Spectrum 3.0L GM Parts & Service Manual

2011 emission certified lpg fuel system

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Contents
Table of Contents
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2011 Emission Certified

LPG Fuel System

3.0L GM Engine

Parts & Service Manual

Including Labor Time Guide

Revision A/March, 2011

Table of Contents

Summary of Contents for Spectrum 3.0L GM

Page 1 2011 Emission Certified LPG Fuel System 3.0L GM Engine Parts & Service Manual Including Labor Time Guide Revision A/March, 2011...
Page 2: Table Of Contents
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 ................
Page 3 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 ....................
Page 5: General Information
General Information...
Page 6 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.
Page 7 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.
Page 8 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.
Page 9: Maintenance
Maintenance...
Page 10 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.
Page 11  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- ...
Page 12  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.
Page 13 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, chunking or separation. If damage to the o-ring Engine oil will be hot. Use protective is found, replace prior to ﬁlling.
Page 14  The measurement of oxygen in the exhaust Inspect Air cleaner element according to the stream is measured in voltage and sent to the Recommended Maintenance Schedule found ECM. The ECM then makes corrections to the in this section. fuel air ratio to ensure the proper fuel charge and ...
Page 15: Fuel System
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...
Page 17 LPG Fuel System...
Page 18 LPG FUEL SYSTEM OPERATION...
Page 19 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.
Page 20 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.
Page 21 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.
Page 22 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.
Page 23 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.
Page 24 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...
Page 25 LPG Closed Loop Schematic...
Page 27 LPG System Diagnosis...
Page 28: Lpg Fuel System Diagnosis
LPG FUEL SYSTEM DIAGNOSIS Regulator Assembly  Verify the manual shut off valve on the FUEL SYSTEM DESCRIPTION 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.
Page 29 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).
Page 30 LPG FUEL SYSTEM DIAGNOSTICS Step Action Value(s) Were you referred to this procedure by a DTC diagnostic Go to Step Go to Chart? 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 cable DTC Step (3)
Page 31 Step Action Value(s)  Connect a calibrated 0-5” PSI pressure gauge to the pri- If NO pressure mary pressure test port of the Regulator. was indi-  Make sure the manual shut-off valve is open and turn the cated, Go ignition to ON.
Page 32 Step Action Values  Remove the FAP sensor from the Fuel Rail and insert the Pressure Test Adapter and connect to 103 kPa (15 PSI) pressure gauge.  Connect the DST to the vehicle DLC connector and open the DST software. ...
Page 33 Step Action Values Inspect the following for heavy-end deposits:  Pressure Regulator. Inspect, clean and/or repair as neces- Go to Step sary (refer to Regulator Repair Instructions). Are all actions complete? Replace the ECM. Go to Step Is the action complete? Replace the Shut Off Valve.
Page 34 Step Action Values Go to Step Go to Was the Adaptive 1 fuel correction less than -15%? (26) Step (25) Go to Step Was the Adaptive 1 fuel correction more than +15%? (27) Engine is running RICH (system is trying to compensate by de- creasing the amount of fuel).
Page 35 Fuel Symptom Diagnostics...
Page 36 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.
Page 37 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.
Page 38 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.
Page 39 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.  Venturi vacuum leaks. Engine Mechanical  Engine Vacuum leaks. Checks  Improper valve timing.
Page 40 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. ...
Page 41 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  Manifold vacuum leaks. Engine Mechanical  Venturi Vacuum Leaks Checks ...
Page 42 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.
Page 43 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.
Page 44 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.
Page 45 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.
Page 46 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.
Page 47 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.
Page 48 Checks Action Check the engine for:  Broken motor mounts.  Improper valve timing. Engine Mechani-  Low compression. cal Check  Improper valve clearance.  Worn rocker arms.  Broken or weak valve springs.  Worn camshaft lobes.
Page 49 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. ...
Page 50 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 ...
Page 51 Electrical Section...
Page 53 DST (Diagnostic Scan Tool)
Page 54 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.
Page 55 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.
Page 56 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.
Page 57 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.
Page 58 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.
Page 59 Select the USB button, then click the OK box. Click on the Search attached device box.
Page 60 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.
Page 61 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.
Page 62 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.
Page 63 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.
Page 64 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.
Page 65 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...
Page 66 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...
Page 67 When connected, the live data stream appears in the Value column.
Page 68 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.
Page 69 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.
Page 70 Use the Browse box to navigate to the location of the calibration file. Enter the password that was supplied with the calibration file.
Page 71 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.
Page 72 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.
Page 73 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.
Page 74 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.
Page 75 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.
Page 76 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.
Page 77 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.
Page 79 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.
Page 81: Wire Schematic
Engine Wire Schematic...
Page 82 2011 3.0L GM Engine IMPCO Emission Certified LPG Fuel System...
Page 85: Engine Wire Harness Repair
Engine Wire Harness Repair...
Page 86 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. Remove outer jacket Wire harnesses should be replaced with proper part number harnesses. When wires are spliced Unwrap aluminum/Mylar tape.
Page 87 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 Locate Damaged Wire.
Page 88 backup, or secondary locking feature for the WEATHER-PACK TERMINAL REPAIR 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.
Page 89: Diagnostic Trouble Codes (Dtcs)
Diagnostic Trouble Codes (DTCs)
Page 90 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.
Page 91 Ignition Control System Diagnostic Chart Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Sys- Go to Step Check? tem Check Section  DST connected and in the system data mode.  Crank the engine and observe the engine Go to Step ~125 RPM Go to Step (3)
Page 92 Step Action Value(s)  Key OFF  Disconnect the connector ECU-C Repair the open  Using a DVOM check for continuity between ignition control Go to Step circuit. See wir- ignition module connector pin B and ECM (11) ing harness connector pin K1 repair section.
Page 94 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.
Page 95 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- Fully 0.32 4.70 0.32 0.30 closed ¼ Open 1.32 3.70 1.32...
Page 96 DTC 51 ETC TPS 1 Range Step Action Value(s)  Did you perform the On-board diagnostics Go to On- (OBD) system check? Board Diag- nostics NOTE: If the 5 volt reference Supply 1 is shorted Go to Step System to ground, various codes may set, including Check/Malfun Throttle, Pedal 1, Oil Pressure, Cam and 5 Volt ction indicator...
Page 97 Step Action Value(s)  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...
Page 98 DTC 91 ETC TPS 1 Range Conditions for Setting the DTC 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...
Page 99 DTC 91 ETC TPS 1 Range Step Action Value(s) Did you perform the On-board diagnostics (OBD) Go to On- system check? Board Diagnostics Go to Step System (2). Check/ Malfunction indicator lamp.  With the monitor connected, Key ON, read If there is a both pedal position sensor voltages.
Page 100 Step Action Value(s)  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 Reinstall the pedal.
Page 102 DTC 100 Oil Pressure Low/High/High at Stall Conditions for Setting the DTC 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.
Page 103 DTC 100 Oil Pressure Low/High/High at Stall Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System. Check Sec- tion Verify that the engine has oil pressure using a mechanical oil pressure gauge before proceed- ing with this chart.
Page 104 Step Action Value(s) Replace ECM Go to Step Is the replacement complete?  Remove all test equipment except the DST.  Connect any disconnected components, fus- es, etc.  Using the DST clear DTC information from the ECM.  Turn the ignition OFF and wait 30 seconds. ...
Page 106 DTC 105 MAT Short to High/Ground/Open Conditions for Setting the DTC  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 ...
Page 107 DTC 105 MAT Short to High/Ground/Open Step Action Value(s)  Did you perform the On-board diagnostics (OBD) system check? NOTE: If the 5 volt reference supply 2 is shorted Go to Step Perform OBD to ground, various codes may set, including System check Pedal 2, and 5 Volt Power Supply Codes, as well as ignition system malfunctions.
Page 108 Step Action Value(s)  Recheck wire harness and TMAP sensor Repair the connectors for damage corrosion or contami- Go to Step nation. circuit as ne- cessary Were any problems found?  Replace the ECU. Go to Step Is the replacement complete?
Page 110 DTC 106 MAP/Low/High/Short/Open Conditions for Setting the DTC  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. ...
Page 111 MAP DIAGNOSTIC AID PSIa PSIa PSIa 34.47 379.2116 723.9495 68.94757 413.6854 758.4233 103.4214 448.1592 792.8971 137.8951 482.633 827.3708 172.3689 517.1068 861.8446 206.8427 551.5806 896.3184 241.3165 586.0543 930.7922 275.7903 620.5281 965.266 310.2641 655.0019 999.7398 344.7379 689.4757 1034.214 PSIa PSIa PSIa 0.725189 7.977074 15.22896 1.450377...
Page 112 DTC 106 MAP/Low/High/Short/Open Step Action Value(s) Did you perform the On-board diagnostics (OBD) Go to On- system check? Board Diag- nostics Go to Step (2) System Check/Malfun ction indicator lamp.  Key ON, engine off. Intermittent  problem. Go Monitor the MAP reading. 508 kPa Go to Step (3) to Preliminary...
Page 113 Step Action Value(s)  Remove all test equipment except the moni- tor.  Using the monitor, reset the adaptive learn.  Connect any disconnected components, fus- es, etc.  Using the monitor, clear DTC information from the ECM. Go to On- ...
Page 114 DTC 110-ECT/Low/High/Short/Open Conditions for Setting the DTC Temp Ohms  ECT sensor voltage less than 0.059. (deg F)  ECT sensor voltage greater than 4.888. 242.4  ECT sensor voltage greater than 4.99. 231.9  211.6 MIL - on during active fault and for 2 seconds after active fault. 201.4 181.9 Circuit Description...
Page 115 DTC 110-ECT/Low/High/Short/Open Step Action Value(s)  Intermittent From Diagnostic tool, monitor ECT. fault. See wir-  Is the displayed temperature reading esti- mated engine temperature schematics and check Key ON, ECT should reflect engine tempera- Go to step2 circuits from ture? C034 to ECU- B for possible...
Page 116 DTC 135 FRP Open/Short/High Conditions for Setting the DTC  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.
Page 117 DTC 135 FRP Open/Short/High Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System Check Sec- tion  Key ON  DST (Diagnostic Scan Tool) connected with the Voltages and Service windows Less than Go to Step Go to Step...
Page 118 Step Action Value(s)  Repair the Using a DVOM check for continuity be- shorted to tween FRP sensor connector signal A ground sig- and sensor ground K2. Go to Step nal circuit. See wire Do you have continuity? harness re- pair section.
Page 120 DTC 168 System Voltage Low/High Conditions for Setting the DTC  System Voltage  Check Condition-Ignition ON  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 ...
Page 121 DTC 168 System Voltage Low/High Step Action Value(s)  Perform charging system diagnostics. Was a fault found? Repair as ne- Go to step 2 cessary NOTE: Do not probe wires without proper ser- vice tool. Permanent harness damage may result. ...
Page 122 DTC 628 Cal Memory Failure Conditions for Setting the DTC  Engine Control Module  Check Condition-Ignition ON  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.
Page 123 DTC 628 Cal Memory Failure Step Action Value(s)  Go to On- Did you perform the On-board diagnostics Board Diag- (OBD) system check? nostics Go to step 2 System Check/Malfun ction indicator lamp.  Reprogram or replace the ECU as required. Go to Step Is the repair completed? ...
Page 124 DTC 630 ECU Checksum Error Conditions for Setting the DTC  Engine Control Module  Check Condition-Ignition ON  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.
Page 125 DTC 630 ECU Checksum Error Step Action Value(s)  Go to On- Did you perform the On-board diagnostics Board Diag- (OBD) system check? nostics Go to step 2 System Check/Malfun ction indicator lamp.  Reprogram or replace the ECU as required. Go to Step Is the repair completed? ...
Page 126 DTC 651 Injector Short/Open Conditions for Setting the DTC  Short to B+  Open Circuit  Short to Ground Circuit Description The ECU injector circuit drives the LPG system.
Page 127 DTC 651 Injector Short/Open Step Action Value(s)  Go to On- Did you perform the On-board diagnostics Board Diag- (OBD) system check? nostics Go to Step System Check/Malfun ction indicator lamp.  For DTC 651-3 short to B+, Go to Step (3) ...
Page 128 Step Action Value(s)  Key OFF, C007 disconnected Repair open  Measure the resistance of the control circuit. Go to Step in the har- <5Ω See table above. (10) ness. Go to Step (14) Is resistance less than 5Ω?  Key OFF, ECU-B disconnected Repair open ...
Page 130 DTC 652 Injector Short/Open Conditions for Setting the DTC  Short to B+  Open Circuit  Short to Ground Circuit Description The ECU injector circuit drives the LPG system.
Page 131 DTC 652 Injector Short/Open Step Action Value(s)  Go to On- Did you perform the On-board diagnostics Board Diag- (OBD) system check? nostics Go to Step System Check/Malfun ction indicator lamp.  For DTC 652-3 short to B+, Go to Step (3) ...
Page 132 Step Action Value(s)  Key OFF, C008 disconnected Repair open  Measure the resistance of the control circuit. Go to Step in the har- <5Ω See table above. (10) ness. Go to Step (14) Is resistance less than 5Ω?  Key OFF, ECU-B disconnected Repair open ...
Page 134 DTC 653 Injector Short/Open Conditions for Setting the DTC  Short to B+  Open Circuit  Short to Ground Circuit Description The ECU injector circuit drives the LPG system.
Page 135 DTC 653 Injector Short/Open Step Action Value(s)  Go to On- Did you perform the On-board diagnostics Board Diag- (OBD) system check? nostics Go to Step System Check/Malfun ction indicator lamp.  For DTC 653-3 short to B+, Go to Step (3) ...
Page 136 Step Action Value(s)  Key OFF, C009 disconnected Repair open  Measure the resistance of the control circuit. Go to Step in the har- See table above. (10) ness. Go to Step (14) Is resistance less than 5Ω?  Key OFF, ECU-B disconnected Repair open ...
Page 138 DTC 654 Injector Short/Open Conditions for Setting the DTC  Short to B+  Open Circuit  Short to Ground Circuit Description The ECU injector circuit drives the LPG system.
Page 139 DTC 654 Injector Short/Open Step Action Value(s)  Go to On- Did you perform the On-board diagnostics Board Diag- (OBD) system check? nostics Go to Step System Check/Malfun ction indicator lamp.  For DTC 654-3 short to B+, Go to Step (3) ...
Page 140 Step Action Value(s)  Key OFF, C010 disconnected Repair open  Measure the resistance of the control circuit. Go to Step in the har- <5Ω See table above. (10) ness. Go to Step (14) Is resistance less than 5Ω?  Key OFF, ECU-B disconnected Repair open ...
Page 142 DTC 1635 Code vs. Cal Version Conditions for Setting the DTC  Engine Control Module  Check Condition-Ignition ON  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.
Page 143 DTC 1635 Code vs. Cal Version Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System Check Sec- tion  Ignition ON  DST (Diagnostic Scan Tool) connected in System Data Mode Intermittent ...
Page 144 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.
Page 146 DTC 522614 Throttle Failed to Enter Limp Home Conditions for Setting the DTC  Electronic Throttle Control  Check Condition-Ignition ON  Fault Condition-Throttle return spring test  MIL-On during active fault Circuit Description Dual throttle position sensors (TPS) are used with the electronic throttle control (ETC) to determine throttle plate position.
Page 147 DTC 522614 Throttle Failed to Enter Limp Home Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Go to Step Check? System Check Section  Ignition ON  DST (Diagnostic Scan Tool) connected in data stream mode. Intermittent ...
Page 148 Step Action Value(s) Using a DVOM check for continuity between Repair the electronic throttle connector pin 4 and ECU-B shorted TPS connector pin D3. circuit to Go to Step ground as ne- Does the DVOM show continuity? cessary. Refer to Wiring Re- pairs.
Page 149 Step Action Value(s)  Remove all test equipment except the DST.  Connect any disconnected components, fus- es, etc.  Using the DST clear DTC information from the ECM.  Turn the ignition OFF and wait 30 seconds.  Start the engine and run to full operating Go to OBD temperature.
Page 150 DTC 522616 Throttle Actual vs. Commanded Error Conditions for Setting the DTC  Electronic Throttle Control  Check Condition-Ignition ON  Fault Condition-TPS 1 and 2 calculated values exceed 10%  MIL-On during active fault Circuit Description Dual throttle position sensors (TPS) are used with the electronic throttle control (ETC) to determine throttle plate position.
Page 151 DTC 522616 Throttle Actual vs. Commanded Error Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Go to Step Check? System Check Section  Ignition ON  DST (Diagnostic Scan Tool) connected in data stream mode. Intermittent ...
Page 152 Step Action Value(s) Using a DVOM check for continuity between Repair the electronic throttle connector pin 4 and ECU-B shorted TPS connector pin D3. circuit to Go to Step ground as ne- Does the DVOM show continuity? cessary. Refer to Wiring Re- pairs.
Page 153 Step Action Value(s)  Remove all test equipment except the DST.  Connect any disconnected components, fus- es, etc.  Using the DST clear DTC information from the ECM.  Turn the ignition OFF and wait 30 seconds.  Start the engine and run to full operating Go to OBD temperature.
Page 154 DTC 522617 Throttle Failed to Fully Open/Close Conditions for Setting the DTC  Electronic Throttle Control  Check Condition-Ignition ON  Fault Condition-TPS 1 and 2 calculated values exceed 10%  MIL-On during active fault Circuit Description Dual throttle position sensors (TPS) are used with the electronic throttle control (ETC) to determine throttle plate position.
Page 155 DTC 522617 Throttle Failed to Fully Open/Close Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Go to Step Check? System Check Section  Ignition ON  DST (Diagnostic Scan Tool) connected in Intermittent data stream mode. Go to Step problem.
Page 156 Step Action Value(s) Using a DVOM check for continuity between Repair the electronic throttle connector pin 5 and ECU-B shorted TPS connector pin M4. circuit to Go to Step ground as ne- (10) Does the DVOM show continuity? cessary. Refer to Wiring Re- pairs.
Page 157 Step Action Value(s)  Remove all test equipment except the DST.  Connect any disconnected components, fus- es, etc.  Using the DST clear DTC information from the ECM.  Turn the ignition OFF and wait 30 seconds.  Start the engine and run to full operating Go to OBD temperature.
Page 158 DTC 522630 Oxygen Sensor Failure to Switch Lean, Bank 1 Conditions for Setting the DTC 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.
Page 159 DTC 522630 Oxygen Sensor Failure to Switch Lean, Bank 1 Step Action Value(s) Did you perform the On-board diagnostics (OBD) Go to On- system check? Board Diagnostics Go to Step System Check/ Malfunction indicator lamp.  No problems With the engine at operating temperature, at this time.
Page 160 Step Action Value(s)  Check pressure drop Replace the Verify the fil-  Check manifold vacuum supply to regulator regulator. Go ter is OK. Go to Step (8) to Step (8). Is the pressure within specifications?  Remove all test equipment except the moni- tor.
Page 162 DTC 522631 Oxygen Sensor Failure to Switch Rich, Bank 1 Conditions for Setting the DTC 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.
Page 163 DTC 522631 Oxygen Sensor Failure to Switch Lean, Bank 1 Step Action Value(s) Did you perform the On-board diagnostics (OBD) Go to On- system check? Board Diagnostics Go to Step System Check/ Malfunction indicator lamp.  No problems With the engine at operating temperature, at this time.
Page 164 Step Action Value(s)  Check pressure drop Replace the Verify the fil-  Check manifold vacuum supply to regulator regulator. Go ter is OK. Go to Step (8) to Step (8). Is the pressure within specifications?  Remove all test equipment except the moni- tor.
Page 166 DTC 522635 Short Term Fuel Lean, Bank 1 Conditions for Setting the DTC 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.
Page 167 DTC 522635 Oxygen Sensor Failure to Switch Lean, Bank 1 Step Action Value(s) Did you perform the On-board diagnostics (OBD) Go to On- system check? Board Diagnostics Go to Step System Check/ Malfunction indicator lamp.  No problems With the engine at operating temperature, at this time.
Page 168 Step Action Value(s)  Check pressure drop Replace the Verify the fil-  Check manifold vacuum supply to regulator regulator. Go ter is OK. Go to Step (8) to Step (8). Is the pressure within specifications?  Remove all test equipment except the moni- tor.
Page 170 DTC 522636 Short Term Fuel Lean, Bank 1 Conditions for Setting the DTC 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.
Page 171 DTC 522636 Oxygen Sensor Failure to Switch Lean, Bank 1 Step Action Value(s) Did you perform the On-board diagnostics (OBD) Go to On- system check? Board Diagnostics Go to Step System Check/ Malfunction indicator lamp.  No problems With the engine at operating temperature, at this time.
Page 172 Step Action Value(s)  Check pressure drop Replace the Verify the fil-  Check manifold vacuum supply to regulator regulator. Go ter is OK. Go to Step (8) to Step (8). Is the pressure within specifications?  Remove all test equipment except the moni- tor.
Page 174 DTC 522690 Bus Failure Conditions for Setting the DTC  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.
Page 175 DTC 522690 Bus Failure Step Action Value(s)  Go to On- Did you perform the On-board diagnostics Board (OBD) system check? Diagnostics Go to Step System Check/ Malfunction indicator lamp.  Reprogram or replace the ECU as required. Go to Step Is the repair completed? ...
Page 176 DTC 522691 Redundant Check Failure Conditions for Setting the DTC  Engine Control Module  Check Condition-Ignition ON  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.
Page 177 DTC 522691 Redundant Check Failure Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System Check Sec- tion  Ignition ON  DST (Diagnostic Scan Tool) connected in System Data Mode Intermittent ...
Page 178 DTC 522692 Redundant General Conversion Failure Conditions for Setting the DTC  Engine Control Module  Check Condition-Ignition ON  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.
Page 179 DTC 522692 Redundant General Conversion Failure Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System Check Sec- tion  Ignition ON  DST (Diagnostic Scan Tool) connected in System Data Mode Intermittent ...
Page 180 DTC 522694 Memory Checksum Error Conditions for Setting the DTC  Engine Control Module  Check Condition-Ignition ON  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.
Page 181 DTC 522694 Memory Checksum Error Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System Check Sec- tion  Ignition ON  DST (Diagnostic Scan Tool) connected in System Data Mode Intermittent ...
Page 182 DTC 522695 Redundant General Conversion Failure Conditions for Setting the DTC  Engine Control Module  Check Condition-Ignition ON  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.
Page 183 DTC 522695 Redundant General Conversion Failure Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System Check Sec- tion  Ignition ON  DST (Diagnostic Scan Tool) connected in System Data Mode Intermittent ...
Page 184 DTC 522698 Redundant Clock Failure Conditions for Setting the DTC  Engine Control Module  Check Condition-Ignition ON  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.
Page 185 DTC 522698 Redundant Clock Failure Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System Check Sec- tion  Ignition ON  DST (Diagnostic Scan Tool) connected in System Data Mode Intermittent ...
Page 186 DTC 522699 Redundant Watchdog Failure Conditions for Setting the DTC  Engine Control Module  Check Condition-Ignition ON  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.
Page 187 DTC 522699 Redundant Watchdog Failure Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System Check Sec- tion  Ignition ON  DST (Diagnostic Scan Tool) connected in System Data Mode Intermittent ...
Page 188 DTC 522700 Redundant SDF Timeout Conditions for Setting the DTC  Engine Control Module  Check Condition-Ignition ON  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.
Page 189 DTC 522700 Redundant SDF Timeout Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System Check Sec- tion  Ignition ON  DST (Diagnostic Scan Tool) connected in System Data Mode Intermittent ...
Page 190 DTC 522710 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.
Page 191 Typical TPS and Throttle Position Readings (assumes 5.00 supply voltage): Actual TPS1 TPS2 TPS1 TPS2 reading Throttle Throttle reading at reading at reading on Monitor Position on Position Throttle Throttle on Moni- Monitor Fully 0.32 4.70 0.32 0.30 closed ¼ Open 1.32 3.70 1.32...
Page 192 DTC 522710 ETC TPS 1 Range Step Action Value(s) Did you perform the On-board diagnostics (OBD) system check? Go to On- Board Diag- nostics NOTE: If the 5 volt reference Supply 1 is shorted Go to Step System to ground, various codes may set, including Check/Malfun Throttle, Pedal 1, Oil Pressure, Cam and 5 Volt ction indicator...
Page 193 Step Action Value(s)  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...
Page 194 DTC 522711 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.
Page 195 Typical TPS and Throttle Position Readings (assumes 5.00 supply voltage): Actual TPS1 TPS2 TPS1 TPS2 reading Throttle Throttle reading at reading at reading on Monitor Position on Position Throttle Throttle on Moni- Monitor Fully 0.32 4.70 0.32 0.30 closed ¼ Open 1.32 3.70 1.32...
Page 196 DTC 522711 ETC TPS 1 Range Step Action Value(s)  Did you perform the On-board diagnostics Go to On- (OBD) system check? Board Diag- nostics NOTE: If the 5 volt reference Supply 1 is shorted Go to Step System to ground, various codes may set, including Check/Malfun Throttle, Pedal 1, Oil Pressure, Cam and 5 Volt ction indicator...
Page 197 Step Action Value(s)  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...
Page 198 DTC 522712 ETC TPS 1 Range Conditions for Setting the DTC 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...
Page 199 DTC 522712 ETC TPS 1 Range Step Action Value(s) Did you perform the On-board diagnostics (OBD) Go to On- system check? Board Diagnostics Go to Step System (2). Check/ Malfunction indicator lamp.  With the monitor connected, Key ON, read If there is a both pedal position sensor voltages.
Page 200 Step Action Value(s)  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 Reinstall the pedal.
Page 202 DTC 522713 ETC TPS 1 Range Conditions for Setting the DTC 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...
Page 203 DTC 522713 ETC TPS 1 Range Step Action Value(s) Did you perform the On-board diagnostics (OBD) Go to On- system check? Board Diagnostics Go to Step System Check/ Malfunction indicator lamp.  With the monitor connected, Key ON, read If there is a both pedal position sensor voltages.
Page 204 Step Action Value(s)  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 Reinstall the pedal.
Page 205 Step Action Value(s)  Remove all test equipment except the moni- tor.  Using the monitor, reset the adaptive learn.  Connect any disconnected components, fus- es, etc.  Using the monitor, clear DTC information Go to On- from the ECM. Board ...
Page 206 DTC 522735 Oxygen Sensor Short/Open Conditions for Setting the DTC  Heated Oxygen Sensor  Check Condition-Ignition ON  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.
Page 207 DTC 522735 Oxygen Sensor Short/Open Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System Check Sec- tion  Ignition OFF  Disconnect HEGO connector C018  Ignition ON System Bat- Go to Step Go To Step ...
Page 208 Step Action Value(s) Using a DVOM measure the resistance of the HEGO heater (sensor side) between pins C and Greater than Go to Step Go to Step 25 Ohms Does the DVOM show a resistance value greater than 25 Ohms? Replace the HEGO sensor Go to Step (10)
Page 210 DTC 522739 Oxygen Sensor Short/Open Conditions for Setting the DTC 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.
Page 211 DTC 522739 Oxygen Sensor Short/Open Step Action Value(s) Did you perform the On-board diagnostics (OBD) Go to On- system check? Board Diagnostics Go to Step System Check/ Malfunction indicator lamp.  Key OFF, disconnect C018  Key ON, measure voltage from C018 pin D Repair open to ground.
Page 212 Step Action Value(s)  Remove all test equipment except the moni- tor.  Using the monitor, reset the adaptive learn.  Connect any disconnected components, fus- es, etc.  Using the monitor, clear DTC information Go to On- from the ECM. Board ...
Page 214 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.
Page 215 DTC 522752 Start Failure Due to Cam Signal Error Step Action Value(s)  Did you perform the On-board diagnostics Perform OBD Go to step 2 System check (OBD) system check?  Intermittent Check connections at C004, ECU-B pin M1, problem. Go M2, L1, and ECU-C pins A4 and F1.
Page 216 Step Action Value(s)  Remove all test equipment except the moni- tor.  Using the monitor, reset the adaptive learn.  Connect any disconnected components, fus- es, etc.  Using the monitor, clear DTC information from the ECM. Go to On- ...
Page 218 DTC 523821 Oil Lamp Circuit Open Conditions for Setting the DTC  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 ...
Page 219 DTC 523821 Oil Lamp Circuit Open Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System. Check Sec- tion Verify that the engine has oil and oil pressure using a mechanical oil pressure gauge before proceeding with this chart.
Page 220 Step Action Value(s) Replace ECM Go to Step Is the replacement complete?  Remove all test equipment except the DST.  Connect any disconnected components, fus- es, etc.  Using the DST clear DTC information from the ECM.  Turn the ignition OFF and wait 30 seconds. ...
Page 222 DTC 524260 5 Volt Power Supply 1 Out of Spec Conditions for Setting the DTC 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”...
Page 223 DTC 524260 5 Volt Power Supply 1 Out of Spec Step Action Value(s)  Go to On- Did you perform the On-board diagnostics Board Diag- (OBD) system check? nostics Go to Step System Check/Malfun ction indicator lamp.  Disconnect all sensors for the 5 volt supply showing the fault.
Page 224 Step Action Value(s)  Remove all test equipment except the moni- tor.  Using the monitor, reset the adaptive learn.  Connect any disconnected components, fus- es, etc.  Using the monitor, clear DTC information from the ECM. Go to On- ...
Page 226 DTC 524261 5 Volt Power Supply 2 Out of Spec Conditions for Setting the DTC 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”...
Page 227 DTC 524261 5 Volt Power Supply 1 Out of Spec Step Action Value(s) Did you perform the On-board diagnostics (OBD) Go to On- system check? Board Diag- nostics Go to Step System Check/Malfun ction indicator lamp.  Disconnect all sensors for the 5 volt supply showing the fault.
Page 228 Step Action Value(s)  Remove all test equipment except the moni- tor.  Using the monitor, reset the adaptive learn.  Connect any disconnected components, fus- es, etc.  Using the monitor, clear DTC information from the ECM. Go to On- ...
Page 230 DTC 524266 ETC Wire Shorted/Fail Conditions for Setting the DTC  Throttle Position Sensor  Check Condition-Ignition ON  Fault Condition-Actual and desired throttle position greater than 10%  Battery voltage greater than 9 volts  MIL-On during active fault Circuit Description Dual throttle position sensors (TPS) are used with the electronic throttle control (ETC) to determine throttle plate position.
Page 231 DTC 524266 ETC Wire Shorted/Fail Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Go to Step Check? System Check Section  Ignition ON  DST (Diagnostic Scan Tool) connected in data stream mode. Intermittent  Go to Step problem.
Page 232 Step Action Value(s) Using a DVOM check for continuity between Repair the electronic throttle connector pin 4 and ECU-B shorted TPS connector pin D3. circuit to Go to Step ground as ne- Does the DVOM show continuity? cessary. Refer to Wiring Re- pairs.
Page 233 Step Action Value(s)  Remove all test equipment except the DST.  Connect any disconnected components, fus- es, etc.  Using the DST clear DTC information from the ECM.  Turn the ignition OFF and wait 30 seconds.  Start the engine and run to full operating Go to OBD temperature.
Page 234 DTC 524286 ETC Wire Shorted/Fail Conditions for Setting the DTC  Throttle Position Sensor  Check Condition-Ignition ON  Fault Condition-Actual and desired throttle position greater than 10%  Battery voltage greater than 9 volts  MIL-On during active fault Circuit Description Dual throttle position sensors (TPS) are used with the electronic throttle control (ETC) to determine throttle plate position.
Page 235 DTC 524286 ETC Wire Shorted/Fail Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Go to Step Check? System Check Section  Ignition ON  DST (Diagnostic Scan Tool) connected in data stream mode. Intermittent  Go to Step problem.
Page 236 Step Action Value(s) Using a DVOM check for continuity between Repair the electronic throttle connector pin 5 and ECU-B shorted TPS connector pin M4. circuit to Go to Step ground as ne- (10) Does the DVOM show continuity? cessary. Refer to Wiring Re- pairs.
Page 237: Servicing The Fuel System
Servicing the Fuel System...
Page 238 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 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 1. Disconnect the negative battery cable 2.
Page 239 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.
Page 240 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.
Page 241 normal operating temperature. VII. FUEL TEMPERATURE/PRESSURE 8. If a DTC code is found, refer to the Electrical SENSOR Section for further diagnosis. VIII. ENGINE COOLANT TEMPERATURE SENSOR (ECT) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Drain the coolant. 3.
Page 242 INSTALLATION PROCEDURE IX. HEATED EXHAUST GAS OXYGEN SENSOR (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.
Page 243 XII. CHECKING/DRAINING OIL BUILD-UP IN THE LOW PRESSURE REGULATOR During the course of normal operation oil or A small amount of fuel may still be present “heavy ends” may build inside the secondary in the fuel line. Use gloves and proper eye chamber of the Regulator.
Page 244 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 1.
Page 245 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.).
Page 246 REMOVAL PROCEDURE 1. Relieve the LPG fuel system pressure. Refer to XVIII. LPG FUEL SYSTEM PRESSURE Contamination of the HEGO sensor can re- RELIEF. sult from the use of an inappropriate RTV Disconnect the negative battery cable. sealer or silicone spray products. Do not use 3.
Page 247 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 Install the Clip Retaining Fuel Injector (con- engine damage. necting it to the Injector Adapter). 4.
Page 248  Oil leaks XVIII. LPG FUEL SYSTEM PRESSURE RELIEF  Oil in the air cleaner  Sludge in the engine A leaking PCV orifice or hose may cause the fol- lowing problems: The LPG fuel system operates at pressure up to 21.5 bar (312 psi). To minimize per- ...
Page 249 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.
Page 250 IMPORTANT: XXII. FUEL VAPOR PORT FITTING The fuel cylinder manual valve contains an Excess Flow Check Valve. Open the manual REMOVAL valve slowly to prevent activating the Excess Flow Relieve the LPG fuel system pressure. Refer Check Valve. to XVIII. LPG FUEL SYSTEM PRESSURE 8.
Page 251 The HEGO is sensitive to silicone based products and can become contaminated. Avoid using silicone sealers/lubricants on any fuel or exhaust related components. 10. Reconnect negative battery cable. 11. Turn key to ON. 12. Check for leaks. If leaks are detected, make repairs.
Page 252 3. Install new Rotor Cap and secure with new XXVIII. VACUUM LINE Screws. Torque to 21 in.lbs. (2.4 Nm) 4. Connect the sensor harness connector. REMOVAL PROCEDURE 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.
Page 253 Fuel Filter and slide out. 7. Discard Fuel Filter. INSTALLATION PROCEDURE 1. Slide the Fuel Filter inside the cushioned clamp and tighten. Place clamps over hoses. 3. Connect hoses to the Fuel Filter. 4. Tighten hose clamps on Fuel Filter. 5.
Page 255: Lpg Parts Diagram
LPG Parts Diagram...
Page 256 THROTTLE BODY ASSEMBLY...
Page 257 MIXER AND THROTTLE BODY ASSEMBLY IMPCO Item # Description Part Number Screw, Hex Sck Cap S1-30295-0655 Washers, Conical Spring 6mm W1-31039-006 Throttle Body A7-324 Gasket, Throttle Body A7-245 Bracket, Fuel Rail Mount B4-51980-001...
Page 258 FUEL RAIL & INJECTORS...
Page 259 FUEL RAIL & INJECTORS IMPCO Item # Description Part Number Sensor, Fuel Rail Pressure A7-473 Screw, Hex Flange M6-1.0 x 35 mm P1-30559 Fuel Rail, 3.0L R8-51549-001 Pin, Retaining P1-30559 O-Ring, Inlet A7-657 Spacer, O-ring A7-656 Injector, LPG/CNG A7-654 O-ring, Adapter A7-655 Adapter, Fuel Injector A4-51981-001...
Page 260 REGULATOR ASSEMBLY...
Page 261 REGULATOR ASSEMBLY IMPCO Item # Description Part Number Regulator Assy (Fully Assembled with all parts) A7-434 Filter Kit (Includes 2, 6, 7, 8, 9) A7-170 Outlet Fitting Service Kit (Includes 3 & 4) A7-172 Screw Kit (Includes 3 screws) A7-176 Inlet Fitting w/O-Ring (Includes 10 &...
Page 262 HOSE ASSEMBLIES COOLANT/VACUUM/FUEL...
Page 263 HOSE ASSEMBLIES COOLANT/VACUUM/FUEL Item IMPCO Description Part Number Fitting, Port AF4-50733-001 Clamp, Oetiker C1-51552-07-170 Hose, Vacuum H1-19231-001 Hose 3/8” ID Fuel/Oil H1-19231-004 Hose, 5/8” Fuel/Oil H1-19231-006 Clamp, Ear Oetiker C2-51552-05-113 Pin, Retaining P1-30559 Clamp, Worm Drive 0130845 Clamp, Oetiker C1-51552-07-256 Hose, 5/8”...
Page 264 THERMOSTAT & HOUSING...
Page 265 THERMOSTAT & HOUSING Item # Description Part Number GM Part Number Bolt 90328100 09424320 Thermostat Housing 7142071 14096853 Gasket, Thermostat Housing 7140310 10105135 Thermostat 7140340 10220957...
Page 266 ENGINE CONTROL MODULE...
Page 267 ENGINE CONTROL MODULE Item Description IMPCO Part Number ECM, Liugong A11-173...
Page 268 SENSORS...
Page 269 SENSORS Qty. IMPCO GM Part Item # Description Used Part Number Number HEGO S8-50328-001 Crank Sensor S8-51822-001 12567712 Sensor, TMAP E1466001 Oil Pressure Switch S10-50352-001 Adapter, Oil Pressure Switch 7242360 Coolant Temp Switch 7144790 Adapter, Coolant Switch 7176570-06...
Page 270 DISTRIBUTOR...
Page 271 DISTRIBUTOR Item # Description Qty. Part Number Part Number Distributor 93442429 93442429 Distributor Cap 89060454 89060454 Rotor 7241620 10467546 Module/Sensor 7245370 10485432...
Page 272 FUSE BOX & BRACKET...
Page 273 FUSE BOX & BRACKET Item # Description Qty. Part Number Screw, Hex M4 x 16mm S1-30295-0416 Washer, Split Lock M4 W1-1988-003 Fuse Box Cover C1-52520-001 Bracket, ECM B4-51789-001 Screw, Hex Flange 90325088 Seal, Fuse Box S3-52522-001...
Page 274 IGNITION COIL...
Page 275 IGNITION COIL Item # Description Qty. Part Number Coil, Ignition 7245530...
Page 276 MANIFOLDS...
Page 277 MANIFOLDS Item # Description Qty. Part Number Gasket, Int/Ext 7152170 Manifold, Exhaust GM 3.0L 7152150 Stud, 3/8-16 x 2” S3-50596-001 Bolt, Socket Head 3/8 x 16 Grade 8 90368100 Washer, Belleville 3/8” W1-50595-037 Screw, Hex Flange M5-0.8 8x8 S1-50237-20-0508 Nut, Serrated N1-30876-037 Washer, 3/8 Type A Hard 92300101...
Page 278 WIRE HARNESS/FUSES/FUSE BOX COVER Fuse Box Layout...
Page 279 WIRE HARNESS/FUSES/FUSE BOX COVER Manufacturer Part Item # Description Part Number Number Cover Littelfuse 1520007Z Fuse 70A 1054112 Littelfuse 299070 Fuse Holder Littelfuse 1520004Z Wire Harness, 4 Cyl AW-50727-001 Auxiliary 10A Minifuse 914584 Littelfuse 297010 Power Fuse 20A Minifuse 7381270 Littelfuse 297020 Starter Fuse 20A Minifuse...
Page 280 PCV VENT & VALVE...
Page 281 PCV VENT & VALVE GM Part Item # Description Part Number Number Vent, Elbow F4-51936-001 06487779 Grommet oil filter cap G3-51937-001 14050440 V3-51806-001 06487779 Grommet, PCV Valve 7120140 14001875...
Page 282 MISCELLANEOUS ENGINE...
Page 283 MISCELLANEOUS ENGINE Item # Description Part Number Engine, MY 2011-2010GM 3.0L 7044670 Sensor, Crank S8-51822-001 Plug, 3/8” NPT Socket Head Brass P3-12 Fitting, Pipe Thread Reducer 7176570-06 Oil Filter PF454 7110851 Plug ½-14 NPT 7242360 Switch, Oil Pressure S10-50352-001 Spark Plug, R44LTS E10-50075 Plug, 14mm Fuel Rail Port P3-50597-001...
Page 284 ALTERNATOR...
Page 285 ALTERNATOR Item # Description Part Number 3/8”-16x1-1/2” Bolt Hx GR5 90305150 Washer, Lock 3/8” 93300000 Washer, Flat 3/8” 92300000 3/8-16x1 ¼” bolt Hx Gr5 90305125 5/16-18x1” Bolt Sched Grd 8 90268100 Sapcer, Fan Mount 3.0L 7143890 5/16-18x1 ¼” Bit Hx Gr5 90205125 Washer, Lock, M8 93200000...
Page 286 STARTER...
Page 287 STARTER Item # Description Part Number Bolt 7242530 Nut Hex M5 x 0.8 Brass 97111000 Washer, Lock Bronze 93003000 Nut, Hex M8 x 1.25 Brass 97331000 Washer, lock med M8 Zn 93930000 Starter Motor 7244520 Bracket, Starter 2kW 3.0L B4-52110-001 Nut Hex #10-24 95000000 Washer, Lock #10 Med...
Page 288 TOOL KIT & ACCESSORIES Standard Oetiker Pliers, IMPCO P/N 14100037 and Injector Test Lamp OTC-6023 (not included in any IMPCO ITK kit)
Page 289 TOOL KIT, IMPCO P/N ITK-4 Item Qty. Description IMPCO Part Number Used Test Kit Gauge 0-5 PSI (2-5205) TG-005 Test Kit-Gage 0-10" WC (2-5010) TG-010 Hose, 3/16" Id Vacuum, Bulk 1.5’ H1-11 Harness, Adapter Gen 2 DLC to Gen 1 DLC E1557400 Fitting Assembly, Test Cap (System II LPR AF4-31105...
Page 290 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...
Page 292 3.0L UPPER...
Page 293 3.0L UPPER Item # Description Part Number Cap, Oil 93802366 Bolt, Vlv 09439930 Reinforcement, Vlv Rkr Arm Cvr 03877670 Cover, Vlv Rkr Arm 02770089 Gasket, Vlv Rkr Arm Cvr 14096154 Rotator, Vlv 14042575 Key, Vlv Stem 24503856 Nut, Vlv Rkr Arm 12557390 Ball, Vlv Rkr Arm 93427660...
Page 294 3.0L LOWER...
Page 295 3.0L LOWER Part Num- Item # Description Ring Kit (STD) 88894219 Ring Kit (0.020” O.S.) 12361570 Ring Kit (0.030” O.S.) 14089026 Piston (w/Pin)(STD) 93442974 Piston (w/Pin)(0.020” O.S.) 93419821 Rod Connecting (Includes 4 & 6) 10108688 Bolt, Connecting Rod (Part of 3) 00461372 Bearing Kit, Connecting Rod (STD) 12493123...
Page 296 Item # Description Part Number Seal, Absorber, Cr/Shf Washer, External Tooth 00136857 Bolt, Cr/Shf Balancer 10126796 Nut, Oil Pan 12338130 Washer 09439510 Bolt, Oil Pan (1/4-20 x 1/2, 1/8 THD) 09442895 Plug, Oil Pan Drn See IMPCO Catalog Gasket, Oil Pan Drn Plug See IMPCO Catalog Pan, Oil 93419740...
Page 297 Item # Description Part Number Gear, Flywhl Ring (Part of 78) 03991408 Washer, Flywhl 00136857 Bolt, Flywhl (7/16”-20 x 31/32) 00839756 Bolt, Vlv Push Rod Cvr 03814350 Bearing, Clu Pilot 14061685 Flywheel, Eng (Includes 73) 93419731 Cover 93423830 Pin, Trans Loc (5/8 x 1 3/16) 01453658 Gasket, Vlv Push Rod Cvr 12378521...
Page 299: Labor Time Guide
Labor Time Guide...
Page 300 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-...
Page 301 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 These are the checks, tests and measurements Replace is used when the part or assembly is required to identify the cause of a failure and/or subject to replacement only.
Page 302 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...
Page 303 FUEL SYSTEM LABOR OPERATIONS Engine-Electrical OPERATION TIME LABOR OPERATION DESCRIPTION NUMBER ALLOWED ENGINE CONTROL MODULE (ECM)–REPLACEMENT E0050 ENGINE CONTROL MODULE (ECM)–REFLASH E0057 ENGINE WIRE HARNESS–REPAIR E1015 ENGINE WIRE HARNESS–REPLACEMENT E2015 PLUGS, SPARK–REPLACE ONE J4226 PLUGS, SPARK–REPLACE ALL J4227 WIRES, SPARK PLUG-REPLACE ALL J4207 COIL, IGNITION–REPLACEMENT J4340...
Page 304 FUEL SYSTEM LABOR OPERATIONS Engine-Sensors OPERATION TIME LABOR OPERATION DESCRIPTION NUMBER ALLOWED ENGINE OIL PRESSURE SENSOR–REPLACEMENT J4590 ENGINE COOLANT TEMP SENSOR AND/OR ADAPTER–REPLACE J4591 CAMSHAFT SENSOR-REPLACEMENT E3019 CRANK POSITION SENSOR –REPLACEMENT J4592 TEMP MANIFOLD PRESSURE SENSOR (TMAP)–REPLACEMENT F1015 FUEL TEMPERATURE/PRESSURE SENSOR–REPLACEMENT E3002 HEATED EXHAUST GAS OXYGEN SENSOR (HEGO)–REPLACEMENT N1002...
Page 305 FUEL SYSTEM LABOR OPERATIONS Fuel Delivery OPERATION TIME LABOR OPERATION DESCRIPTION NUMBER ALLOWED PRESSURE REGULATOR-REPLACEMENT M1001 INCLUDES: Transfer of all fittings PRESSURE REGULATOR REPAIR (SEE M1001 FOR REPLACEMENT) E3005 ADD: Allowance for the replacement of regulator port O-rings 0.3 FUEL FILTER, HIGH PRESSURE LIQUID-REPLACE E3041 FUEL FILTER, LOW PRESSURE VAPOR-REPLACE E3042...
Page 306 FUEL SYSTEM LABOR OPERATIONS Exhaust OPERATION TIME LABOR OPERATION DESCRIPTION NUMBER ALLOWED CATALYTIC CONVERTER–REPLACEMENT N1001 RESTRICTED EXHAUST SYSTEM DIAGNOSIS E3017 Hoses OPERATION TIME LABOR OPERATION DESCRIPTION NUMBER ALLOWED COOLANT HOSES–REPLACE ALL T1001 INCLUDES: Drain & Fill Radiator COOLANT HOSE PORT FITTING-REPLACE E3047 FUEL VAPOR HOSE—REPLACE ALL E3048...
Page 307 FUEL SYSTEM LABOR OPERATIONS Engine-Exterior Components OPERATION TIME LABOR OPERATION DESCRIPTION NUMBER ALLOWED WATER PUMP AND/OR GASKET-REPLACE J3480 STARTER–REPLACEMENT J4560 ALTERNATOR–REPLACEMENT J4570 DRIVE BELT–REPLACEMENT J4571 THERMOSTAT, AND/OR GASKET–REPLACEMENT J4580 FLYWHEEL/HARMONIC BALANCER–REPLACEMENT J0720...
Page 308 FUEL SYSTEM LABOR OPERATIONS Engine-Manifolds & Cylinder Head Components OPERATION TIME LABOR OPERATION DESCRIPTION NUMBER ALLOWED INTAKE MANIFOLD AND/OR GASKET-REPLACEMENT J0210 EXHAUST MANIFOLD AND/OR GASKET–REPLACEMENT J0108 VALVE COVER AND/OR GASKET-REPLACEMENT J0308 Includes: R&R intake manifold. ROCKER ARM–REPLACEMENT J0358 Includes: R&R intake manifold and rocker cover(s). ADD: Replace all rocker arms: STUD, VALVE ROCKER ARM BALL-REPLACEMENT J0388...
Page 309 FUEL SYSTEM LABOR OPERATIONS Engine–Internal Components OPERATION TIME LABOR OPERATION DESCRIPTION NUMBER ALLOWED TIMING COVER OIL SEAL–REPLACEMENT J0750 Includes: R&R balancer TIMING COVER AND/OR GASKET–REPLACEMENT J0780 Includes: R&R balancer TIMING CHAIN–REPLACEMENT J0820 ADD: Replace crankshaft gear CAMSHAFT TIMING GEAR–REPLACEMENT J0840 ADD: Replace crankshaft gear CAMSHAFT–REPLACEMENT J0850...
Page 310 FUEL SYSTEM LABOR OPERATIONS Engine–Internal Components OPERATION TIME LABOR OPERATION DESCRIPTION NUMBER ALLOWED BEARING, CONNECTING ROD–REPLACE ONE Includes: R&R engine oil pan and fluid, and use of plastic type gauge J1180 ADD: Replace connecting rod bearings Each additional (NOT to equal or exceed ALL) All rod bearings PISTON, ROD AND/OR RINGS–REPLACEMENT Includes: R&R all necessary components and use of plastic type gauge...
Page 311 ENGINE REPAIR OPERATIONS Engine–Replacement OPERATION TIME LABOR OPERATION DESCRIPTION NUMBER ALLOWED BLOCK, ENGINE FITTED–REPLACEMENT Includes: R& R all components, fluids and accessories J1800 ADD: To recondition all valves and guides ENGINE, PARTIAL–REPLACEMENT Includes: R& R all components, fluids and accessories J1820 ADD: To recondition all valves and guides ENGINE, ASSEMBLY–REPLACEMENT...
Page 312 MISCELLANEOUS OPERATION TIME LABOR OPERATION DESCRIPTION NUMBER ALLOWED ADDITIONAL DIAGNOSTIC TIME Policy “B” G0001 Subject to review by IMPCO Technical Support Policy “B” FASTENER OR FITTING TIGHTENING G0003 DRIVE TESTS G0006 SUBLET TIME Policy “S”* G0007 *Requires Prior Approval By IMPCO Technical Support; Policy “S”...
Page 313 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.
Page 314 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...
Page 315 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...
Page 316 LABOR TIME STUDY FORM Watch Time Step Labor Description (Min/Sec) (Attach additional sheets if necessary) Total Repair Time (minutes/seconds)
Page 317: Definitions
Definitions...
Page 318 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-...
Page 319 Knock: Sound produced when an engine’s air/fuel tane level is 89. mixture is ignited by something other than the Spectrum III (90-pin) ECM. spark plug, such as a hot spot in the combustion GCP: Greenhouse Effect: A scientiﬁc theory suggesting chamber.
Page 320 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.
Page 321 Spark Line: The portion of an oscilloscope pattern Technical Service Bulletin. TSB: that represents the time during which the air/fuel ULEV: Ultra Low Emission Vehicle. mixture is being burned in the combustion cham- Universal Serial Bus. A plug or interface sup- USB: ber.
Page 323: Appendix
Appendix...
Page 324 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...
Page 325 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.
Page 326 Extended ECT Temperature vs. Resistance Degrees F. Degrees C. Ohms±10% 1188 1459 1802 2238 2796 3520 4450 5670 7280 9420 12300 16180 21450 28680 52700 100700...
Page 327 DTC (SPN & FMI Chart)