Air Gap Test; Encoder Flywheel / Keyway Inspection - Taylor-Dunn G0-010-00 Service And Replacement Parts Manual

FUEL SYSTEM
9. If resistance of the wires to the ECU are in spec and
not shorted to chassis ground, test the shield wire
(third pin on the CPS connector) for good continuity to
ground (under one ohm).
10. If continuity to ground on the shield is in specification,
inspect harness routing compared to a known good
vehicle, as well as for accessories that may create
interference. Routing close to ignition cables, stator
wires, or HID bulbs and other high voltage
accessories may cause issues.
NOTICE
It should be noted that dynamic operation is what is
read by the ECU, not static testing like resistance
measuring as advised here. While the static tests
advised will lead to properly diagnosing almost all
situations, there are failure modes that will not be
noticed by resistance testing and still set trouble codes.
If there are concerns, please contact Technical Service
for guidance.

AIR GAP TEST

NOTICE
The CPS air gap is non-adjustable, however
differences in air gap readings may indicate an
improper or damaged CPS sensor
improper components are suspected, compare the
components to known good components.
Measuring the air gap between the CPS sensor
w
flywheel encoder must be done using multiple
measurements as the stator cover design does not
allow direct air gap measurement.
q
1. Disconnect the CPS
2. Remove the CPS.
3. Measure the distance between the sensor mounting
flange and the bottom face of the sensor.
4. Rotate the engine until a tooth of the encoder
flywheel is positioned in line with the CPS mounting
location.
5. Using a depth gauge, measure the distance from the
encoder flywheel tooth to the mounting surface of the
CPS.
6. Subtract the sensor length from the sensor mounting
point to encoder flywheel measurement. Verify that
the calculated air gap is within specification.
4.26
q w
or flywheel
q
from the main harness.
1.0 ± 0.26 mm (0.059 ± 0.010")
• If the resistance and air gap is correct proceed to

Encoder Flywheel / Keyway Inspection.

• If the air gap is incorrect, compare the CPS flange
to sensor face measurement to a known good
sensor. If the sensor is correct proceed to Encoder
Flywheel / Keyway Inspection.
• Is the CPS sensor is incorrect, follow the "CPS
. If
Replacement" procedure.
ENCODER FLYWHEEL / KEYWAY INSPECTION
1. Access the CPS.
and
2. Disconnect the CPS from the main wiring harness.
3. Drain the coolant.
Properly dispose of the coolant.
4. Disconnect the coolant hose at the water pump.
5. Remove the fasteners retaining the stator cover.
6. Inspect the flywheel for corrosion, warping, and
damaged or missing components.
At this time measure flywheel run-out using a dial
indicator near the teeth on the flywheel. If the run-out
causes the CPS air gap to be out of tolerance, identify
whether the flywheel is out of round, or if the crankshaft
9929758 R01 - 2019 TAYLOR-DUNN G-100 Service Manual
MEASUREMENT
CPS Air Gap:
NOTICE
NOTICE
is bent.
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