate but at a reduced accuracy. If the 5 volt supplies are outside the
malfunction range sensors and components may fail to operate. The voltage being outside the malfunction
limits may be an indication of a short to ground or short to battery voltage somewhere in the system.
Voltage supply at the 5 volt reference is less than 4.8 volts or greater than 5.2 volts.
NOTE: If the 5 volt supply is shorted to ground through wiring or a sensor, this code may set.
Circuit Description
The ECU has two externally available 5 volt regulated power supplies. These power supplies are used as
a power source and or a reference voltage for the various sensors and components used in the fuel sys-
tem. If there is an out of spec fault in either 5 volt supply, the system will go to the Limp Home mode.
5 Volt Supply 1 Table

Supply 1 ECU-A pin G2 Pedal 1 5 volt supply VIC 1 pin M
ECU-B pin G1 Not Used
ECU-B pin G2 Throttle position sensor supply pin 2
ECU-C pin B3 Not Used
Supply 2 ECU-A pin F2 Pedal 2 5 volt supply VIC 1 pin S
ECU-B pin J2 FRP Pin B and Crank Sensor Pin 1
ECU-B pin H2 MAP Sensor supply pin 3
222

nostics
Go to Step
1 System
(2)
Check/Malfun
ction indicator
lamp.
 Disconnect all sensors for the 5 volt supply
showing the fault.
 Refer to the wiring diagram and measure the
2 voltage from the 5 volt supply to the ground
and 5.2 volts (3) (5)
of each sensor or component
Are all supplies between 4.8 and 5.2 volts?

 One at a time, reconnect a sensor while Intermittent
monitoring the voltage at another sensor. problem. Go
Go to Step
3 to Preliminary
(4)
Does the voltage go out of range when recon- and Intermit-
necting a sensor? tent Checks
 Examine the connector of the sensor that Replace the
causes the voltage to go out of range. sensor that
Repair as ne-
causes the
4 cessary. Go
Is there any damage to the connector? fault in the
to Step (8).
voltage. Go to
step last
 Refer to the 5 volt supply table and check
each supply circuit for a short to power or Repair as re-
Go to Step
5 ground. quired. Go to
(6)
Step (8).
Are there any harness faults?
 Reconnect all connectors.
 Clear all codes.
Replace the
 With the Key ON, engine off, monitor the sys- Go to Step
6 ECU. Go to
tem for any faults. (7)
Step (8)
Does the fault return? Are any faults detected?
 Flex the connectors at the ECU while watch- Intermittent
Repair or re-
ing for faults. problem. Go
place the
7 to Preliminary
harness. Go
Does the fault return? and Intermit-
to Step (8).
tent Checks
223

tor.
es, etc.
ty. lamp.
codes.

codes?
224

225

The voltage output of the two power supplies are compared against two range limits. The first “Out of
Spec” limits are 4.8 to 5.2 volts the second “Malfunction” limits are 4.5 to 5.5 volts. If the 5 volts supplies
are outside the “Out of Spec” limits but not outside the broader “Malfunction” limits the sensors and com-
ponents will continue to operate but at a reduced accuracy. If the 5 volt supplies are outside the
malfunction range sensors and components may fail to operate. The voltage being outside the malfunction
limits may be an indication of a short to ground or short to battery voltage somewhere in the system.
Voltage supply at the 5 volt reference is less than 4.8 volts or greater than 5.2 volts.
NOTE: If the 5 volt supply is shorted to ground through wiring or a sensor, this code may set.
Circuit Description
The ECU has two externally available 5 volt regulated power supplies. These power supplies are used as
a power source and or a reference voltage for the various sensors and components used in the fuel sys-
tem. If there is an out of spec fault in either 5 volt supply, the system will go to the Limp Home mode.

Supply 1 ECU-A pin G2 Pedal 1 5 volt supply VIC 1 pin M
ECU-B pin G1 Not Used
ECU-B pin G2 Throttle position sensor supply pin 2
ECU-C pin B3 Not Used
Supply 2 ECU-A pin F2 Pedal 2 5 volt supply VIC 1 pin S
ECU-B pin J2 FRP Pin B and Crank Sensor Pin 1
ECU-B pin H2 MAP Sensor supply pin 3
226

system check? Board Diag-
nostics
Go to Step
1 System
(2)
Check/Malfun
ction indicator
lamp.
 Disconnect all sensors for the 5 volt supply
showing the fault.
 Refer to the wiring diagram and measure the
2 voltage from the 5 volt supply to the ground
and 5.2 volts (3) (5)
of each sensor or component.
Are all supplies between 4.8 and 5.2 volts?

 One at a time, reconnect a sensor while Intermittent
monitoring the voltage at another sensor. problem. Go
Go to Step
3 to Preliminary
(4)
Does the voltage go out of range when recon- and Intermit-
necting a sensor? tent Checks
 Examine the connector of the sensor that Replace the
causes the voltage to go out of range. sensor that
Repair as ne-
causes the
4 cessary. Go
Is there any damage to the connector? fault in the
to Step (8).
voltage. Go to
step last
 Refer to the 5 volt supply table and check
each supply circuit for a short to power or Repair as re-
Go to Step
5 ground. quired. Go to
(6)
Step (8).
Are there any harness faults?
 Reconnect all connectors.
 Clear all codes.
Replace the
 With the Key ON, engine off, monitor the sys- Go to Step
6 ECU. Go to
tem for any faults. (7)
Step (8)
Are any faults detected?
 Flex the connectors at the ECU while watch- Intermittent
Repair or re-
ing for faults. problem. Go
place the
7 to Preliminary
harness. Go
Does the fault return? and Intermit-
to Step (8).
tent Checks
227

tor.
es, etc.
ty. lamp.
codes.

codes?
228

229

DTC 524266 ETC Wire Shorted/Fail
 Throttle Position Sensor

 Fault Condition-Actual and desired throttle position greater than 10%
 Battery voltage greater than 9 volts
Circuit Description
closing as commanded. This fault will set if the ECM detects a problem with the ETC TPS, malfunctioning
throttle control motor or sticking throttle valve assembly.
230

Go to Step
(2)
Section
 Ignition ON
2

bore? found. Go to
Step (17)
 Ignition OFF
Repair the
C017
shorted to
ground TPS
ECU-B
Go to Step
(6)
Refer to Wir-
Go to Step
(7)
Refer to Wir-
Go to Step
(8)
Refer to Wir-
231

Go to Step
8 ground as ne-
(9)
to Wiring Re-
pairs.
Go to Step
9 ground as ne-
(10)
to Wiring Re-
pairs.
Go to Step
10 ground as ne-
(11)
to Wiring Re-
pairs.
Go to Step
11 -
(12)
es, etc.
the ECM.
12 System OK
stored codes.

codes?
Replace the ECM
Go to Step
13 -
(14)
232

es, etc.
the ECM.
14 System OK
stored codes.

codes?
233

 Throttle Position Sensor

 Fault Condition-Actual and desired throttle position greater than 10%
 Battery voltage greater than 9 volts
Circuit Description
closing as commanded. This fault will set if the ECM detects a problem with the ETC TPS, malfunctioning
throttle control motor or sticking throttle valve assembly.
234

Go to Step
(2)
Section
 Ignition ON
2

bore? found. Go to
Step (17)
 Ignition OFF
Repair the
C017
shorted to
ground TPS
ECU-B
Go to Step
(6)
Refer to Wir-
Go to Step
(7)
Refer to Wir-
Go to Step
(8)
Refer to Wir-
Go to Step
8 ground as ne-
(9)
to Wiring Re-
pairs.
235

Go to Step
9 ground as ne-
(10)
to Wiring Re-
pairs.
Go to Step
10 ground as ne-
(11)
to Wiring Re-
pairs.
Go to Step
11 -
(12)
es, etc.
the ECM.
12 System OK
stored codes.

codes?
Replace the ECM
Go to Step
13 -
(14)
es, etc.
the ECM.
14 System OK
stored codes.

codes?
236

Servicing the Fuel System
237

I. ENGINE CONTROL MODULE II. FUSE BOX MOUNTING BRACKET
This procedure relates to removal and installation

of the ECM--see Diagnostic Scan Tool for access-
ing ECM software.
REMOVAL PROCEDURE
ECM
REMOVAL PROCEDURE
1. Disconnect the negative battery cable.
1. Disconnect the negative battery cable
2. Disconnect the electrical connectors from the
2. Remove the four Screws, Washers and
ECM. Rotate the locking tabs on each connec-
Spacers securing the ECM to the Bracket.
tor to unlock the electrical connectors. 3. Remove the two Bolts securing the Fuse Box
Disconnect the connector closest to the nega-
bracket to the Coil Bracket.
tive battery terminal first. Disconnect the
center connector second. Disconnect the con-
INSTALLATION PROCEDURE
nector closest to the positive battery terminal
last. 1. Secure the Coil Bracket and Fuse Box bracket
3. Remove the screws securing the ECM,
by placing with two Bolts to the engine. Tor-
que 29.5-36.8 ft.lbs. (40-50 Nm).
INSTALLATION PROCEDURE 2. Attach the Fuse Box with four Screws (if re-
moved). Torque to 2-3 ft. lbs. (2.7-4 Nm).
1. Place the ECM in position and secure with
screws. Tighten the nuts to 9 to 11 N•m III. ENGINE WIRE HARNESS REPLACEMENT
(79.66 to 97.36 in. lbs).
2. Connect the electrical connectors to the ECM. 1. Disconnect negative battery cable.
Connect the electrical connector closest to the 2. Lay out the new Wire Harness, noting the lo-
positive battery terminal first. Connect the cen- cation, type of connectors, and identifying
ter connector second. Connect the connector markings. Take special note of identical or
closest to the negative battery terminal last. similar connectors (such as the coils or HEGO
Rotate the locking tabs to lock the electrical Sensors) to avoid crossing connections during
connectors in position. installation. NOTE the routing of the existing
3. Connect the negative battery cable. wire harness in and around the engine and the
4. Turn the ignition key to the ON position vehicle. Refer to the Electrical Schematic.
5. Start the vehicle and check for proper opera-
tion of the electronic throttle body and the
ECM by exercising the accelerator pedal with
the vehicle in neutral.
238

3. Remove electrical connection from Oil Pres-
sure Sender.
4. Using a wrench, hold the brass adapter (to
prevent from turning) and turn the Switch
Ensure that all connections are made to
counter-clockwise and remove. Do not re-
the correct locations on the engine and its
move the brass adapter from the engine block
components. Crossing connections may
(unless it is to be replaced).
cause poor engine performance, a MIL
warning and/or permanent damage to the
ECM.
1. Apply Loctite 567 (or equivalent high-temp
3. Remove all Wire Harness connectors on the thread locker/sealer) to the threads on the Oil
vehicle. Pressure Sender. If the Brass Adapter was
4. Remove all clips and brackets holding the removed or is to be added to a new Sender,
Wire Harness and remove harness from ve- add thread locker/sealer and thread on to the
hicle. engine block. Torque to 2-3 turns past tight.
5. Lay the new wire harness over the engine and 2. Install Oil Pressure Sender. Torque to 2-3
route each end to its connection. Verify that turns past tight, ensuring the electric con-
all connectors match prior to installation. nector (screw) is accessible.
6. Connect all connectors and Ring Terminals. 3. Attach electrical connector.
7. Install all clips and brackets to hold down the 4. Reconnect negative battery cable.
harness. 5. Start the engine and let run until it reaches
8. Reconnect negative battery cable. normal operating temperature. Check for oil
9. Start the vehicle. leaks around sensor. If leaks are found, repair
10. Check for MIL illumination. If a DTC code is as necessary.
found, refer to the Electrical Section for further 6. If a DTC code is found, refer to the Electrical
diagnosis. Section for further diagnosis.
IV. OIL PRESSURE SENDER V. DISTRIBUTOR
The Oil Pressure Sender, shown installed on

the side of the engine below the ECM and The Distributor
above the starter.
REMOVAL PROCEDURE REMOVAL PROCEDURE
1. Disconnect the negative battery cable. 1. Disconnect negative battery cable.

2. Locate the Oil Pressure Sender on the side of 2. Mark each Spark Plug Wire with its corres-
the engine. ponding cylinder or position on the Distributor
239

Cap. 10. If a DTC code is found, refer to the Electrical
3. Remove Spark Plug Wires from the Distributor Section for further diagnosis.
Cap by pulling and twisting each Spark Plug
Wire boot ½ turn. VI. TEMPERATURE MANIFOLD PRESSURE
4. Remove Ignition Coil wire. SENSOR (TMAP)
5. Remove the electrical connector from the
base of the Distributor. REMOVAL PROCEDURE
6. Remove the two Screws that hold the Distribu-
tor Cap to the housing and remove Cap. 1. Disconnect the negative battery cable.
7. Using a grease pencil or similar marking tool, 2. Locate the TMAP Sensor on the Intake Mani-
mark the location of the Rotor on the distribu- fold plenum.
tor housing and engine. 3. Disconnect electrical connector.
8. Remove the Distributor hold down bolt. 4. Remove the retaining screw.
5. Remove TMAP Sensor by pulling straight up
IMPORTANT with a slight rocking motion.
Do not engage the starter, or change the positions
of the cam or crankshaft, timing gears or any oth-
er internal engine components while the
distributor is removed. Any change in the position
of these components will alter the timing.
1. Align the Rotor with the mark made on the

Distributor housing (the location of the rotor
when it was removed) and place into the en-
gine ensuring the rotor, distributor housing
and the mark on the engine are all in align-
ment when the Distributor is fully seated. TMAP Sensor
2. Install the Distributor mounting clam Bolt and
tighten to 18 ft. lbs (25 Nm). Verify that the INSTALLATION PROCEDURE
rotor and Distributor housing remain in line
with the mark. 1. Install the TMAP and secure with Retaining
3. Install Distributor Cap. Screw. Torque to 7-9 ft.lbs. (9.5-12.2 Nm).
2. Reconnect electrical connector.
IMPORTANT 3. Reconnect the negative battery cable.
Do not reuse old Distributor Cap Screws. Use 4. Start engine and run until it reaches normal
new Screws only. operating temperature.
5. Check for MIL illumination. If a DTC code is
4. Connect the electrical connection to the base found, refer to the Electrical Section for further
of the Distributor. diagnosis.
5. Connect Spark Plug wires to the Distributor
Cap, ensuring the wires are connected to the
correct cylinder. NOTE that the firing order is
1-3-4-2. Refer to the IGNITION SYSTEM
SPECIFICATIONS in the Appendix for addi-
tional information.
6. Connect Ignition Coil wire to Distributor Cap.
7. Reconnect negative battery cable.
8. Start engine. Run engine through all throttle
ranges and under load to ensure normal oper-
ation.
9. Using the DST, clear DTC information from
the ECM.
240

VII. FUEL TEMPERATURE/PRESSURE normal operating temperature.
SENSOR 8. If a DTC code is found, refer to the Electrical
Section for further diagnosis.
VIII. ENGINE COOLANT TEMPERATURE

SENSOR (ECT)
REMOVAL PROCEDURE

2. Drain the coolant.
3. Locate the ECT just below the thermostat
housing .
4. Remove electrical connector from the ECT.
REMOVAL PROCEDURE
1. Relieve the LPG fuel system pressure. Refer

to XVIII. LPG FUEL SYSTEM PRESSURE
RELIEF. The coolant may be hot. Use caution when
2. Disconnect the negative battery cable. removing hose(s) to prevent contact.
3. Locate the Fuel Temperature Sensor on the
fuel rail. INSTALLATION PROCEDURE
Sensor. 1. Apply a light coat of Loctite 567 or equivalent
5. Unscrew the sensor from the Fuel Rail. pipe thread sealant on the threads of the ECT.
1. Lubricate the O-ring on the Fuel Temperature

Sensor with a light coat of Vaseline or petro-
leum jelly. Do not contaminate the tip of the
sensor.
The HEGO is sensitive to silicone based

products and can become contaminated.
Avoid using silicone sealers/lubricants on
any fuel or exhaust related components.
2. Install the sensor into the Fuel Rail. Torque

2. Install the ECT into the engine and torque
to 6-7.5 ft. lbs. (8-10 Nm). DO NOT
until tight.
EXCEED 7.5 ft. lbs. (10 Nm).
3. Connect the ECT electrical connector.
3. Reconnect the electrical connector to the Fuel
4. Refill the cooling system.
Temperature Sensor.
5. Reconnect the negative battery cable.
6. Start the vehicle and let run until it reaches
5. Open valve on the LPG tank.
normal operating temperature.
6. Turn ignition key to ON and check for leaks at
7. If a DTC code is found, refer to the Electrical
the inlet and outlet fittings using a commercial
grade soapy solution or an electronic leak de-
8. Allow the engine to cool, check coolant level
tector. If leaks are detected make repairs.
and add coolant if necessary.
241

IX. HEATED EXHAUST GAS OXYGEN SENSOR INSTALLATION PROCEDURE
(HEGO)
1. Inspect Throttle Body Gasket. Replace if ne-
cessary.
REMOVAL PROCEDURE
2. Place Throttle Body and Gasket on the Intake
Manifold plenum, align and secure with four
1. Disconnect Negative battery cable.
Screws. Torque to 7-9 ft.lbs. (9.5-12.2 Nm).
2. Locate the Oxygen Sensor.
3. Connect electrical connector.
3. Disconnect the Oxygen sensor electrical con-
nector.
5. Start Engine. Verify correct operation in all
throttle ranges.
6. Using the DST, clear DTC information from
the ECM.
7. Turn the ignition OFF and wait 30 seconds.
normal operating temperature.
HEGO and Fitting XI. REGULATOR
4. Using an Oxygen Sensor socket, remove the

Oxygen Sensor.
IMPORTANT
Before installing the Oxygen sensor lubricate
threads with anti-seize compound GM P/N
5613695 or equivalent. Avoid contaminating sen-
sor tip with compound.
1. Install Oxygen Sensor.

2. Reconnect electrical connector to the Oxygen
Sensor.
normal operating temperature and is in closed
loop. Regulator
Section for further diagnosis. REMOVAL PROCEDURE
X. THROTTLE BODY AND/OR GASKET 1. Relieve the LPG fuel system pressure. Refer
REMOVAL PROCEDURE RELIEF.
2. Disconnect Negative battery cable.
1. Disconnect the negative battery cable. 3. Remove the electrical connector on the Shu-
2. Remove the air intake. toff Valve.
3. Remove Throttle Body electrical connector. 4. Remove the Fuel Hose from the regulator.
4. Remove four Screws that secure the Throttle 5. Remove the LPG Fuel Line at the flare fitting
Body. attached to the Shutoff Valve.
5. Remove the Throttle Body and the Gasket.
242

XII. CHECKING/DRAINING OIL BUILD-UP IN
THE LOW PRESSURE REGULATOR
A small amount of fuel may still be present During the course of normal operation oil or
in the fuel line. Use gloves and proper eye “heavy ends” may build inside the secondary
protection to prevent burns. If liquid fuel chamber of the Regulator. These oil and heavy
continues to flow from the connections ends may be a result of poor fuel quality, conta-
when removed, make sure the manual mination of the fuel, or regional variation of the
valve is fully closed. fuel make up. A significant build up of oil can af-
fect the performance of the secondary diaphragm
6. Clamp both Coolant Hoses as close to the response. The Recommended Maintenance
Regulator as possible. Schedule found in this section recommends that
7. Remove Coolant hoses. the oil be drained periodically. This is the mini-
mum requirement to maintain the emission
warranty. More frequent draining of the Regulator
is recommended for special situation where subs-
tandard fuel may be a problem. IMPCO
recommends the Regulator be drained at every
The coolant may be hot. Use caution when engine oil change if contaminated or substandard
removing hose(s) to prevent contact. fuel is suspected or known to be have been used
or in use with the emission complaint fuel system.
This is known as special maintenance, and failure
8. Remove the Bolt securing the Regulator. to follow this recommendation may be used to de-
ny a warranty claim.
IMPORTANT:
1. Secure Regulator with Bolt. Torque to 12.5 Draining the Regulator when the engine is warm
ft.lbs. (17 Nm). will help the oils to flow freely and permit easier
2. Attach the LPG Fuel Line at the flare fitting removal from the Regulator.
attached to the Shutoff Valve.
3. Reconnect LPG Fuel Line (to Fuel Rail). To drain the Regulator, follow the steps below:
4. Connect Coolant Lines secure with hose
clamps. Remove clamps from hoses (if used 1. Move the equipment to a well ventilated area
during removal). and ensure no external ignition sources are
5. Connect the fuel supply line (from tank). present.
6. Slowly open LPG Tank Valve. 2. Turn off LPG Valve and Relieve the LPG fuel
system pressure. Refer to XVIII. LPG FUEL
IMPORTANT: SYSTEM PRESSURE RELIEF.
The fuel cylinder manual valve contains an 3. Disconnect Negative battery cable.
Excess Flow Check Valve. Open the manual
valve slowly to prevent activating the Excess Flow
Check Valve.
7. Reconnect negative battery cable. Turn igni-

tion key to ON and check for leaks at the inlet A small amount of fuel may still be present in
and outlet fittings using a commercial grade the fuel line. Use gloves and proper eye pro-
soapy solution or an electronic leak detector. tection to prevent burns. If liquid fuel
If leaks are detected make repairs. continues to flow from the connections when
8. Start engine and check for fuel and coolant removed, make sure the manual valve is fully
leaks. If leaks are detected make repairs. closed.
9. Check for MIL illumination.
10. Run engine to normal operating temperature 4. Remove the plug on the Regulator under the
and turn key to OFF. lower coolant port.
11. Check coolant level and add coolant if neces- 5. Place a small receptacle in the engine com-
sary. partment to catch any liquid that may come
243

out of the Regulator. 12. Dispose of any drained material in safe and
6. Inspect the Regulator for any large dried par- proper manner.
ticles and remove. Use a safety solvent to
remove any build up. XIII. FUEL FILTER ELEMENT (HIGH PRESSURE)
REMOVAL PROCEDURE

Use only Safety Solvents for the cleaning to XVIII. LPG FUEL SYSTEM PRESSURE
of the regulator and its components. Sol- RELIEF.
vents such as carburetor or brake cleaners 2. Disconnect negative battery cable.
may damage gaskets, seals, O-rings, di-
aphragms or other non-metal components.
A small amount of fuel may still be present in

the fuel line. Use gloves and proper eye pro-
Contamination of the HEGO sensor can re- tection to prevent burns. Make sure the
sult from the use of an inappropriate RTV manual valve is fully closed.
sealer or silicone spray products. Do not use
silicone sprays or hoses which are assem-
bled using silicone lubricants. Always use
“oxygen sensor safe” RTV sealant for repair
procedures. Silicon contamination will cause
a high but false HEGO signal voltage (rich
duce the amount of fuel delivery to the
engine, causing a severe driveability prob-
lem. If silicone contamination is suspected,
remove and visually inspect the sensor ele-
ment. If contaminated, the portion of the
have a white powdery coating. Always be
sure to eliminate the cause of contamination
before replacing the sensor.
Regulator, showing filter related components.
7. Reinstall the Plug. Torque until tight.
8. Connect negative battery cable. 3. Disconnect the fuel inlet and outlet lines from
9. Open Valve on LPG tank. the LPG Regulator.
4. Remove the fuel inlet fitting (7) and O-ring (6).
IMPORTANT: 5. Remove the plastic body (5), foam filter (4),
The fuel cylinder manual valve contains an paper filter element (3), and filter gasket (2).
Excess Flow Check Valve open the manual 6. Remove the screws (5), fuel outlet fitting (4)
valve slowly to prevent activating the Excess O-ring (3), and filter (2). Discard O-ring and fil-
Flow Check Valve. ter.
10. Turn Key ON. Check for leaks at the inlet and INSTALLATION PROCEDURE
outlet fittings using a soapy solution or an
electronic leak detector. If leaks are detected 1. Install new filter (2) in port for fuel outlet fitting.
make repairs. Install new O-ring (3) and fuel outlet fitting (4).
11. Start engine and check for leaks at all ser- 2. Install retaining screws (5) for fuel outlet fitting
viced fittings. If leaks are detected make (4). Tighten screws to 2 to 3 N•m (17.7 to
repairs. 26.55 in. lb.).
244

3. Install the filter gasket (6), new paper filter valve slowly to prevent activating the Excess Flow
element (7), new foam filter (8), and plastic Check Valve.
body (9).
4. Install the fuel inlet fitting (11) and O-ring (10). 5. Slowly open the fuel valve on tank.
Tighten to 18 to 20 N•m (13.3 to 14.75 ft.lbs.). 6. Turn the key to the ON position and back to
5. Connect the fuel inlet line to the LPG Regula- the OFF position to pressurize the fuel sys-
tor. tem. Check for leaks.
6. Connect the negative battery cable. 7. Check for leaks at connections by using soapy
7. Slowly open the fuel valve on tank. solution or electron leak detector. If leaks are
detected, make proper repairs.
IMPORTANT: 8. Start engine and ensure correct operation in
The fuel cylinder manual valve contains an all throttle ranges.
Excess Flow Check Valve. Open the manual 9. Check for leaks at connections by using soapy
valve slowly to prevent activating the Excess Flow solution or electron leak detector. If leaks are
Check Valve. detected, make proper repairs.
8. Turn the key to the ON position and back to XV. FUEL RAIL
the OFF position to pressurize the fuel sys-
tem. Check for leaks. REMOVAL PROCEDURE
9. Check for leaks at connections by using soapy
solution or electron leak detector. If leaks are 1. Relieve the LPG fuel system pressure. Refer
detected, make proper repairs. to XVIII. LPG FUEL SYSTEM PRESSURE
10. Start engine and ensure correct operation in RELIEF.
all throttle ranges. 2. Disconnect the negative battery cable.
11. Check for leaks at connections by using soapy 3. Remove the pin securing the fuel inlet hose,
solution or electron leak detector. If leaks are then remove fitting from the fuel rail.
detected, make proper repairs. 4. Remove Fuel Pressure Sensor electrical con-
nection.
XIV. LOCK-OFF SOLENOID AND CARTRIDGE 5. Remove two bolts securing the Fuel Rail.
6. Carefully pull the rail flush along the Fuel Rail
1. Relieve the LPG fuel system pressure. Refer and away from the Fuel Injectors.
to XVIII. LPG FUEL SYSTEM PRESSURE 7. If rail is to be replaced, remove the Fuel Pres-
RELIEF. sure Sensor. Refer to VII. FUEL PRESSURE
2. Disconnect negative battery cable. SENSOR.
3. Disconnect the electrical connector from the
lock-off solenoid. INSTALLATION PROCEDURE
4. Remove the nut and solenoid from the car-
tridge 1. Install Fuel Pressure Sensor, if removed Refer
5. Remove the cartridge from the LPG Regula- to VII. FUEL PRESSURE SENSOR.
tor. 2. Lubricate Fuel Injector O-rings with petroleum
jelly or Vaseline.
1. Install new cartridge into LPG Regulator. Tigh-

ten cartridge to 16 to 24 N•m (11.8 to 17.7
ft.lbs.).
2. Install solenoid and nut onto cartridge. Tigh-
ten nut to 7.85 N•m (69.5 in.lbs.).
3. Connect electrical connector to solenoid.
4. Connect the negative battery cable.
IMPORTANT:
The fuel cylinder manual valve contains an
245

REMOVAL PROCEDURE

Contamination of the HEGO sensor can re- to XVIII. LPG FUEL SYSTEM PRESSURE
sult from the use of an inappropriate RTV RELIEF.
sealer or silicone spray products. Do not use 2. Disconnect the negative battery cable.
silicone sprays or hoses which are assem- 3. Remove the Fuel Rail. Refer to XV. FUEL
bled using silicone lubricants. Always use RAIL.
“oxygen sensor safe” RTV sealant for repair 4. Remove Injector electrical connector.
procedures. Silicon contamination will cause 5. Remove Clip Retaining Fuel Injector (connect-
a high but false HEGO signal voltage (rich ing it to the Injector Adapter).
remove and visually inspect the sensor ele- The Fuel Injectors are held in place with an
ment. If contaminated, the portion of the internal "C" ring. When removing the fuel in-
sensor exposed to the exhaust stream will jectors, pull the injectors straight out. Do not
have a white powdery coating. Always be pry the injectors with a screwdriver or prybar,
sure to eliminate the cause of contamination as this can damage the injectors or injector
before replacing the sensor. adapters.
3. Carefully place the Fuel Rail over the injec- 6. Remove Injector.
tors, sliding along the Fuel Rail Bracket.
Ensure the Fuel Injectors and O-rings are INSTALLATION PROCEDURE
properly seated.
4. Align holes on Fuel Rail with holes in the 1. Inspect the O-rings on the Injector and Injector
bracket and insert screws. Torque to 7-9 Adapter and replace if necessary. Lubricate
ft.lbs. (9.5-12.2 Nm). with Vaseline or petroleum jelly.
5. Connect Fuel Pressure Sensor electrical con-
nection.
6. Insert fuel inlet port fitting and secure with pin.
tion key to ON and check for leaks at the inlet
and outlet fittings using a commercial grade Contamination of the HEGO sensor can re-
soapy solution or an electronic leak detector. sult from the use of an inappropriate RTV
If leaks are detected make repairs. sealer or silicone spray products. Do not use
8. Start engine and check leaks. If leaks are silicone sprays or hoses which are assem-
detected make repairs. bled using silicone lubricants. Always use
9. Check for MIL illumination. “oxygen sensor safe” RTV sealant for repair
XVI. FUEL INJECTOR a high but false HEGO signal voltage (rich
2. Install the Fuel Injectors into the Fuel Injector
246

Adapters. Push the Injectors into the Adapters take Manifold to prevent dirt or debris from en-
using hand pressure only. tering the engine, possibly causing permanent
3. Install the Clip Retaining Fuel Injector (con- engine damage.
necting it to the Injector Adapter).
4. Ensure all Injectors are properly aligned to INSTALLATION PROCEDURE
mate to the Fuel Rail.
5. Install Fuel Rail. Refer to X. FUEL RAIL 1. Lubricate the O-rings on the Fuel Injector
6. Connect the electrical connector(s) to the fuel Adapter with Vaseline or petroleum jelly and
injector(s). Verify that the connectors place back on the Intake Manifold, ensuring it
click/lock into place. is properly seated.
7. Connect the fuel line to the fuel rail.
and outlet fittings using a commercial grade
soapy solution or an electronic leak detector. Contamination of the HEGO sensor can re-
If leaks are detected make repairs. sult from the use of an inappropriate RTV
9. Start engine and check leaks. If leaks are sealer or silicone spray products. Do not use
detected make repairs. silicone sprays or hoses which are assem-
10. Check for MIL illumination. bled using silicone lubricants. Always use
“oxygen sensor safe” RTV sealant for repair
XVII. FUEL INJECTOR ADAPTERS procedures. Silicon contamination will cause
a high but false HEGO signal voltage (rich
REMOVAL PROCEDURE exhaust indication). The ECM will then re-
2. Install Injector of top of Adapter. Refer to XI.

FUEL INJECTOR.
3. Install Fuel Rail. Refer to X. FUEL RAIL.
and outlet fittings using a commercial grade
soapy solution or an electronic leak detector.
If leaks are detected make repairs.
Fuel Injector Adapter 5. Start engine and check leaks. If leaks are
detected make repairs.
1. Relieve the LPG fuel system pressure. Refer 6. Check for MIL illumination.
RELIEF.
3. Remove the Fuel Rail. Refer to X. FUEL
RAIL.
4. Remove the Injector(s). Refer to XI. FUEL
INJECTOR.
5. Remove the Fuel Injector Adaptor(s) from the
Intake Manifold.
6. Place tape or rag over the opening in the In-
247

XVIII. LPG FUEL SYSTEM PRESSURE RELIEF  Oil leaks
 Oil in the air cleaner
 Sludge in the engine
A leaking PCV orifice or hose may cause the fol-

The LPG fuel system operates at pressure lowing problems:
up to 21.5 bar (312 psi). To minimize per-
sonal injury, relieve the LPG fuel system  Rough Idle
pressure before servicing the LPG fuel sys-  Stalling
tem components.  High idle speed
FUNCTIONAL CHECK
1. Close the LPG fuel tank manual shut-off valve
(MSV). Any blow-by in excess of the system capacity,
2. Start and run the vehicle until the engine stalls from a badly worn engine, sustained heavy load,
from lack of fuel. etc., is exhausted into the air cleaner and is drawn
3. Turn the ignition switch to OFF. back into the engine.
Proper operation of the crankcase ventilation sys-
tem depends on a sealed engine. If irregular oil
flow or dilution is noted and the crankcase ventila-
tion system is functioning properly, check the
Residual vapor pressure will be present in engine for another possible cause. Correct any of
the fuel system. Ensure the work area is these problems first.
well ventilated before disconnecting any
fuel line. If an engine is idling rough, inspect for a clogged
PCV orifice, a dirty vent filter, air cleaner element,
or plugged hose. Replace any faulty items found.
Use the following procedure:
1. Remove the PCV hose from the rocker arm

Never use an open flame of any type to cover.
check for LPG leaks. 2. Operate the engine at idle.
3. Place your thumb over the end of the hose in
order to check for vacuum. If there is no va-
IMPORTANT cuum at the hose end, inspect for plugged
Always inspect the LPG fuel system for leaks after hoses and/or clogged or damaged manifold
performing service. Check for leaks at the fittings vacuum port.
of the serviced or replaced component. Use a 4. Turn the engine OFF.
commercially available liquid leak detector or an 5. Inspect the PCV orifice in the valve cover for
electronic leak detector. When using both me- debris or blockage. Clean with carburetor
thods, use the electronic leak detector first to cleaner as necessary.
avoid contamination by the liquid leak detector
XX. COOLANT HOSE
XIX. CRANKCASE VENTILATION SYSTEM
INSPECTION/DIAGNOSIS REMOVAL PROCEDURE
RESULTS OF INCORRECT PCV OPERATION 1. Stop engine.
2. Drain coolant.
A plugged positive crankcase ventilation (PCV)
orifice or hose may cause the following conditions:
 Rough or unstable idle

 Stalling or low idle speed
248

IMPORTANT
Hoses are designed for specific applications. DO
NOT use Hose material or length other than spe-
cified by the OEM. DO NOT mix the inlet or outlet
The coolant may be hot. Use caution when ends of the Hose when reinstalling.
removing hose(s) to prevent contact.
3. Remove clamps from each end of the Hose
and remove Hose. 1. Slide Hose Clamps over each end of the Fuel
Hose.
INSTALLATION PROCEDURE 2. Insert Port Fittings into each end of the Hose.
3. Slide each Hose Clamp to a position approx-
IMPORTANT imately ½” from the end of the Hose and
Coolant hoses are specifically designed for their tighten.
application. DO NOT use hose material or length 4. Lightly lubricate new O-ring with Vaseline or
other than the OEM specified parts. DO NOT mix petroleum jelly prior to installation.
the inlet or outlet ends of the Hose when reinstal-
ling.
1. Slide Clamps over each end of the Hose.

2. Insert Port Fittings into each end of the Hose. Contamination of the HEGO sensor can re-
3. Slide Hose Clamp to a position approximately sult from the use of an inappropriate RTV
½” from the end of the Hose and tighten. sealer or silicone spray products. Do not use
4. Refill with coolant. silicone sprays or hoses which are assem-
5. Start engine and let run until it reaches operat- bled using silicone lubricants. Always use
ing temperature. “oxygen sensor safe” RTV sealant for repair
6. Check for leaks. If leaks are detected, make procedures. Silicon contamination will cause
repairs. a high but false HEGO signal voltage (rich
7. Stop engine and allow to cool. Check coolant exhaust indication). The ECM will then re-
level and add coolant as necessary. duce the amount of fuel delivery to the
XXI. FUEL VAPOR HOSE lem. If silicone contamination is suspected,
REMOVAL PROCEDURE ment. If contaminated, the portion of the
1. Relieve the LPG fuel system pressure. Refer have a white powdery coating. Always be
to XVIII. LPG FUEL SYSTEM PRESSURE sure to eliminate the cause of contamination
RELIEF. before replacing the sensor.
2. Disconnect negative battery cable.
3. Remove Retaining Clips securing Port Fittings 5. Reinstall Hose at both ends and secure using
on both ends and remove with Hose attached. Retaining Pins.
4. Remove Hose Clamps. 6. Reconnect negative battery cable.
5. Remove Port Fittings from Hose. 7. Open LPG tank valve.
8. Turn Key to the ON position for several
seconds, then turn back to OFF. Check for
leaks at the inlet and outlet fittings using a
soapy solution or an electronic leak detector.
Residual vapor pressure will be present in If leaks are detected, make repairs.
the fuel system. Ensure the work area is 9. Start engine and check for leaks.
well ventilated before disconnecting any 10. If a DTC code is found, refer to the Electrical
fuel line. Section for further diagnosis.
249

XXII. FUEL VAPOR PORT FITTING IMPORTANT:
REMOVAL Excess Flow Check Valve. Open the manual
1. Relieve the LPG fuel system pressure. Refer Check Valve.
RELIEF. 8. Turn Key to the ON position for several
2. Disconnect negative battery cable. seconds, then turn back to OFF. Using a liq-
3. Remove retaining clip securing the Port Fitting uid or electronic leak detection tool, inspect
in the port and remove. the REGULATOR, fuel hoses and all serviced
4. Loosen Hose Clamp securing the Port Fitting fittings for leaks.
in the Hose and pull Port Fitting from hose. 9. Start engine and check for leaks.
INSTALLATION XXIII. REGULATOR PRESSURE CHECK
IMPORTANT 1. Refer to XXIV. LPG FUEL RAIL PRESSURE

Port Fittings are designed for specific applications, CHECK to check the Regulator outlet pres-
DO NOT any other adapter or fitting other than the sure.
part specified by the OEM.
XXIV. LPG FUEL RAIL PRESSURE CHECK
1. Slide Hose Clamp over the Hose.
2. Insert Port Fitting into hose. 1. Relieve the LPG fuel system pressure. Refer
3. Slide Hose Clamp over the end of the Hose to XVIII. LPG FUEL SYSTEM PRESSURE
and tighten. RELIEF.
4. Lightly lubricate O-rings on the Port Fitting 2. Disconnect the negative battery cable.
with Vaseline or petroleum jelly. 3. Remove the Fuel Pressure Sensor. Refer to
VII. FUEL TEMPERATURE/PRESSURE
SENSOR.
Contamination of the HEGO sensor can re-

sult from the use of an inappropriate RTV
sealer or silicone spray products. Do not use Residual vapor pressure will be present in
silicone sprays or hoses which are assem- the fuel system. Ensure the work area is
bled using silicone lubricants. Always use well ventilated before disconnecting any
“oxygen sensor safe” RTV sealant for repair fuel line.
a high but false HEGO signal voltage (rich 4. Connect the test fitting, Hose and Gauge.
exhaust indication). The ECM will then re- 5. Open LPG Tank Valve.
duce the amount of fuel delivery to the 6. Connect negative battery cable.
engine, causing a severe driveability prob- 7. Turn ignition to ON and note value on gauge.
lem. If silicone contamination is suspected, 8. Relieve the LPG fuel system pressure. Refer
remove and visually inspect the sensor ele- to XVIII. LPG FUEL SYSTEM PRESSURE
ment. If contaminated, the portion of the RELIEF.
sensor exposed to the exhaust stream will 9. Remove Gauge. Install Fuel Temperature
have a white powdery coating. Always be Sensor. Refer to VII. FUEL
sure to eliminate the cause of contamination TEMPERATURE/PRESSURE SENSOR.
5. Reinstall Hose Port into port and secure using

a Retaining Pin.
7. Open LPG tank valve.
250

The HEGO is sensitive to silicone based
products and can become contaminated.
Avoid using silicone sealers/lubricants on
any fuel or exhaust related components.

11. Turn key to ON.
12. Check for leaks. If leaks are detected, make
repairs.
XXV. LPG FUEL SYSTEM LEAK TEST
1. Use a commercially available liquid leak detec-

tor or an electronic leak detector and follow the
manufacturer’s instructions.
IMPORTANT
When using both methods, use the electronic leak
detector first to avoid contamination by the liquid 1. Back Pressure Gauge
leak detector. 2. Heated Exhaust Gas Oxygen Sensor
(HEGO 1--Sensor between the engine and
XXVI. RESTRICTED EXHAUST SYSTEM catalytic converter).
DIAGNOSIS 3. Exhaust Pipe/Muffler
PROCEDURE: Exhaust Back Pressure Test
1. Stop Engine. Carefully remove the HEGO. XXVII. CATALYTIC CONVERTER

2. Install Exhaust Back Pressure Test Gauge
(J35314-A) in place of the HEGO. REMOVAL PROCEDURE
3. With the engine idling at normal operating
temperature, observe the exhaust system 1. Remove the Catalytic Converter using the
back pressure reading on the gauge. Reading OEM end product processes
should not exceed 8.6 kPa (1.25 psi).
4. Increase engine speed to 2000 RPM and ob- INSTALLATION PROCEDURE
serve gauge. Reading should not exceed
20.7 kPa (3 psi). IMPORTANT
5. If the back pressure at either speed exceeds The Catalytic Converter is specifically designed to
specification, a restricted exhaust system is meet the emission control of the certified engine.
indicated. Use only the OEM specified part. Install the Cata-
6. Inspect the entire exhaust system for a col- lytic Converter using the OEM end product
lapsed pipe, heat distress or possible internal processes.
catalytic converter failure.
7. If there are no obvious reasons for the exces- 1. Start engine
sive back pressure, the catalytic converter is 2. Check for any DTC codes and clear
likely damaged and should be replaced. 3. Verify engine is in closed loop and no MIL
8. Check for MIL. If a DTC code is found, refer lights are present.
to the Electrical Section for further diagnosis. 4. If a DTC code is found, refer to the Electrical
251

XXVIII. VACUUM LINE 3. Install new Rotor Cap and secure with new
Screws. Torque to 21 in.lbs. (2.4 Nm)
REMOVAL PROCEDURE 4. Connect the sensor harness connector.
5. Connect Spark Plug wires to the Distributor
1. Remove the Vacuum Line from each fitting. Cap, ensuring the wires are connected to the
correct cylinder. NOTE that the firing order is
INSTALLATION PROCEDURE 1-3-4-2. Refer to the IGNITION SYSTEM
SPECIFICATIONS in the Appendix for addi-
IMPORTANT tional information.
DO NOT use a hose other than the OEM specified 6. Start engine. If a DTC code is found, refer to
part. the Electrical Section for further diagnosis.
1. Reinstall the Fuel Vapor Hose to each fitting. XXXI. FUEL FILTER REPLACEMENT
2. Start engine and check for leaks using a soa-
py solution or an electronic leak detector. If NOTE: The following instructions only include the
leaks are detected make repairs. low pressure LPG Vapor Fuel Filter and not the
high pressure liquid LPG fuel filter on the regula-
XXIX. LPG FUEL CONTROL SYSTEM CHECK
tor. Refer to XIII. FUEL FILTER ELEMENT (HIGH
1. The fuel system can be thoroughly diagnosed PRESSURE) for the high pressure filter on the
by use of the DST tool. See section Regulator.
DIAGNOSTIC SCAN TOOL.
XXX. CAMSHAFT POSITION SENSOR

REMOVAL PROCEDURE
1. Disconnect negative battery cable.

2. Label Spark Plug Wires with matching Distribu-
tor Cap numbers and remove by pulling and
twisting each spark plug wire boot ½ turn.
3. Remove Ignition Coil wire. Low Pressure LPG Vapor Fuel Filter
base of the Distributor. 1. Move the equipment to a well ventilated area
5. Remove the two Screws that hold the Distribu- and verify that sparks, ignition and any heat
tor Cap to the housing and remove Cap. sources are not present.
6. Remove the Rotor Screws. 2. Relieve the LPG fuel system pressure. Refer
7. Turn the engine crankshaft to align the square to XVIII. LPG FUEL SYSTEM PRESSURE
slot in the reluctor wheel with the Cam Sensor. RELIEF.
8. Remove the two screws securing the CMP 3. Disconnect negative battery cable.
Sensor
9. Remove the Camshaft Sensor from the Dis-
tributor.
IMPORTANT A small amount of fuel may still be present in

Do no not reuse the old Distributor Cap, Rotor or the fuel line. Use gloves and proper eye pro-
Cam Sensor Screws. tection to prevent burns. Make sure the
manual valve is fully closed.
1. Mount Camshaft Sensor on Distributor and
secure with new Screws. Torque to 19 in.lbs.
(2.2 Nm) 4. Remove the clamps securing the fuel hoses to
2. Install the Rotor on the reluctor wheel and se- the fuel filter.
cure with new Rotor Screws. Torque to 18 5. Remove the hoses connected to the fuel filter.
in.lbs. (2.0 Nm). 6. Loosen the Cushioned Clamp securing the
252

Fuel Filter and slide out.
7. Discard Fuel Filter.
1. Slide the Fuel Filter inside the cushioned

clamp and tighten.
2. Place clamps over hoses.
3. Connect hoses to the Fuel Filter.
4. Tighten hose clamps on Fuel Filter.
5. Retighten clamp securing Fuel Filter.
6. Connect negative battery cable.
7. Open LPG fuel valve on tank.
IMPORTANT:
Check Valve.
8. Turn Key to ON. Check for leaks at the inlet

and outlet fittings, and the filter housing end
connection using a soapy solution or an elec-
tronic leak detector. If leaks are detected
make repairs.
9. Start engine and check for leaks once more.
XXXIV. PCV
REMOVAL
1. Remove Hose Clamp on Hose connected to

PCV and remove Hose.
2. While gently rocking back and forth, pull PCV
from its mounting gasket and remove.
253

254

LPG Parts Diagram
255

THROTTLE BODY ASSEMBLY
256

MIXER AND THROTTLE BODY ASSEMBLY
IMPCO
Item # Description Qty
Part Number
1 Screw, Hex Sck Cap 4 S1-30295-0655
2 Washers, Conical Spring 6mm 4 W1-31039-006
3 Throttle Body 1 A7-324
4 Gasket, Throttle Body 2 A7-245
5 Bracket, Fuel Rail Mount 1 B4-51980-001
257

FUEL RAIL & INJECTORS
258

FUEL RAIL & INJECTORS
IMPCO
Part Number
1 Sensor, Fuel Rail Pressure 1 A7-473
2 Screw, Hex Flange M6-1.0 x 35 mm 2 P1-30559
3 Fuel Rail, 3.0L 1 R8-51549-001
4 Pin, Retaining 1 P1-30559
5 O-Ring, Inlet 4 A7-657
6 Spacer, O-ring 4 A7-656
7 Injector, LPG/CNG 4 A7-654
8 O-ring, Adapter 4 A7-655
9 Adapter, Fuel Injector 4 A4-51981-001
10 O-ring, FKM-75 .362 ID 4 GMN-033
259

REGULATOR ASSEMBLY
260

REGULATOR ASSEMBLY
IMPCO
Part Number
1 Regulator Assy (Fully Assembled with all parts) 1 A7-434
Filter Kit (Includes 2, 6, 7, 8, 9) 1 A7-170
Outlet Fitting Service Kit (Includes 3 & 4) 1 A7-172
5 Screw Kit (Includes 3 screws) 1 A7-176
Inlet Fitting w/O-Ring (Includes 10 & 11) 1 A7-171
12 Drain Plug & O-ring Kit (Includes 12 & O-ring) 1 A7-173
13 Lock-Off Assembly 1 A7-175
261

HOSE ASSEMBLIES COOLANT/VACUUM/FUEL
262

HOSE ASSEMBLIES COOLANT/VACUUM/FUEL
Item IMPCO
Description Qty
# Part Number
1 Fitting, Port 1 AF4-50733-001
2 Clamp, Oetiker 2 C1-51552-07-170
3 Hose, Vacuum 1 H1-19231-001
4 Hose 3/8” ID Fuel/Oil 1 H1-19231-004
5 Hose, 5/8” Fuel/Oil 1 H1-19231-006
6 Clamp, Ear Oetiker 2 C2-51552-05-113
7 Pin, Retaining 1 P1-30559
8 Clamp, Worm Drive 4 0130845
9 Clamp, Oetiker 4 C1-51552-07-256
10 Hose, 5/8” ID Fuel/Oil 1 H1-19231-006
11 Bracket, Vapor Filter 1 A10-167
12 Filter, LPG Vapor 1 A8-367
13 Hose, Formed Gate 1
H1-50599-001
14 Hose, Formed Gate 1
15 Clamp, Worm Drive 1 A10-169
16 Bolt, M8 x 1.25 x 25 2 1510113
17 Nut, Hex 2 97330010
263

THERMOSTAT & HOUSING
264

THERMOSTAT & HOUSING
Item # Description Qty Part Number GM Part Number

1 Bolt 2 90328100 09424320
2 Thermostat Housing 1 7142071 14096853
3 Gasket, Thermostat Housing 1 7140310 10105135
4 Thermostat 1 7140340 10220957
265

ENGINE CONTROL MODULE
266

ENGINE CONTROL MODULE
Item
Description Qty IMPCO Part Number
#
1 ECM, Liugong 1 A11-173
267

SENSORS
1 2
6 7
268

SENSORS
Qty. IMPCO GM Part

Item # Description
Used Part Number Number
1 HEGO 1 S8-50328-001
2 Crank Sensor 1 S8-51822-001 12567712
3 Sensor, TMAP 1 E1466001
4 Oil Pressure Switch 1 S10-50352-001
5 Adapter, Oil Pressure Switch 1 7242360
6 Coolant Temp Switch 1 7144790
7 Adapter, Coolant Switch 1 7176570-06
269

DISTRIBUTOR
270

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

FUSE BOX & BRACKET
272

FUSE BOX & BRACKET

1 Screw, Hex M4 x 16mm 4 S1-30295-0416
2 Washer, Split Lock M4 4 W1-1988-003
3 Fuse Box Cover 1 C1-52520-001
4 Bracket, ECM 1 B4-51789-001
5 Screw, Hex Flange 2 90325088
6 Seal, Fuse Box 1 S3-52522-001
273

IGNITION COIL
274

IGNITION COIL

1 Coil, Ignition 1 7245530
275

MANIFOLDS
276

MANIFOLDS

1 Gasket, Int/Ext 1 7152170
2 Manifold, Exhaust GM 3.0L 1 7152150
3 Stud, 3/8-16 x 2” 2 S3-50596-001
4 Bolt, Socket Head 3/8 x 16 Grade 8 4 90368100
5 Washer, Belleville 3/8” 8 W1-50595-037
6 Screw, Hex Flange M5-0.8 8x8 4 S1-50237-20-0508
7 Nut, Serrated 2 N1-30876-037
8 Washer, 3/8 Type A Hard 4 92300101
9 Screw, Hex Flange M6 x 12mm 8 S1-30871-02-0612
10 Screw, Hex Flange M6-1.0x x 16mm 3 S1-30871-02-0616
11 Screw Hex Flange M6-1.0 x 12mm 5 S1-50237-02-0620
12 Shield, Heat-GM 3.0L 2 Piece 1 7152160
13 Heat Shield, RB Exhaust 1 G4-50067-001
14 Heat Shield, Alternator 3.0L 1 G4-50068-001
15 TMAP Sensor 1 E1466001
16 Fitting, 1/8 NPT 3/8 Hose Brass 1 2H-103B
17 Fitting, 1/8 NPT .19 ID Hose 1 F4-4
18 Bracket, Maxifuse Mount 1 B4-51889-001
19 Gasket, Exhaust Flange 1 7152175
20 Strap, Cnvlt Cdt 13mm 2 S17-51979-001
21 Sensor, O2 1 S8-50328-001
277

WIRE HARNESS/FUSES/FUSE BOX COVER
Fuse Box Layout
278

WIRE HARNESS/FUSES/FUSE BOX COVER
Manufacturer Part
Item # Description Qty Part Number
Number
1 Cover 1 Littelfuse 1520007Z
2 Fuse 70A 1 1054112 Littelfuse 299070
3 Fuse Holder 1 Littelfuse 1520004Z
4 Wire Harness, 4 Cyl 1 AW-50727-001
Auxiliary 10A Minifuse 1 914584 Littelfuse 297010
Power Fuse 20A Minifuse 1 7381270 Littelfuse 297020
Starter Fuse 20A Minifuse 1 7381270 Littelfuse 297020
VSW 10A Minifuse 1 914584 Littelfuse 297010
Starter Relay Starter Relay 1 885014 3011CCR1U0112VDC
Power Relay Power Relay 1 885014 3011CCR1U0112VDC
Shut Off
Lock Off 1 885014 3011CCR1U0112VDC
Valve Relay
279

PCV VENT & VALVE
280

PCV VENT & VALVE
GM Part
Item # Description Qty Part Number Number
1 Vent, Elbow 1 F4-51936-001 06487779
2 Grommet oil filter cap 1 G3-51937-001 14050440
3 PCV 1 V3-51806-001 06487779
4 Grommet, PCV Valve 1 7120140 14001875
281

MISCELLANEOUS ENGINE
282

MISCELLANEOUS ENGINE

1 Engine, MY 2011-2010GM 3.0L 1 7044670
2 Sensor, Crank 1 S8-51822-001
3 Plug, 3/8” NPT Socket Head Brass 1 P3-12
4 Fitting, Pipe Thread Reducer 1 7176570-06
5 Oil Filter PF454 1 7110851
6 Plug ½-14 NPT 1 7242360
7 Switch, Oil Pressure 1 S10-50352-001
8 Spark Plug, R44LTS 4 E10-50075
9 Plug, 14mm Fuel Rail Port 4 P3-50597-001
10 Fitting, 1/2NPT 5/8 NIP Brass 1 F4-17920
11 Strap, Lifting Eye 1 7010130
12 Screw, Hex Flange 3/8-16 x 1 1 90325100
283

ALTERNATOR
284

ALTERNATOR

1 3/8”-16x1-1/2” Bolt Hx GR5 2 90305150
2 Washer, Lock 3/8” 15 93300000
3 Washer, Flat 3/8” 5 92300000
4 3/8-16x1 ¼” bolt Hx Gr5 2 90305125
5 5/16-18x1” Bolt Sched Grd 8 4 90268100
6 Sapcer, Fan Mount 3.0L 1 7143890
7 5/16-18x1 ¼” Bit Hx Gr5 1 90205125
8 Washer, Lock, M8 1 93200000
9 Bracket, Alternator 1 7144570
10 Alternator, 7SI 1 7244700
11 Nut, Hex Flange Serrated M5 x 1.0 2 N1-30876-M06
12 Nut, 3/8”-16 Grade 5 1 95300000
13 Spacer, Alternator Brkt 1 7244570
14 Bracket, Alt Lower 1 7244560
15 Bolt, Hex 3/8-16 x 4” Grade 5 1 90305400
16 Bolt, M8-1.25 Hx Head Grd 10.9 1 98333025
17 Washer, Lock, Med, M8, Zn 1 93930000
18 Washer, Flat Heavy 5/6” 1 92200020
19 Pulley, Water Pump 1 7144040
20 Pulley, Crankshaf 1 7071620
21 3/8-24x2” bolt Hx Gr5 1 90315200
22 5/16”-18 x ¾” Grade 5 8 90215075
23 3/8-16x3-1/2 Blt Sched Gr5 1 7144160
24 ASM Fan Hub 3.0L 1 7144220
25 Pulley Twin Belt 1 7144130
26 Ring Retaining OD 0.669 1 7144030
27 Pully ASM P/B Boos Pump Idler 1 7030110
28 Bracket Tensioner 1 7144000
29 Pulley, Water Pump-Mod 1 7144040
30 Bracket Fan Tensioner MTG 1 7143881
285

STARTER
286

STARTER

1 Bolt 2 7242530
2 Nut Hex M5 x 0.8 Brass 1 97111000
3 Washer, Lock Bronze 1 93003000
4 Nut, Hex M8 x 1.25 Brass 1 97331000
5 Washer, lock med M8 Zn 1 93930000
6 Starter Motor 1 7244520
7 Bracket, Starter 2kW 3.0L 1 B4-52110-001
8 Nut Hex #10-24 1 95000000
9 Washer, Lock #10 Med 1 93000000
10 Washer Flat #10 1 92000000
11 5/16-18 ¾” Bolt Hex Gr5 1 9205075
12 Washer, Loc, Med 5/16 1 93200000
13 Washer, flat, SAE, 5/16” 1 92200000
287

TOOL KIT & ACCESSORIES
1 2 3 4 5
6 7 8 9 10
11 12 13 14
Standard Oetiker Pliers, IMPCO P/N 14100037 and Injector Test Lamp OTC-6023 (not included in any IMPCO ITK kit)
288

TOOL KIT, IMPCO P/N ITK-4
Item Qty.
Description IMPCO Part Number
# Used
1 Test Kit Gauge 0-5 PSI (2-5205) 1 TG-005
2 Test Kit-Gage 0-10" WC (2-5010) 1 TG-010
3 Hose, 3/16" Id Vacuum, Bulk 1.5’ H1-11
4 Harness, Adapter Gen 2 DLC to Gen 1 DLC 1 E1557400
Fitting Assembly, Test Cap (System II LPR
5 1 AF4-31105
Secondary Pressure Test Adapter)
6 Fitting, 1/8 NPT 3/16Hs Nip Brass 2 F4-4
7 Assembly, Fitting Test Cap 3/4 1 AF4-50254-002
8 Pin, Retainer 10 P1-30559
9 Case, Metal, 14.25 x 9 x 4.25 1 C9-50724-001
10 Fitting, 1/8 NPT 1/4Hs El Nylon 2 F4-8
11 Tool, 20IPR Torx-Plus Bit 1 T7-50172
12 Fitting, ¼ UNF, ¼ HS Vac Nip 1 F4-2
13 Gauge, Test Fuel System 1 TG-31119-001
14 ASM, CAN Dongle (ECOM Cable) 1 E2046002
289

The follow parts manual includes GM Service parts and their GM part numbers for the 3.0L 2011
engine. The IMPCO part number for the complete service block is:
3.0L (GM Engine Code BL3)
7044670
290
291
3.0L UPPER
292
3.0L UPPER
1 Cap, Oil 1 93802366

2 Bolt, Vlv 5 09439930
3 Reinforcement, Vlv Rkr Arm Cvr 5 03877670
4 Cover, Vlv Rkr Arm 1 02770089
5 Gasket, Vlv Rkr Arm Cvr 1 14096154
6 Rotator, Vlv 4 14042575
7 Key, Vlv Stem 16 24503856
8 Nut, Vlv Rkr Arm 8 12557390
9 Ball, Vlv Rkr Arm 8 93427660
10 Arm Kit, Vlv Rkr w/Ball 8 05723551
11 Rod, Vlv Push 8 93414888
12 Shield, Vlv Stem Oil 12 10007818
13 Stud, Vlv 8 03814692
14 Cap, Vlv Sprg 8 10038209
15 Seal, Vlv Stem Oil 8 10214034
16 Spring, Vlv 8 94666172
17 Bolt, Cyl Hd 10 10166832
18 Plug, Cyl Hd Core Hole 2 03826506
19 Gasket, Eng Cool Therm Hsg 1 10140501
20 Housing, Eng Cool Therm 1 93442430
21 Bolt, Eng Cool Therm Hsg 3 09424320
22 Lifter, Vlv 8 05232720
Head, Cyl Cmpl w/Valves, Springs, Re-
23 1 93442423
tainers & Seals
24 Insert, Vlv Push Rod 8 NSS
25 Plug, Inj Hole 4 P3-50597-001*
26 Valve, Int 4 14075641
27 Valve, Exh 4 94665131
28 Gasket, Cyl HD 1 14096660
AR=As Required; NSS=Not Sold Separately; NA=Not Available
*IMPCO Part Number
293
3.0L LOWER
294
3.0L LOWER
Part Num-
ber
Ring Kit (STD) 88894219
1 Ring Kit (0.020” O.S.) 4 12361570
Ring Kit (0.030” O.S.) 14089026
Piston (w/Pin)(STD) 93442974
2 4
Piston (w/Pin)(0.020” O.S.) 93419821
3 Rod Connecting (Includes 4 & 6) 4 10108688
4 Bolt, Connecting Rod (Part of 3) 8 00461372
Bearing Kit, Connecting Rod (STD) 12493123
5 4
Bearing Kit, Connecting Rod (O.S. 0.001”) 12493124
6 Nut, Conn Rod (Part of 3) 1 00326312
7 Bearing, Oil Pmp Drive 8 03866766
8 Gasket W/Pmp 1 10101256
9 Pump, Water 1 88894247
10 Bolt, W/Pmp 1 09442184
11 Hub, Fan W/Pmp (Part of 9) 1 NSS
12 Washer, 6.3mm ID 3 11503663
13 Bolt, Cm/Shaft 3 09442895
14 Bolt, W/Pmp 5/16” 2 09440366
15 Key, Cm/Shft 2 00106751
16 Bolt, CM/Shaft 2 09442008
17 Washer, CM/Shf 1 10101744
18 Gear, CM/Shf 1 02771369
19 Plate Kit, CM/Shf 1 12508079
20 Ring, CM/Shf 1 00549631
21 Bearing, CM/Shf 4 14002525
22 Camshaft, Eng 1 02770015
23 Valve, Oil Filter 1 25013759
24 Pin, Cyl HD 8 00585927
25 Fitting, Oil Fltr 1 03853870
Bearing Kit, Cr/Shf (#1,2,3,4)(0.001” U.S.) 12329955
Bearing Kit, Cr/Shf (#1,2,3,4)(STD) 12329954
26 4
Bearing Kit, Cr/Shf (#5)(0.001” U.S.) 10048778
Bearing Kit, Cr/Shf (#5)(STD) 12329774
27 Key, Woodruff #9 1 00106751
28 Seal, Cr/Shft Frt Oil 1 12577710
29 Gear, Cr/Shf 1 02768986
30 Gasket, Front Engine Cvr 1 14096156
31 Cover, Eng Frt 1 03992251
32 Balancer, Cr/Shf 1 03826280
295
33 Seal, Absorber, Cr/Shf 1 NSS

34 Washer, External Tooth 1 00136857
35 Bolt, Cr/Shf Balancer 1 10126796
36 Nut, Oil Pan 10 12338130
37 Washer 10 09439510
38 Bolt, Oil Pan (1/4-20 x 1/2, 1/8 THD) 10 09442895
39 Plug, Oil Pan Drn 1 See IMPCO Catalog
40 Gasket, Oil Pan Drn Plug 1 See IMPCO Catalog
41 Pan, Oil 1 93419740
42 Bolt, Oil Pan (1/4-20 x 1/2, 1/8 THD) 14 09440033
43 Screw, RD HD Slotted 4 00133043
44 Washer 4 09439510
45 Cover, O/Pmp 1 03792507
46 Gasket O/Pmp Cover 1 03789970
47 Spring, Oil Pressure Rlf Vlv 1 03814903
48 Plug, Oil Press Rlf Vlv 1 03930824
49 Valve, Oil Pressure Rlf 1 03829433
50 Bolt, O/Pmp 3 09424877
51 Reinforcement, Eng Frt Cvr (Incl w/31) 1 NSS
52 Gasket, Oil Pan 1 14096637
53 Bolt, Eng Frt Cvr 12 09442895
54 Pump, Oil 1 14091485
55 Nozzle, Cm/Shf Gr Lub 1 03875950
56 Bracket, O/Pmp 1 03970417
57 Crankshaft 1 93442002
58 Bolt, Hex 1/4-20 x 3/4 1 09425113
59 Washer, Flat 1 11609328
60 Nut, O/Pmp 1 09442946
61 Pin, Oil Press Flf Vlv 1 12551790
62 Screen, O/Pmp (Part of 54) 1 02778192
63 Bolt, Cr/Shf Brg Cap 8 03872781
64 Cap, Cr/Shf Brg 4 03970194
65 Pin, Cr/Shf RR Oil Seal 1 09441003
66 Housing, Cr/Shf RR Oil Seal (Incl 71 & 72) 1 14088556
67 Bolt, Cr/Shf Oil Seal 2 14096659
68 Bolt, Cr/Shf RR Oil Seal Hsg 2 14096658
69 Gasket, Cr/Shf RR Oil Seal Hsg 1 12555771
70 Stud, Cr/Shf Brg Cap 1 03852870
71 Stud, Cr/Shf RR Oil Seal (Part of 66) 2 14080362
72 Seal, Cr/Shf (Part of 66) 1 10088158
296
73 Gear, Flywhl Ring (Part of 78) 1 03991408

74 Washer, Flywhl 1 00136857
75 Bolt, Flywhl (7/16”-20 x 31/32) 6 00839756
76 Bolt, Vlv Push Rod Cvr 4 03814350
77 Bearing, Clu Pilot 1 14061685
78 Flywheel, Eng (Includes 73) 1 93419731
79 Cover 1 93423830
80 Pin, Trans Loc (5/8 x 1 3/16) 2 01453658
81 Gasket, Vlv Push Rod Cvr 1 12378521
82 Plug, Eng Blk Oil Gal 1 14090911
83 Engine Block 1 NSS
84 Plug, CM/Shf 1 110241154
85 Plug, Eng Blk Core Hole AR 03826505
86 Plug, Oil 1 NSS
87 Plug, Eng Blk Oil 1 03835577
88 Tube, Oil Lvl 1 93434708
89 Indicator, Oil Lvl 1 14025224
90 Sealer, Vlv Push Rod Cvr AR 12346286
91 Stud, Vlv Push Rod Cvr 4 00352169
92 Nut, Vlv Push Rod Cvr 4 00451399
93 Washer, Vlv Push Rod Cvr 4 02436163
94 Ring, Cr/Shf Psn Sen Reluctor 1 NSS
95 Seal, Cr/Shf Psn Sen Conn 1 NSS
96 Sensor, Cr/Shf Posn 1 12567712
97 Bolt, Cr/Shf Posn Sen 1 11588712
98 Gasket, F/Pmp 1 93802517
99 Cover, F/Pmp OPG 1 93439184
100 Washer, F/Pmp MT 2 02436162
101 Bolt, F/Pmp 2 09424877
102 Plug, Eng Blk Core Hole 2 88891749
297
298
Labor Time Guide
299
INTRODUCTION TIME ALLOWANCES
This Guide provides the labor times for repairs The labor times include the removal, disassem-
and service operations covered under warranty bly, cleaning, re-assembly, installation and/or
for IMPCO Technologies Engine Systems Divi- adjustment of the affected component or assem-
sion fuel systems. It applies to 2008 model year bly. Any cleaning time is limited to the
3.0L GM Emission Certified Engines installation or replacement of components (such
as mating surfaces) and does not include clean-
The warranty reimbursement for the labor opera- ing other areas of the vehicle contaminated by
tions can be calculated when used in conjunction failure of the component (e.g. coolant sprayed
with the IMPCO Policy & Procedures Manual. inside the engine compartment). Labor opera-
tions that require more than one technician are
The labor times published in this Guide identify adjusted to represent the total time for all techni-
labor operations and labor times required to per- cians.
form a repair, replacement and/or adjustment
operation. These times represent those of an av- GLOSSARY OF TERMS
erage technician in a typical dealership using
standard hand tools, equipment and some Spe- OPERATION DESCRIPTION
cial Service Tools. They are not intended to be
used as retail labor rates. The Operation Description identifies the repair to
be performed and may include sub-headings
LABOR TIME STUDY DEVELOPMENT such as: ADD conditions, NOTES, INCLUDES
and other information. This information is essen-
GENERAL tial for both the technician and warranty claim
processing personnel to properly complete a
The labor times published in this Guide were de- warranty claim for accurate cost recovery.
veloped by IMPCO using genuine IMPCO parts
and procedures listed in the IMPCO Service Ma- FAILED PART / CAUSAL PART
nual. They include the actual time required to
perform the operation and diagnose the system The Failed or Causal Part is the part that caused
or component failure. All operations also include the repair and/or replacement of other parts. The
a standard allowance for “access time” to locate technician must identify the part as defective
the vehicle, move it to a safe and suitable work (i.e., one that exhibits a flaw or manufacturer’s
area, access the engine, use of Special Service defect in material or workmanship). The Causal
Tools and time to open packaged parts. The Part must be tagged for warranty failure analy-
times also provide for operation variables but do sis identification prior to returning it to IMPCO
not include time to remove and/or replace non- Technologies.
IMPCO components and accessories.
TROUBLE CODES / CONDITION CODING
TOOLS
Each failed or causal part must be coded to iden-
The labor time studies were based on the use of tify the manufacturer’s defect of the part as
standard hand tools and Special Service Tools. accurately as possible (see Trouble Code chart).
No power-operated tools were used. The labor The code selected by the repairing technician
times were developed by general technicians fol- identifies the manufacturer’s defect and/or work-
lowing procedures described in the Service manship condition qualifying the repair for
Manual Supplement, Service Publications and warranty coverage.
good shop practices. The times were calculated
using an engine mounted on a stand. ADD CONDITIONS
Add Conditions may be required to complete or
supplement a labor operation and are included in
the Add sections under the Labor Operation De-
scription. If an ADD is performed, the allowed
300
labor time for the ADD must be recorded on the complete when the cause of failure has been
shop repair order under the Operation Number. identified.
REPLACE REPAIR DIAGNOSIS

Replace is used when the part or assembly is These are the checks, tests and measurements
subject to replacement only. This includes the required to identify the cause of a failure and/or
transfer of attached components from the original failed part. Examples include:
part to the new part, the installation of the new
part and any inspection, adjustment, or required  Cleaning and inspection of all parts.
cleaning or lubrication operations.  Use of test equipment.
 Use of common instruments such as an
R&R OR REPLACE ohmmeter, volt-amp meter, a leak detector or
a cooling system pressure tester that may be
R&R refers to a part or assembly that is removed required by IMPCO Service Manual Supple-
and re-installed after the part has been aligned, ment procedures.
adjusted, repaired as a separate operation or
removed for a sublet repair. Replace means the Repair Diagnosis is the responsibility of the tech-
part or assembly can be replaced with a new (or nician.
exchanged) part or assembly (see the Replace
paragraph above). LABOR OPERATION NUMBER
INCLUDES A Labor Operation Number is assigned to the
labor performed and must be recorded on the
The INCLUDES which follow some of the Labor warranty claim. The Labor Operation Number
Descriptions are provided to assist in determining can be found in this Guide or IMPCO Technical
whether or not certain items or functions are in- Service Bulletins.
cluded within the operation (these are not all
encompassing to simplify the use of this Guide). OVERLAPPING LABOR
Examples include:
Overlapping labor is labor time is where two op-
 Fuel System Evacuation erations include the same repair steps.
 Leak Check Overlapping time is not compensated; therefore,
 Cooling system drain and refill the repeated labor time must be deducted from
the second labor operation so that the total time
Refer to the IMPCO Service Manual Supplement
entered is less than the sum of the combined la-
or use the Request for Review Form to question
bor times.
and/or recommend changes.
CUSTOMER PROBLEM ANALYSIS DUPLICATE LABOR
It is the duty of the service technician to translate Duplicate Labor is the same labor charged twice,
the customer's complaint into a specific symp- either to two different cost recovery sources, or
tom. Examples include: stalling, hesitation, overlapping labor charged to the same or differ-
surges, engine cranks but will not start, etc. ent cost recovery sources. Duplicate Labor is
Symptoms also include readily apparent failures not eligible for compensation unless authorized
to the senses of sight, touch, sound and smell, by IMPCO.
such as leaking coolant line or cracked casting.
STRAIGHT TIME
SYMPTOM DIAGNOSIS
Straight Time is applicable only when a labor op-
Symptom Diagnosis is the process used to de- eration is required and no labor operation
termine the source of the problem and is the description or operation number exists in this
responsibility of both the technician and dealer- Guide. All Straight Time is governed by Policy
ship management. Symptom Diagnosis is “A” and is subject to review and approval by
IMPCO before payment is reimbursed. Precise
301
labor step documentation indexed to time is re- time that is necessary to complete a satisfactory
quired and must be recorded on the shop repair diagnosis that beyond the normal time allowed.
order to identify and justify this expense. Prior This time must be identified as Additional Diag-
approval may be obtained by contacting IMPCO nostics and follow the same time recording and
Technical Assistance 1-866-473-2851. labor step documentation as Straight Time.
ADDITIONAL OR OTHER LABOR It is the responsibility of qualified dealership su-

pervisory personnel to assist technicians in both
Additional or Other Labor may be required when customer Problem Analysis and Symptom Diag-
unusual or abnormal conditions are encountered. nosis.
This time must be identified as such and follow
the same time recording and labor step docu- TECHNICAL ASSISTANCE
mentation as Straight Time. Warranty
compensation for all additional time falls under Service technicians must call the OEM Technical
Policy “A” and is subject to review and approval Assistance whenever extensive diagnosis or re-
by IMPCO before payment is reimbursed. Prior pair advice is required, or to verify a vehicle’s
approval may be obtained by contacting IMPCO warranty.
Technical Assistance at 1-866-473-2851.
OEM Technical Assistance personnel must con-
POLICY CODES tact IMPCO Technical Service personnel to
obtain authorization for those repairs or addition-
Certain IMPCO Policy Codes apply to the Gener- al labor that require prior authorization for
ic Labor Operations listed on page 7. Policy warranty compensation. IMPCO Technical As-
codes and descriptions are: sistance may be contacted at (1-866-473-2851)
between the hours of 8:00 a.m. and 5:00 p.m.
Policy “A” – Is subject to review by IMPCO be- Pacific Time Monday through Friday except holi-
fore reimbursement. days.
Policy “B” – Will require approval from IMPCO
before expense is incurred COMPLETED WARRANTY CLAIMS
Policy “S” – Sublet of work to a facility outside
the normal OEM dealer network, and requires OEMs can choose to submit their electronic
approval from IMPCO prior to incurring the ex- forms via an FTP site using the OEM user ID and
pense Passwords (supplied by IMPCO Technical Assis-
tance). The forms may be submitted individually
All prior approvals may be obtained by contacting or batched. The claims will be reviewed and ap-
IMPCO Technical Assistance at 1-866-473-2851. proved or declined and the OEM will be notified
via an electronic response from the IMPCO war-
ranty administrator. The OEM may then submit
NORMAL & ADDITIONAL DIAGNOSTICS
an invoice for payment of approved claims to
IMPCO for payment of those claims.
Normal repair diagnosis time is included in all
labor time operations. Additional Diagnostics is
302
FUEL SYSTEM LABOR OPERATIONS
Engine-Electrical
OPERATION TIME
LABOR OPERATION DESCRIPTION
NUMBER ALLOWED
ENGINE CONTROL MODULE (ECM)–REPLACEMENT E0050 0.8
ENGINE CONTROL MODULE (ECM)–REFLASH E0057 0.3
ENGINE WIRE HARNESS–REPAIR E1015 0.9
ENGINE WIRE HARNESS–REPLACEMENT E2015 1.5
PLUGS, SPARK–REPLACE ONE J4226 0.4
PLUGS, SPARK–REPLACE ALL J4227 0.7
WIRES, SPARK PLUG-REPLACE ALL J4207 0.3
COIL, IGNITION–REPLACEMENT J4340 0.6
BRACKET, FUSE BOX-REPLACE E3037 0.4
LPG FUEL CONTROL SYSTEM CHECK

M1007 0.3
INCLUDES: Connect scan tool or test equipment. Check for trouble codes
(DTCs), check HEGO operation, disconnect scan tool or test equipment.
ELECTRONIC THROTTLE BODY–REPLACEMENT M0075 0.8
THROTTLE BODY/GASKET–REPLACEMENT E3012 0.8
CAP, DISTRIBUTOR - REPLACE J4360 0.2
ROTOR, DISTRIBUTOR - REPLACE J4380 0.2
DISTRIBUTOR ASSEMBLY - REPLACE J4530 0.8
303

Engine-Sensors
OPERATION TIME
NUMBER ALLOWED
ENGINE OIL PRESSURE SENSOR–REPLACEMENT J4590 0.5
ENGINE COOLANT TEMP SENSOR AND/OR ADAPTER–REPLACE J4591 0.6
CAMSHAFT SENSOR-REPLACEMENT E3019 0.6
CRANK POSITION SENSOR –REPLACEMENT J4592 0.7
TEMP MANIFOLD PRESSURE SENSOR (TMAP)–REPLACEMENT F1015 0.7
FUEL TEMPERATURE/PRESSURE SENSOR–REPLACEMENT E3002 0.5
HEATED EXHAUST GAS OXYGEN SENSOR (HEGO)–REPLACEMENT N1002 0.8
304

Fuel Delivery
OPERATION TIME
NUMBER ALLOWED
PRESSURE REGULATOR-REPLACEMENT
M1001 0.8
INCLUDES: Transfer of all fittings
PRESSURE REGULATOR REPAIR (SEE M1001 FOR REPLACEMENT) 0.9

E3005
ADD: Allowance for the replacement of regulator port O-rings 0.3 0.3
FUEL FILTER, HIGH PRESSURE LIQUID-REPLACE E3041 0.5
FUEL FILTER, LOW PRESSURE VAPOR-REPLACE E3042 0.3
BRACKET, LOW PRESSURE VAPOR LPG FILTER-REPLACE E3052 0.3
BRACKET, REGULATOR MOUNTING–REPLACEMENT E3009 0.5
FUEL INJECTOR, ADAPTER AND/OR FUEL RAIL-REPLACE 1.0
ADD: Each Additional Fuel Injector E3044 0.2

ADD: Fuel Injector Hose 0.1
ADD: Fuel Injector Adapter (each) 0.1
FUEL RAIL BRACKET-REPLACE E3046 0.3
LEAK CHECK LPG SYSTEM G0004 0.2
LPG FUEL SYSTEM PRESSURE CHECK

M1006 0.3
INCLUDES: Connect fuel pressure gauges. Check regulator primary and
secondary pressure. Disconnect gauges.
SHUT-OFF VALVE–REPLACEMENT F1003 0.8
305

Exhaust
OPERATION TIME
NUMBER ALLOWED
CATALYTIC CONVERTER–REPLACEMENT N1001 5.0
RESTRICTED EXHAUST SYSTEM DIAGNOSIS E3017 0.3
Hoses
OPERATION TIME
NUMBER ALLOWED
COOLANT HOSES–REPLACE ALL

T1001 0.7
INCLUDES: Drain & Fill Radiator
COOLANT HOSE PORT FITTING-REPLACE E3047 0.3
FUEL VAPOR HOSE—REPLACE ALL

E3048 0.4
INCLUDES: Replacement of Vapor Hose Port Fittings
FUEL VAPOR HOSE PORT-FITTING-REPLACE E3049 0.2
VACUUM LINE-REPLACE ONE 0.4

T1002
ADD: Additional Line Replace Allowances. Diagnosis Time: 0.1 0.1
PCV-INSPECT OR REPLACE E3050 0.3
306

Engine-Exterior Components
OPERATION TIME
NUMBER ALLOWED
WATER PUMP AND/OR GASKET-REPLACE J3480 0.7
STARTER–REPLACEMENT J4560 0.6
ALTERNATOR–REPLACEMENT J4570 0.5
DRIVE BELT–REPLACEMENT J4571 0.5
THERMOSTAT, AND/OR GASKET–REPLACEMENT J4580 0.4
FLYWHEEL/HARMONIC BALANCER–REPLACEMENT J0720 0.5
307

Engine-Manifolds & Cylinder Head Components
OPERATION TIME
NUMBER ALLOWED
INTAKE MANIFOLD AND/OR GASKET-REPLACEMENT J0210 1.0
EXHAUST MANIFOLD AND/OR GASKET–REPLACEMENT J0108 1.0
VALVE COVER AND/OR GASKET-REPLACEMENT

J0308 0.3
Includes: R&R intake manifold.
ROCKER ARM–REPLACEMENT 0.4

Includes: R&R intake manifold and rocker cover(s). J0358
ADD: Replace all rocker arms: 0.3
STUD, VALVE ROCKER ARM BALL-REPLACEMENT J0388 0.5

ADD: To replace an additional stud 0.3
CYLINDER HEAD GASKET-REPLACEMENT

J0508 2.3
Includes: R&R intake manifold, rocker covers(s) and compression test.
CYLINDER HEAD-REPLACEMENT
J0518 3.0
Includes: R&R intake manifold, rocker cover(s) and compression test.
VALVE–RECONDITION OR REPLACEMENT 2.9

ADD: Each additional cylinder 0.4
J0528
ADD: To recondition all valves 0.9
ADD: To ream and fit guides for oversize stems 0.2
VALVE SPRING, CAP AND/OR SEALS–REPLACEMENT 2.5

Includes: R&R rocker cover(s)
J0548
ADD: Each additional cylinder 0.3
ADD: All springs, caps and/or seals 0.9
PUSH ROD–REPLACEMENT, ONE CYLINDER 0.8

Includes: R&R rocker cover(s) J0588
ADD: To replace all push rods: 0.2
LIFTER, VALVE–REPLACEMENT, ONE CYLINDER 0.9

Includes: R&R rocker cover(s) J0628
ADD: To replace all lifters: 0.3
308

Engine–Internal Components
OPERATION TIME
NUMBER ALLOWED
TIMING COVER OIL SEAL–REPLACEMENT
J0750 0.7
Includes: R&R balancer
TIMING COVER AND/OR GASKET–REPLACEMENT

J0780 2.0
Includes: R&R balancer
TIMING CHAIN–REPLACEMENT 1.6

J0820
ADD: Replace crankshaft gear 0.2
CAMSHAFT TIMING GEAR–REPLACEMENT 3.9

J0840
ADD: Replace crankshaft gear 0.2
CAMSHAFT–REPLACEMENT J0850 6.0
OIL PAN AND/OR GASKET–REPLACEMENT

J1000 2.2
Includes: Fluid replacement
PUMP, ENGINE OIL–REPLACEMENT

J1020 2.5
Includes: R&R engine oil pan and fluid replacement
SEAL, REAR MAIN BEARING–REPLACEMENT

Includes: R&R engine oil pan and fluid, replace lower seal and repack J1120 2.8
upper seal
BEARING, CRANKSHAFT MAIN–REPLACE ONE 4.1
Includes: R&R engine oil pan and fluid, and use of plastic type gauge
ADD: Replace main bearings

Each additional (NOT to equal or exceed ALL) 0.5
J1200
All main bearings 1.2
ADD: Replace connecting rod bearings

All rod bearings 1.2
309

Engine–Internal Components
OPERATION TIME
NUMBER ALLOWED
BEARING, CONNECTING ROD–REPLACE ONE 2.9
Includes: R&R engine oil pan and fluid, and use of plastic type gauge
J1180
ADD: Replace connecting rod bearings
All rod bearings 2.0
PISTON, ROD AND/OR RINGS–REPLACEMENT 3.3
Includes: R&R all necessary components and use of plastic type gauge
ADD: Replace rings only

Each piston (NOT to exceed ALL) 0.4
All pistons 2.2
J1308
ADD: To replace connecting rods only
Each rod (NOT to exceed ALL) 0.3
All rods 1.2
ADD: To replace pistons only

Each piston (NOT to exceed ALL) 0.4
All pistons 2.4
PLUG, EXPANSION–REPLACEMENT
Note: Use appropriate labor operation(s) for removal of necessary J1600 0.3
component(s) to gain access to plug
PLUG, OIL GALLERY–REPLACEMENT

Note: Use appropriate labor operation(s) for removal of necessary J1640 0.3
component(s)
310

ENGINE REPAIR OPERATIONS
Engine–Replacement
OPERATION TIME
NUMBER ALLOWED
BLOCK, ENGINE FITTED–REPLACEMENT 9.0
Includes: R& R all components, fluids and accessories J1800
ADD: To recondition all valves and guides 2.6
ENGINE, PARTIAL–REPLACEMENT 7.2

Includes: R& R all components, fluids and accessories J1820
ADD: To recondition all valves and guides 2.6
ENGINE, ASSEMBLY–REPLACEMENT
J1880 3.5
Includes: R&R all components, fluids and accessories
ENGINE, MOUNTS, FRONT–REPLACEMENT J1506 0.3
311

MISCELLANEOUS
OPERATION TIME
NUMBER ALLOWED
ADDITIONAL DIAGNOSTIC TIME Policy “B” G0001
0.5
Subject to review by IMPCO Technical Support Policy “B”
FASTENER OR FITTING TIGHTENING G0003 0.1
DRIVE TESTS G0006 0.2
SUBLET TIME Policy “S”* G0007

0.0
*Requires Prior Approval By IMPCO Technical Support; Policy “S”
312

REQUEST FOR REVIEW OF LABOR TIMES
IMPCO will provide all possible assistance in the development process, the content of individual stan-
dards, the means for accomplishing repairs within the times established and the assurance that every
effort has been made to maintain the accuracy of these times. IMPCO will review and, if necessary, ad-
just any allowance that is inconsistent with the time actually being spent on warranty repairs that are
within the scope and definitions described in this guide.
Although the same methods of labor time allowance development are applied to every labor time study,
the actual time required to make a repair on a like component may vary. Changes to labor times are
made based on one or more of the following:
 Design change of the component.
 Design change in other components that affect the accessibility to the repaired component.
 Change in the procedure or method of repair.
 Change in the tools or equipment used to make the repair.
 Final review and verification of times after receiving a Request for Review form.
Questions and/or suggestions regarding labor operations or time allowances in the Labor Time Guide
must be submitted on a Request for Review form. This form is the last page of this guide.
A properly completed form will provide IMPCO detailed information identifying the technician’s difficulties
in performing a labor operation within the published labor time allowance. When completing this form, it
is important that all vehicle identification data affecting or influencing the operation in question be pro-
vided.
OEM RESPONSIBILITIES
Your request for review must include a detailed, step by step description of your labor procedure in the
space provided. This will allow IMPCO to both understand your concern and potential cause(s) for the
variance between your actual time and the published labor time.
When submitting a Request for Review, the following steps are required:
 Verify that the technician has followed Service Manual Supplement procedure and utilized all neces-
sary equipment and is properly trained.
 Complete the Request for Review Form included in this Guide.
 Use one form for each labor allowance in question (or combination of standards representing one re-
pair job).
 Provide specific performance time for two repairs performed by the same technician to assist in de-
termining average time.
 Identify the technician involved, should it be necessary to review the process.
 Provide comments that may help in identifying the problem area including individual step times.
 Sign and forward the form to IMPCO.
IMPCO RESPONSIBILITIES
Upon receipt of the Request for Review form, IMPCO will review the procedure and consider changing
the labor time. Changes in a labor time will appear as a Warranty Bulletin or the next revision of the La-
bor Time Guide.
313

COMPLETING THE REQUEST FOR REVIEW FORM
When completing the request for review form, include a detailed description of each step, list all compo-
nents, numbers, type of fasteners, and any Special Service Tools or procedures that are required. Use
the Labor Time Study form and include it with the Request for Review sheet on page 18.
When complete, send both forms to:
IMPCO Technologies
3030 South Susan Street
Santa Ana, CA. 92704
Attn: Technical Service Labor Time Review
314

REQUEST FOR REVIEW
Please insure this Request for Review is filled out completely so that it can be investigated
and processed without delay.
SERVICE FACILITY INFORMATION

Service Facility Name:
Service Facility Address:
City: State: Zip Code
Telephone Number ( ) Fax Number: ( )
CURRENT PUBLISHED
OPERATION NUMBER TIME SUGGESTED TIME
VEHICLE INFORMATION:
Model Year Model Line SERIAL#
Mileage _____________________ Engine _______________________
TECHNICIAN INFORMATION:
Technician’s Name
Are you certified in this area of repair? Yes No
How many times have you performed this repair? Once Twice How many?
Is the IMPCO Service Manual Supplement accurate? Yes No Describe the inaccuracy:
(Please include any additional inaccuracies and/or suggestions on a separate sheet. We

welcome your input.)
Have you attended an IMPCO Technical Training Class for this type of work? Yes No
SERVICE MANAGER SIGNATURE: (required)
Date: (required) _____________________

A detailed, step by step labor description is required on the back of this form before a labor
time study will be considered for review.
315

LABOR TIME STUDY FORM
Watch Time
Step Labor Description
(Min/Sec)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
(Attach additional sheets if necessary)
Total Repair Time (minutes/seconds)
316

Definitions
317

Air Valve Vacuum (AVV): The vacuum signal tak- CNG: Compressed Natural Gas.
en from below the air valve assembly and above CKP: Crankshaft Position Sensor
the throttle butterfly valve. CMP: Camshaft Position Sensor
ADP: Adaptive Digital Processor. Conductor: A material, normally metallic, that
Air/Fuel Ratio: The amount or balance of air and permits easy passage of electricity.
fuel in the air fuel mixture that enters the engine. Contaminants: Impurities or foreign material
Analog Voltmeter: A meter that uses a mechani- present in fuel.
cal needle to point to a value on a scale of Control Module: One of several informal names
numbers. It is usually of the low impedance type for a solid state microcomputer which monitors
and used to measure voltage and resistance. engine conditions and controls certain engine
Aromatics: Pertaining to or containing the six- functions; i.e. air/fuel ratio, injection and ignition
carbon ring characteristic of the benzene series. time, etc. The formal name and the one used
Found in many petroleum distillates. throughout this manual is ECM, or Engine Control
Backfire: Combustion of the air/fuel mixture in the Module.
intake or exhaust manifolds. A backfire can occur Converter: A LPG fuel system component contain-
if the intake or exhaust valves are open when ing varying stages of fuel pressure regulation
there is a mis-timed ignition spark. combined with a vaporizer.
Benzene: An aromatic (C6H6). Sometimes blended Cryogen: A refrigerant used to obtain very low
with gasoline to improve anti-knock value. Ben- temperatures.
zene is toxic and suspected of causing cancer. Current: The volume or flow of electrons through a
Bi-Fueled: A vehicle equipped to run on two fuels. conductor. Measured in amperes or amps.
Blow-By: Gases formed by the combustion of fuel DBW: Drive By Wire
and air, which ordinarily should exert pressure Dedicated Fuel System: A motor fuel system de-
only against the piston crown and first compres- signed to operate on only one fuel type.
sion ring. When rings do not seal, these gases Diaphragm: A thin, flexible membrane that sepa-
escape or “blow by” the side of the piston into the rates two chambers. When the pressure in one
crankcase. chamber is lower than in the other chamber, the
BTU: British Thermal Unit. A measurement of the diaphragm will move toward the side with the low
amount of heat required to raise the temperature pressure.
of 1lb. of water 1 degree F. Diaphragm Port: The external port located at the
Butane: An odorless, colorless gas, C4H10 found in fuel inlet assembly and connected to the vacuum
natural gas and petroleum. One of the five LP chamber above the air valve diaphragm.
gases. DLC: Data Link Connector.
CAFE: Corporate Average Fuel Economy. DTC: Diagnostic Trouble Code
CARB: California Air Resources Board. DST: Diagnostic Scan Tool.
Carbon Monoxide (CO): A chemical compound of DVOM: Digital Volt/ohm Meter. A meter that uses a
a highly toxic gas that is both odorless and color- numerical display in place of a gauge and is
less. usually of the high impedance type.
Carburetor: An apparatus for supplying an inter- ECT: Engine Coolant Temperature.
nal-combustion engine a mixture of vaporized fuel ECM: Electronic Control Module
and air. ECOM: A DLC cable supporting CAN and serial
Cathode Ray Tube: A vacuum tube in which ca- communication with a Spectrum II or III ECM.
thode rays usually in the form of a slender beam EFI: Electronic Fuel Injection. A fuel injection sys-
are projected on a fluorescent screen and pro- tem, which uses a microcomputer (ECM) to
duce a luminous spot. determine and control the amount of fuel, re-
Circuit: A path of conductors through which elec- quired by, and injected into, a particular engine.
tricity flows. EGO: Exhaust Gas Oxygen, used to describe a
Closed Loop Operation: Applies to systems utiliz- sensor. Also known as “HEGO” (Heat Exhaust
ing an oxygen sensor. In this mode of operation, Gas Oxygen) sensor, “O2” or “Oxygen sensor.
the system uses oxygen sensor information to de- EGR: Exhaust Gas Recirculation.
termine air/fuel ratio. Adjustments are made EPA: Environmental Protection Agency: A regulat-
accordingly and checked by comparing the new ing agency of the Federal government which,
oxygen sensor to previous signals. No stored in- among other duties, establishes and enforces au-
formation is used. tomotive emissions standards.
318

Ethanol: Grain alcohol (C2H5OH), generally pro- Hydrocarbon: A chemical compound made up of
duced by fermenting starch or sugar. hydrogen and carbon (HC). Gasoline and almost
Evaporative Emissions Controls: An automotive all other fuels are hydrocarbons.
emission control system designed to reduce hy- Hydrostatic Relief Valve: A pressure relief device
drocarbon emissions by trapping evaporated fuel installed in the liquid LPG hose on a LPG fuel
vapors from the fuel system. system.
Excess Flow Valve: A check valve that is caused IAT: Intake Air Temperature
to close by the fuel when the flow exceeds a pre- Ideal Mixture: The air/fuel ratio at which the best
determined rate. compromise of engine performance to exhaust
FTV: Fuel Trim Valve. emissions is obtained. Typically 14.7:1.
FFV: Flexible Fuel Vehicle. Ignition Reserve: The difference between availa-
Firing Line: The portion of an oscilloscope pattern ble voltage and the required voltage.
that represents the total amount of voltage being ILEV: Inherently Low Emission Vehicle.
expended through the secondary circuit. IMPCO: Imperial Machine Products Company.
FMVSS: Federal Motor Vehicle Safety Standards. IMPCO Technologies, Inc. A manufacturer of both
FPP: Foot Pedal Position Sensor LPG and Gasoline fuel systems.
Fuel Injector: a spring loaded, electromagnetic Impedance: A form of opposition of AC electrical
valve which delivers fuel into the intake manifold, current flow (resistance) measured in ohms.
in response to an electrical input from the control Insulation: A nonconductive material used to cover
module. wires in electrical circuits to prevent the leakage
Fuel Lock: A solenoid-controlled valve located in of electricity and to protect the wire from corro-
the fuel line to stop the flow when the engine sion.
stops or the ignition switch is off. Intercept: An electrical term for a type of splice
Gasohol: 10 percent ethanol, 90 percent gasoline. where the original circuit is interrupted and redi-
Often referred to as E-10. rected through another circuit.
Gasoline: A motor vehicle fuel that is a complex ITK: IMPCO Test Kit
blend of hydrocarbons and additives. Typical oc- Knock: Sound produced when an engine’s air/fuel
tane level is 89. mixture is ignited by something other than the
GCP: Spectrum III (90-pin) ECM. spark plug, such as a hot spot in the combustion
Greenhouse Effect: A scientific theory suggesting chamber. Also caused by a fuel with an octane
that carbon dioxide from the burning of fossil fuels rating that is too low and/or incorrect ignition tim-
is causing the atmosphere to trap heat and cause ing. Also called detonation or ping.
global warming. Lambda Sensor: A feedback device, usually lo-
HC: Hydrocarbon. An organic chemical compound. cated in the exhaust manifold, which detects the
HD 10: A fuel of not less than 80% liquid volume amount of oxygen present in exhaust gases in re-
propane and not more than 10% liquid volume lation to the surrounding atmosphere. (See
propylene. HEGO).
HD 5: A fuel of not less than 90% liquid volume LDV: Light Duty Vehicle.
propane and not more than 5% liquid volume Lean Mixture: An air to fuel ratio above the stoi-
propylene. chiometric ratio; too much air.
HDV: Heavy Duty Vehicle. LEV: Low Emission Vehicle.
Heavy Ends: A term used to describe the buildup Limp-in or Limp Home: A mode where the ECM
of wax-like impurities that fall out of LPG when or a component has failed, but the vehicle re-
vaporized. mains operational although the engine may
HEGO: Heated Exhaust Gas Oxygen, used to de- operate minimally. This term may also describe
scribe a sensor. Also known as “EGO” (Exhaust the drivability characteristics of a failed computer
Gas Oxygen sensor), “O2” or “Oxygen sensor. system.
Hg: Chemical symbol for the element mercury. Liquid Petroleum Gas (LPG): A fuel commonly
Used in reference to a measure of vacuum (inch- known as propane consisting mostly of propane
es of Hg). (C3H8), derived from the liquid components of
Histogram: The graphical version of a table which natural gas stripped out before the gas enters the
shows what proportion of values fall into specific pipeline, and the lightest hydrocarbons produced
categories over a specific period of time. during petroleum refining. Octane level of LPG is
107.
319

LPG: Liquified Petroleum Gas. Oxygenate: Oxygenates (such as MTBE, ethanol
M85: A blend of gasoline and methanol consisting and methanol) added to gasoline to increase the
of 85% methanol and 15% gasoline. oxygen content and therefore reduce exhaust
Measurements of Pressure: 1 PSI=2.06” Hg emissions.
(mercury) = 27.72” H2O (water column). At sea Ozone: A radical oxygen module (O3) that is found
level atmospheric pressure is 29.92” Hg. in the upper atmosphere and filters out ultraviolet
Methanol: Known as wood alcohol (CH3OH), a radiation from the sun. Ground level ozone is
light, volatile, flammable alcohol commonly made formed by NOX, during the formation of photo-
from natural gas. chemical smog.
MIL: Malfunction Indicator Lamp. Particulates: Microscopic pieces of solid or liquid
Misfire: Failure of the air/fuel mixture to ignite dur- substances such as lead and carbon that are dis-
ing the power stroke. charged into the atmosphere by internal
Mixer: Fuel introduction device that does not in- combustion engines.
clude a throttle plate. Positive Crankcase Ventilation (PCV): An auto-
MFI: Multiport Fuel Injection. A fuel injection system motive emission control system designed to
that uses one injector per cylinder mounted on reduce hydrocarbon emissions by routing crank-
the engine to spray fuel near the intake valve case fumes into the intake manifold rather than to
area of combustion chamber. the atmosphere.
MSV: Manual Shut-Off Valve. Refers to the ma- Power Derate: A mode of reduced engine power
nually operated valve on the LPG tank. output for the purposes of protecting engine com-
MTBE: Methyl Tertiary Butyl Ether. Oxygenate add ponents during a failure or malfunction.
to gasoline to reduce harmful emissions and to Pressure Differential: The differential between
improve the octane rating. atmospheric pressure and intake manifold (re-
Multi-fuel System: A motor fuel system designed ferred to as vacuum) pressure.
to operate on two different fuels, such as LPG Pressure Regulator: A device to control the pres-
and gasoline. sure of fuel delivered to the fuel injector(s).
Natural Gas: A gas formed naturally from buried Primary Circuit: The low-voltage or input side of
organic material, composed of a mixture of hy- the ignition coil.
drocarbons, with methane (CH4) being the Propane: An odorless and colorless gas, C3H8,
dominant component. found in natural gas and petroleum.
NGV: Natural Gas Vehicle. Psia: pounds per square inch absolute
NOX: See Oxides of Nitrogen. PTV: Pressure Trim Valve
OBD: On Board Diagnostic Reactivity: Refers to the tendency of an HC in the
Octane Rating: The measurement of the antiknock presence of NOX and sunlight to cause a smog-
value of a motor fuel. forming reaction. The lighter the HC, the lower
OEM: Original Equipment Manufacturer, the vehicle reactivity tends to be.
manufacturer. Regulator: An assembly used to reduce and con-
Open-Loop: An operational mode during which trol the pressure of a liquid or vapor.
control module memory information is used to de- Resistance: The opposition to the flow of current in
termine air/fuel ratio, injection timing, etc., as an electrical circuit. Measured in ohms.
opposed to actual oxygen sensor input. Rest Pressure: Fuel pressure maintained within
Orifice: A port or passage with a calibrated open- the system after engine shutdown.
ing designed to control or limit the amount of flow Rich Mixture: An air to fuel ratio below the stoichi-
through it. ometric ratio; too much fuel.
Oscilloscope: An instrument that converts voltage SAE: Society of Automotive Engineers.
and frequency readings into traces on a cathode Secondary Circuit: The high-voltage output side of
ray tube (also see Cathode Ray Tube). the ignition coil.
Oxides of Nitrogen: Chemical compounds of ni- SEFI or SFI: Sequential Electronic Fuel Injection or
trogen bonded to various amounts of oxygen Sequential Fuel Injection.
(NOX). A chief smog forming-agent. Sensors: Devices that provide the control module
Oxygen Sensor: An automotive fuel system that with engine information as needed to properly
produces a signal in accordance with the oxygen control engine function.
content of the exhaust gas. (See Lambda Sen-
sor).
320

Spark Line: The portion of an oscilloscope pattern TSB: Technical Service Bulletin.
that represents the time during which the air/fuel ULEV: Ultra Low Emission Vehicle.
mixture is being burned in the combustion cham- USB: Universal Serial Bus. A plug or interface sup-
ber. plied on most personal computers.
Splice: An electrical term for the joining of two or Vaporization: A process in which liquid changes
more conductors at a single point. states into gas.
Stoichiometric Ratio: An ideal fuel/air ratio for Venturi Air Valve Vacuum (VAVV): An amplified
combustion in which all of the fuel and most of air valve vacuum signal coming from the venturi
the oxygen will be burned. area of the mixer, directly exposed to airflow be-
Sulfur Oxides: Chemical compounds where sulfur fore the addition of vaporized LPG.
is bonded to oxygen produced by the combustion Volt/ohmmeter (VOM): A combination meter used
of gasoline or any other fuel that contains sulfur. to measure voltage and resistance in an electrical
As sulfur oxides combine with water in the at- circuit. Available in both analog and digital types.
mosphere to form sulfuric acid. May also referred to as AVOM and DVOM.
System Pressure: The fuel pressure maintained in Voltage: The electrical pressure that causes cur-
the system during normal engine operation. rent to flow in a circuit. Measured in volts.
Tap: An electrical term for a type of splice where Voltage Drop: A lowering of the voltage in a circuit
the original circuit is not interrupted. when resistance or electrical load is added.
TBI: Throttle Body Injection. Any of several injec- Voltmeter: A meter that uses a needle to point to a
tion systems that have the fuel injector(s) value on a scale of numbers usually of the low
mounted in a centrally located throttle body. impedance type; used to measure voltage and
Throttle Body: Controls engine RPM by adjusting resistance.
the engine manifold vacuum to the mixer. Con- VSS: Vehicle Speed Sensor
sists of a housing shaft, throttle liner and butterfly Xylene: C6H4 (CH3)2. Any of three toxic, flammable,
valve. and oily isomeric aromatic hydrocarbons that are
TLEV: Transitional Low Emission Vehicle. dimethyl homologues of benzene and usually ob-
TMAP: Combined Air Inlet and Manifold Pressure tained from petroleum or natural gas distillates.
Sensor. ZEV: Zero Emission Vehicle.
Toluene: A liquid aromatic hydrocarbon C7H8.
TPS: Throttle Position Sensor.
321

322

Appendix
323

Altitude vs. Barometric Pressure
Altitude Measured Kilopascals Pounds Per Square

In Feet (ft) (kpa) Inch (PSIA)
14,000 56-64 8.1-9.2
13,000 58-66 8.4-9.6
12,000 61-69 8.8-10.0
11,000 64-72 9.3-10.4
10,000 66-74 9.6-10.7
9,000 69-77 10.0-11.2
8,000 71-79 10.3-11.4
7,000 74-82 10.7-11.9
6,000 77-85 11.2-12.3
5,000 80-88 11.6-12.8
4,000 83-91 12.0-13.2
3,000 87-95 12.6-13.8
2,000 90-98 13.0-14.2
1,000 94-102 13.6-14.8
0 96-104 13.9-15.0
-1,000 101-105 14.6-15.2
324

Ignition System Specifications
Firing Order 1-6-5-4-3-2

Spark Plug Type R44LTS (AC Plug)
Spark Plug Gap .035 in (0.889 mm)
Spark Plug Torque 11 lb ft (15 N·m)
Spark Plug Wire Resistance 1000 Ohms per ft.
325

Extended ECT Temperature vs. Resistance
Degrees F. Degrees C. Ohms±10%

302 150 47
284 140 60
266 130 77
248 120 100
230 110 132
212 100 177
194 90 241
176 80 332
158 70 467
140 60 667
122 50 973
113 45 1188
104 40 1459
95 35 1802
86 30 2238
77 25 2796
68 20 3520
59 15 4450
50 10 5670
41 5 7280
32 0 9420
23 -5 12300
14 -10 16180
5 -15 21450
-4 -20 28680
-22 -30 52700
-40 -40 100700
326

DTC (SPN & FMI Chart)
327

2011 Emission Certified LPG Fuel System 3.0L GM Engine: Including Labor Time Guide

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2011 Emission Certified LPG Fuel System 3.0L GM Engine: Including Labor Time Guide

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2011 Emission Certified

LPG Fuel System

Parts & Service Manual

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General Information ................................................................................................ 5

Fuel System ........................................................................................................... 17

LPG Fuel System Diagnosis ................................................................................ 27

LPG Symptom Diagnostics .................................................................................. 35

Electrical Section .................................................................................................. 51

Diagnostic Scan Tool ...................................................................................... 53

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Engine Wire Harness Repair .............................................................................85

Diagnostic Trouble Codes (DTCs) ....................................................................89

Servicing the Fuel System .................................................................................... 237

LPG Parts Diagram ................................................................................................ 255

Labor Time Guide .................................................................................................. 299

Definitions .............................................................................................................. 317

Appendix ................................................................................................................ 323

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SERVICING YOUR EMISSIONS

LPG engines and fuel systems are designed to

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Unlike gasoline or propane vapors that

Typical Warning Label:

Do not allow LPG to contact the skin.

A “CAUTION” label or statement is used when it

Less severe than WARNING but has

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A “NOTE” statement applies to a specific item or

PROPER USE OF THIS SERVICE MANUAL,

 The service procedures defined in this ma-

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When performing maintenance on the engine,

The engine installed in this equipment uses a ser-

 The regular removal of dust, dirt and debris

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COOLANT ENGINE CRANKCASE OIL

ENGINE ELECTRICAL SYSTEM MAINTNANCE

The engine’s electrical system incorporates com-

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It is noted that the GF-4 oils are also “backward

OEM’s may opt for higher viscosity oils based on

IMPORTANT: 1. Start the engine and run until it reaches nor-

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LPG FUEL SYSTEM

The service valve mounted in the end of the cylind-

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A throttle related failure will cause a “LIMP

THREE WAY CATALYTIC CONVERTER

The Catalytic Converter is a component of the

Speed control is maintained by the amount of pres-

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HEATED EXHAUST GAS OXYGEN SENSOR

The Heated Exhaust Gas Oxygen (HEGO) Sen-