Impco HHI Service Manual

2007-2009 lpg & bi 2.0l service manual hhi 2009 emission certified & bi-fuel system 2.0l engine

page of 485

/ 485
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

2007-2009

2009 Emission Certified

LPG & Bi

Emission Certified

& Bi-Fuel System

2.0L Engine

2.0L

Service Manual

Revision A/June, 2009

HHI

System

Table of Contents

Need help?

Do you have a question about the HHI and is the answer not in the manual?

Questions and answers

Summary of Contents for Impco HHI

Page 1 2007-2009 2009 Emission Certified Emission Certified LPG & Bi & Bi-Fuel System System 2.0L 2.0L Engine Service Manual Service Manual Service Manual Revision A/June, 2009...
Page 2: Table Of Contents
Table of Contents Table of Contents General Information..................................5 An overview of this Service Manual of this Service Manual Maintenance ....................................11 General maintenance and maintenance interval information General maintenance and maintenance interval information LPG Fuel System ..........................
Page 3 Servicing the Fuel System Servicing the Fuel System ........................457 Step by step instructions on how Step by step instructions on how repair and/or replace fuel related components omponents Definitions ....................................475 Definitions of phrases and acronyms used throughout this Service Manual Definitions of phrases and acronyms used throughout this Service Manual Definitions of phrases and acronyms used throughout this Service Manual Tool Kit &...
Page 5: General Information
General Information...
Page 6 IMPCO speci- fied parts will qualify for reimbursement. HOW TO IDENTIFY THE ENGINE YEAR Refer to the IMPCO Labor Time Guide for ad- ditional information. The 2.0L engine blocks have been stamped with a serial number. The number can be...
Page 7 GENERAL INFORMATION Gasoline IMPCO recommends the use of name brand Do not allow LPG to accumulate in high detergent gasoline. Gasoline is a mixture areas below ground level such as in a of many different hydrocarbons, including ole- service pit or underground ventilation fins, which are heavy, waxy compounds.
Page 8 Metric and Imperial fasten- or improper performance of the vehicle or a ers used in the installation of the IMPCO fuel component. system. Check to insure proper fit when using a socket or wrench on any fastener to prevent A “NOTE”...
Page 9 GENERAL INFORMATION Always leak check any fuel system connection after servicing! Use an electronic leak detector and/or a liquid leak detection solution. Failure to leak check could result in serious bodily injury, death, or serious property dam- age.
Page 11: Maintenance
Maintenance...
Page 12 MAINTENANCE SERPENTINE BELT SYSTEM The maintenance of an engine and related com- Serpentine belts utilize a spring-loaded tensioner ponents are critical to its operating performance to keep the belt properly adjusted. Serpentine and lifespan. Industrial engines operate in envi- belts should be checked according to the main- ronments that often include hot and cold tenance schedule in this section.
Page 13 COOLANT ENGINE CRANKCASE OIL Check coolant level in coolant recovery tank and OIL RECOMMENDATION coolant as required. Add 50/50 mixture of ethylene glycol antifreeze and distilled water or Select an engine oil that will best match the pre- coolant per engine manufacturer’s instructions. vailing daytime temperature: Do not add plain water.
Page 14 supplier do not review, approve or recommend CHANGING THE ENGINE OIL such products. IMPORTANT: SYNTHETIC OILS When changing the oil, always change the oil ﬁlter. Synthetic oils have been available for use in in- dustrial engines for a relatively long period of 1.
Page 15 9. Dispose of oil and ﬁlter in a safe manner. using a soapy solution or an electronic leak detector and repair if necessary. FUEL SYSTEM INSPECTION AND  Check to make sure ﬁlter is securely mounted. MAINTENANCE  Check ﬁlter housing for external damage or distortion.
Page 16 15. Connect the vacuum line. lem. IMPCO recommends the EPR be drained at 16. Reconnect the outlet hose and secure the every engine oil change if contaminated or subs- hose clamp.
Page 17 IMPORTANT: EXHAUST SYSTEM AND CATALYTIC The fuel cylinder manual valve contains an CONVERTER INSPECTION AND MAINTENANCE Excess Flow Check Valve. Open the manual valve slowly to prevent activating the Excess Flow Check Valve. IMPORTANT: The exhaust system on this emission certiﬁed en- 19.
Page 18 LPG & BI-FUEL CERTIFIED ENGINE MAINTENANCE REQUIREMENTS Perform the following maintenance on the engine at the hours indicated and at equivalent hour intervals thereafter. Interval Hours Daily 1000 1500 2000 2500 3000 3500 4000 4500 5000 General Maintenance Section Visual check for fluid leaks Check engine oil level Check coolant level Every 100 hours or 60 days of operation...
Page 19: Lpg Fuel System
LPG Fuel System...
Page 20 LPG FUEL SYSTEM OPERATION...
Page 21 DESCRIPTION AND OPERATION OF THE FUEL SYSTEMS LPG FUEL SYSTEM The primary components of the LPG fuel system are the Fuel Storage Tank, Electronic Pressure Typical LPG Cylinder Regulator (EPR), Fuel Mixer, Throttle Control De- vice, electric Shut-Off Valve, Engine Control Module (ECM), Oxygen Sensor and a Catalytic 1.
Page 22 FUEL FILTER Voltage to the LPG Shut-Off Valve is controlled by the engine control module (ECM). LPG, fuel like all other motor fuels is subject to contamination from outside sources. Refueling of ELECTRONIC PRESSURE REGULATOR (EPR) the equipment tank and removal of the tank from the equipment can inadvertently introduce dirt The EPR is a combination vaporizer and pressure and other foreign matter into the fuel system.
Page 23 The EPR is an emission control device The air/fuel mixer is an emission control and should only be serviced by qualified device. Components inside the mixer are technicians. specifically calibrated to meet the engine’s emissions requirements and should never AIR FUEL MIXER be disassembled or rebuilt.
Page 24 CATALYTIC CONVERTER Oxygen sensor (HEGO) mounted in the exhaust system. The HEGO sensor sends a voltage sig- The Catalytic Converter is a component of the nal to the controller which then outputs signals to emissions system which is designed and cali- the EPR to change the amount of fuel being deli- brated to meet the emission standards in effect vered from the regulator or mixer to the engine.
Page 25 TMAP SENSOR T–MAP Sensor The Heat Exhaust Gas Oxygen (HEGO) 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.
Page 26 changes. The sensor's output is monitored by the ECM to determine a cold start condition and to regulate various fuel and emission control functions via a closed loop emission system. OIL PRESSURE SENDER/SWITCH The Oil Pressure Switch is Mounted on the side of the Engine Block The Engine Oil Pressure switch or sender is de- signed to ensure adequate lubrication throughout...
Page 27 LPG Closed Loop Schematic...
Page 29: Lpg Fuel System Diagnosis
LPG System Diagnosis...
Page 30 LPG FUEL SYSTEM DIAGNOSIS The Electronic Pressure Regulator Assembly (EPR), Shown with Port Fittings and Shut-off Valve. FUEL SYSTEM DESCRIPTION is also generates lift for the mixer air valve and is commonly referred to as air valve vacuum. The Engine Control Module (ECM) receives in- Once in the mixer, the fuel is combined with air formation from various engine sensors in order and is drawn into the engine for combustion.
Page 31 TOOLS REQUIRED:  7/16” Open end wrench (for test port plugs)  Test port adapter  Straight Blade screw driver  Needle nose pliers  Diagnostic Scan Tool (DST) PRESSURE GAUGES  0-10” Water Column Gauge  0-10 PSI Gauge TEST DESCRIPTION The numbers below refer to step numbers on the Diagnostic Table:...
Page 32 LPG FUEL SYSTEM DIAGNOSTICS Step Action Value(s) Go to Were you referred to this procedure by a DTC diagnostic Chart? Go to Step 3 Step 2 Connect the Diagnostic Scan Tool (DST) to the ECM Data Link Go to appli- Go to Connector (DLC) and check for any DTCs.
Page 33 Step Action Value(s) If NO pressure was indi-  Connect a calibrated 0-5” PSI pressure gauge to the pri- cated, Go mary pressure test port of the EPR. to Step 14  Make sure the manual shut-off valve is open and turn the 2.0 –...
Page 34 Step Action Values  Insert the Secondary Pressure Test Adapter into the EPR port from which you removed the LPG Temp Sensor.  Connect a CALIBRATED 0-10” water column (WC) vacuum gauge or manometer to the secondary pressure test port of the EPR.
Page 35 Step Action Values Inspect the following for heavy-end deposits:  Electronic Pressure Regulator. Inspect, clean and/or repair as necessary (refer to EPR Repair Instructions).  Inspect the diaphragm through the Mixer air inlet for any de- Go to Step posits or contaminants. DO NOT disassemble the Mixer. The Mixer is calibrated and disassembly may alter its calibra- tion and adversely affect engine performance and/or emissions.
Page 36 Step Action Values Go to Step Was the Adaptive 1 fuel correction more than +15%? 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: ...
Page 37 ADDITIONAL STEPS Step Action Value(s) Go to Ap- Perform the On-Board Diagnostic (OBD) System check. plicable Go to Are any DTCs present in the ECM? DTC Ta- Step 2 Go to Fuel Go to Has the Fuel system diagnosis been performed? system Step 3 Diagno-...
Page 39: Lpg Symptom Diagnostics Tics
LPG Symptom Diagnostics...
Page 40 LPG 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 41 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 tables. 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 42 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 43: Gasoline Fuel System
NO START Checks Action Important: The LPG Fuel system is more sensitive to intake manifold lea- kage than the gasoline fuel system. Check for the following:  Vacuum leaks. Engine Mechanical  Improper valve timing. Checks  Low compression.  Improper valve clearance.
Page 44 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 vehicle’s operator is using the correct starting procedure. ...
Page 45 HARD START 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:  Vacuum leaks  Improper valve timing Engine Mechanical  Low compression Checks ...
Page 46 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 idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out. Preliminary Checks None 1.
Page 47 HESITATION, SAG, STUMBLE Checks Action DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition may cause the engine to stall if it’s severe enough. Preliminary Checks None.
Page 48 BACKFIRE Checks Action DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Preliminary Check None. Important! LPG, being a gaseous fuel, requires higher secondary igni- tion system voltages for the equivalent gasoline operating conditions. The ignition system must be maintained in peak condition to prevent backﬁre.
Page 49 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 partially applying the accelerator pedal.  Refer to the LPG Fuel system OBD System Check. ...
Page 50 POOR FUEL ECONOMY Checks Action DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Al- so, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by refueling records. ...
Page 51 ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING Checks Action DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine. Preliminary Check None.
Page 52 ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING Checks Action Check the engine for:  Broken motor mounts.  Improper valve timing.  Low compression. Engine Mechanical  Check Improper valve clearance.  Worn rocker arms.  Broken or weak valve springs. ...
Page 53 SURGES/CHUGGLES Checks Action DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accelerator pedal. Preliminary Checks None. Sensor Checks Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance. ...
Page 55: Gasoline Fuel System
Gasoline Fuel System...
Page 56 GAS FUEL SYSTEM OPERATION...
Page 57 GASOLINE MULTIPORT FUEL INJECTION as indicated in the Recommended Maintenance SYSTEM (MFI) Schedule. A more frequent replacement of the ﬁlter may be required if the equipment operates in a dus- The primary components of the Gasoline Multiport ty or dirty environment. Fuel Injection (MFI) fuel system are the gasoline fuel tank, electric fuel pump, fuel ﬁlter, fuel rails, FUEL METERING BODY AND PRESSURE...
Page 58 Wire (DBW) application, there is no direct mechani- cal connection between the operator pedal and the throttle shaft. Speed and load control are deter- mined by the ECM. Defaults programmed into the ECM software and throttle position sensors allow the ECM to maintain safe operating control over the engine.
Page 59 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, the MIL light can be used to identify the diagnostic code to activate the “blink”...
Page 60 determine engine load (the vacuum drops COOLANT TEMPERATURE SENSOR when the engine is under load or at wide open throttle). When the engine is under load, The Engine Coolant Temperature sensor or ECT the computer may alter the fuel mixture to im- is a variable resistance thermistor that changes prove performance and emissions.
Page 61 Gasoline Closed Loop Control Schematic...
Page 63: Gasoline Fuel System Diagnosis
Gasoline System Diagnosis...
Page 64 GASOLINE SYSTEM DIAGNOSIS Gasoline Injection Systems FUEL SYSTEM DESCRIPTION used fuel is returned to the fuel tank by a sepa- rate return fuel line. The fuel pump pressure The Engine Control Module (ECM) receives in- test port is located on the fuel rail. formation from various engine sensors in order DIAGNOSTIC AIDS to control the operation of the fuel injectors.
Page 65 4. Connect fuel pressure gage (Refer to the Fuel Injection Pressure Tester Owner’s Ma- NOTICE: Do not allow the pressure to ex- nual supplied in the IMPCO Test Kit for ceed TBD kPa (TBD psi) as damage to the fuel pressure regulator may result.
Page 66 GASOLINE FUEL SYSTEM DIAGNOSTIC CHART Step Action Value(s) Did you perform the On Board (OBD) System Go to OBD Go to Step Check? System Check Section Important: Inspect the fuel system for damage or Check all sys- external leaks before proceeding with this diag- tem power nostic.
Page 67 Step Action Value(s)  Operate the vehicle within the conditions of the customer concern. Refer to the  Go to Step Monitor the adaptive parameters with the symptom diag- (15) nostic charts Do any of the DST readings indicate a lean con- dition? ...
Page 68 Step Action Value(s)  Inspect the engine fuel return pipe and the Go to Step Go to Step chassis fuel return pipe for a restriction. (23) (21) Did you find and correct the condition?  Turn OFF the ignition.  Relieve the fuel pressure.
Page 69 Step Action Value(s)  Open the fuel return pipe shut-off valve.  Remove the upper intake manifold. Install the engine compartment fuel feed and fuel return pipes to the fuel meter body. Go to Step Go to Step  (21) (19) Turn ON the ignition, with the engine OFF.
Page 71: Gasoline Symptom Diagnostics Symptom Diagnostics
Gasoline Symptom Diagnostics...
Page 72 GAS SYMPTOM DIAGNOSTICS Checks Action Before using this section, you should have performed On Board Diagnostic 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 73 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 tables. If a fault is an intermittent, the use of the DTC Preliminary Checks tables may result in the replacement of good parts.
Page 74 NO START Checks Action DEFINITION: The engine cranks OK but does not start. Preliminary Checks None. Using the DST:  Check for proper communication with both the ECM  Check all system fuses located in the engine fuse holder. Refer to En- ECM Checks gine Controls Schematics.
Page 75 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 vehicle’s operator is using the correct starting procedure. ...
Page 76 HARD START Checks Action Check the exhaust system for a possible restriction:  Inspect the exhaust system for damaged or collapsed pipes. Exhaust System Checks  Inspect the muffler for signs of heat distress or for possible internal failure.  Check for possible plugged catalytic converter. Refer to Restricted Ex- haust System Diagnosis.
Page 77 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 idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out. Preliminary Checks None.
Page 78 HESITATION, SAG, STUMBLE Checks Action DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition may cause the engine to stall if it’s severe enough. Preliminary Checks None.
Page 79 BACKFIRE Checks Action DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Preliminary Check None.  Check for the proper primary ignition coil wire output voltage using the spark tester J26792 or the equivalent. ...
Page 80 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 partially applying the accelerator pedal.  Refer to the Gas Fuel system OBD System Check. ...
Page 81 POOR FUEL ECONOMY Checks Action DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Al- so, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by refueling records. ...
Page 82 ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING Checks Action DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine. Preliminary Check None.
Page 83 SURGES/CHUGGLES Checks Action DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accelerator pedal. Preliminary Checks None. Sensor Checks Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance. ...
Page 85: Electrical Section
Electrical Section...
Page 87: Diagnostic Scan Tool
Diagnostic Scan Tool...
Page 88 CONTENTS  Installation of the DST package to a personal computer (PC).  Software login and password functionality.  DST service pages.  Updating the ECM calibration using a MOT file.  DTC pages. Examples and snapshots used in this manual are based off of the initial DST tool release as of July, 2007. This tool is frequently updated and the illustrations may vary depending on the changes included in any updated DST display Interface.
Page 89  Open the DST_Series III folder  Open the Latest_GCP_Display folder...
Page 90  Double click on “setup.exe” (application file) to start the windows installer. If a previous version of the GCP software is installed, the uninstaller may remove the previous version and exit. You will be required to start the installer again to install the new version. ...
Page 91  Click “Next” to continue  Click “Next” to continue...
Page 92  Click the “Finish” box to complete the installation.  Click “Yes” to restart your computer...
Page 93  Once installed, the software can be accessed from Start Menu →Programs → Impco GCP Display → Impco GCP Display...
Page 94 INSTALLING THE USB ADAPTER DRIVER If your computer does not have an RS232 serial port you will need to install the USB adapter driver. You do not need to install this driver if you plan to use the ECOM DLC cable. ...
Page 95  Open the “USB Driver” folder  Double click on “setup.exe” (application file) and follow the on screen prompts. Installing the ECOM DLC cable driver The ECOM USB cable is designed to replace both the serial DLC and the USB adapter cables. It also provides communication to the ECM on the CAN line for systems that are CAN enabled.
Page 96  Double click on “setup.exe” (application file).  Click “Next” to continue...
Page 97  Select install ECOM drivers only. Click “Next” and follow the on screen prompts.
Page 98 PASSWORD LOGIN Figure 1 shows the password dialog box, which is displayed when a software session begins. Login can be accomplished in two ways. 1. Enter an “All S/N Password” which is a password applicable to all ECMs of a given original equip- ment manufacturer (OEM).
Page 99 PASSWORD DIALOG BOX FUNCTIONS  Clear Password Button Erases the current password from the password field.  Paste Password Button Allows the user to copy a 16-character string from any word processor and paste the string in the password field. ...
Page 100 If the Single S/N password entered is correct for the software but does not match the entered S/N of the targeted ECM, the prompt in Figure 3 will be displayed. Figure 3: Incorrect Serial Number Message Figure 4 shows the communication status if a valid software password is entered when attempting to connect to an ECM with a different key.
Page 101  Connect the system diagnostic cable to the RS232 port on the back of the computer. If you do not have a RS232 port, use the USB to RS232 adapter supplied in the IMPCO ITK test kit. Be sure to install the USB driver to enable the USB adapter for use with your computer.
Page 102  You will now need to configure the ECOM communication protocol.  Select the CAN for systems with CAN enabled or serial for all others. Then select OK. You are now ready to connect using the ECOM USB DLC cable.
Page 103 DST SERVICE PAGES Gauge Page Provides system data in large easy to read displays. Displays ECM configuration information for the ECM software, hardware, serial numbers and calibration dates.
Page 104 Raw Volts Page The raw volts page displays the sensor inputs and outputs in a raw voltage format. This page is most commonly used to check values in the diagnostic trouble shooting charts. Service 1...
Page 105 The Service 1 screen is used to clear the adaptive learn, shows the MIL status and provides a display for rpm, coolant temperature and spark advance. It also provides a large display to monitor the closed loop mixture control. Tests Page Provides diagnostic information voltages and sensor outputs and includes diagnostic engine tools such as spark and injector kill controls.
Page 106 INJECTOR KILL The Injector Kill mode is used to disable individual fuel injectors. If the Injector Kill mode is selected with the engine running below 1000 rpm, the minimum throttle command will lock into the position it was in when the test mode was entered. If the Injector Kill mode is selected with the engine running above 1000 rpm, the throttle will continue to operate normally.
Page 107 Faults Page Stores DTC codes that may have occurred in the past (Historic Faults) or current set codes (Active Faults). Includes useful system voltages and sensor readings used while working with the fuel and emission trouble shooting charts. Shows power derate mode status. To erase a historic DTC code, double click on the code with the left mouse button.
Page 108 Figure 5: Tagged Variables for Plot/Log Once the variables have been tagged as highlighted by the green color fill, select the “Plot/Log” func- tion in the top menu bar as shown below in figure 6. Figure 6...
Page 109  Select “Plot Tags” to open the snapshot window Other functions available from the Plot/Log menu include:  Clear Tags: Releases all plot/log variables.  Plot Tags (Ctrl + P, or P): Graphically plot all tagged variables.  Load Plot Setup: Loads and tags variables for plotting/logging that have been stored in a plot file (.plt).
Page 110 Start plot Variable selector Figure 7: DST Plot  Click on the “Start” button to start the DST plot function.  Click on the variable selector button to view selected sensors...
Page 111 Figure 8: DST Plot Snapshot  Click on the “Save” button to save the snapshot as a file. To replay the saved file, open the edis_saplot program from the windows start menu.
Page 112  Start Menu → Programs → Impco GCP Display → edis_saplot DST PLOT INTERFACE FUNCTIONS A graphic tool incorporated in the plotter is the snapshot function. This function allows data collected in a plot to be transferred into a second window for quick graphical post-processing. The snapshot allows the user to zoom in/out, pan left/right, and move cursors along the signal traces to measure the variable val- ues in virtual real-time.
Page 113 DST LOGGER Another data capture function incorporated in the software is the DST logger. This tool serves as a PC data logger for any variable available in the ECM through the interface software. Figure 9 shows the in- terface display for configuring the DST Log. The interface allows the user to create the filename, set the sample rate for acquisition, set the time interval for sampling, and display the progress of acquisi- tion.
Page 114  Turn the ignition key to the ON position.  Verify the DST is “connected” to the ECM.  From the “File” menu select “Reprogram target.”  Navigate to the media where you have stored the MOT file. In the example above the MOT file was stored on the on the floppy (A) drive.
Page 115  Click “Yes” to continue.  Click the “Yes” box to continue with the update. Refrain from using other functions on the computer while the download takes place. Do not disconnect the DLC, remove power or use the PC for any other func- tion during this process.
Page 116 Message is displayed confirming the update was successful.
Page 117 MALFUNCTION INDICATOR LAMP (MIL) The Spectrum Fuel system has built-in diagnostics for system trouble shooting. The system has a dash mounted malfunction indicator lamp (MIL) that provides indications of an emissions related problem. Most engine control system related problems that affect emissions or drivability of the vehicle will set a (DTC) diagnostic trouble code and illuminate the MIL.
Page 118 DLC COMMUNICATION ERROR The ECM 5 volt reference circuit powers the Spectrum diagnostic link cable. In the event that the 5 volt reference signal is open or shorted to ground, you will not be able to connect to the system. If you are unable to connect, follow the quick checks listed below: Be sure you are using the correct password and latest software for the system you are connecting to.
Page 119 Diagram 1 When using the DST program to clear a DTC, always select the “Clear All Faults” function to imme- diately turn the MIL OFF after a successful repair (as shown in diagram 1 above). 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.
Page 121: Wire Schematic
Engine Wire Schematic...
Page 122 HHI 2007-2009 Emission Certified LPG & Bi-Fuel System 2.0L Engine...
Page 123 HHI 2007-2009 Emission Certified LPG & Bi-Fuel System 2.0L Engine Connector Manufacturer Description Type Manufacturer Remarks Number (CN) Number Female 90P 900901-00 Gold Pin Female 3P 85205-3 Electronic Throttle Control Female 6P 1-967616-1 TMAP Female 4P 368162-1 Female 3P KBP016-0327...
Page 125: Engine Wire Harness Repair
Engine Wire Harness Repair...
Page 126 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 prop- er part number harnesses. When wires are Unwrap aluminum/Mylar tape.
Page 127 METRI-PACK REPAIRING TWISTED LEADS Some connectors use terminals called Metri-Pack Series 150. They are also called “Pull-To-Seat” terminals because of the method of installation. The wire is inserted through the seal and connector, the terminal is crimped on the wire and then pulled back Locate Damaged Wire.
Page 128 WEATHER-PACK TERMINAL REPAIR backup, or secondary locking feature for the connec- tor. They are used to improve the connector reliability by retaining the terminals, if the small ter- minal lock tabs are not positioned properly. Weather-Pack connections cannot be replaced with standard connections.
Page 129: Diagnostic Trouble Codes (Dtcs) Ic Trouble Codes (Dtcs)
Diagnostic Trouble Codes (DTCs)
Page 130 DTC 16-Never Crank Synced at Start Conditions for setting the DTC  Crankshaft Position sensor  Check Condition-Engine cranking  Fault Condition-Cranking rpm above 90 and more than 4 cranking revolutions without syn- chronization  MIL Command-ON Circuit Description The Crankshaft position sensor is a 5 volt powered sensor mounted in the engine block. A pulse wheel located on the crankshaft is used to measure engine rpm and its signal is used to synchronize the ignition and fuel systems.
Page 131 DTC 16-Never Crank Synced at Start Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Check? Go to Step System Check Sec- tion Repair the  Check that the ECM ground terminal CN28 is circuit as ne- clean, tight and in the proper location.
Page 132 Step Action Value(s)  Replace CKP sensor Go to Step (10) Is the replacement complete?  Replace ECM Go to Step (11) Is the replacement complete?  Remove all test equipment except the DST.  Connect any disconnected components, fus- es, etc.
Page 134 DTC 92-FRP High Voltage (Bi-fuel/Gasoline Only) Conditions for Setting the DTC   Fuel pressure check  Check condition-engine running  Fault Condition-FP voltage greater than 4.80 volts  MIL-On  Adaptive-disabled Circuit Description The FRP (fuel rail pressure) sensor is a combined temperature and pressure sensor located in the gasoline delivery system that provides accurate gasoline supply information to the ECM.
Page 135 DTC 92-FRP High Voltage (Bi-fuel/Gasoline Only) Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON Intermittent  DST (Diagnostic Scan Tool) open in System problem Greater than Go to Step Data Mode...
Page 136 Step Action Value(s)  Key OFF  Repair the Disconnect the ECM wire harness connector circuit as ne- Go to Step cessary. See  Check for continuity on the sensor ground wire harness circuit 120 between FRP sensor connector repair sec- CN16 and ECM connector CN1 tion.
Page 138 DTC 107-TMAP Low Voltage Conditions for Setting the DTC  Manifold Absolute Pressure Sensor  Check Condition-Engine cranking or running  Fault Condition-MAP voltage less than 0.050 with throttle position greater than 5.0% and en- gine RPM less than 4000 ...
Page 139 DTC 107-MAP Low Voltage Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine running.  Intermittent DSC (Diagnostic Scan Tool) connected in System Data Mode problem Go to Step Go to Inter-...
Page 140 Step Action Value(s) Repair the  Check for continuity on MAP sensor circuit as ground circuit 120 between MAP sensor necessary. Go to Step connector CN4 and ECM connector CN1 Refer to Wir- (17) ing Repairs in Engine Do you have continuity between them? Electrical.
Page 141 Step Action Value(s) Repair the  Check for continuity between MAP sensor circuit as connector CN4 signal circuit 123 and en- necessary. Go to Step gine ground Refer to Wir- (15) ing Repairs in Engine Do you have continuity? Electrical. Repair the ...
Page 142 DTC 108-MAP High Pressure Conditions for Setting the DTC   MAP pressure check  Check condition-engine running  Fault Condition-MAP greater than 16.00 psia with TPS less than 3.0% and RPM greater than 1000  MIL-On  Adaptive-disabled Circuit Description The Manifold Absolute Pressure sensor is a pressure transducer connected to the intake mani- fold.
Page 143 DTC 108-MAP High Pressure Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine running at full operating temperature. Intermittent  DST (Diagnostic Scan Tool) connected in the problem System Data Mode Go to Step...
Page 144 Step Action Value(s) Repair the  Disconnect ECM connector C001 circuit as ne-  Check for continuity on sensor ground circuit cessary. 120 between MAP sensor connector CN4 Go to Step Refer to Wir- and ECM connector CN1 ing Repairs in Engine Elec- Do you have continuity between them? trical.
Page 146 DTC 111-IAT Higher Than Expected 1 Conditions for Setting the DTC  Intake Air Temperature  Check Condition-Engine Running  Fault Condition-Intake Air Temperature greater than 200 degrees F. with engine rpm great- er than 1000  MIL-On  Adaptive-Disabled during active fault ...
Page 147 DTC 111-IAT Higher Than Expected 1 Diagnostic Aid  This fault will set when inlet air is much hotter than normal. The most common cause of high inlet air temperature is a problem with the inlet air system. Ensure that the air inlet is not obstructed, modified or damaged.
Page 148 DTC 112-IAT Low Voltage Conditions for Setting the DTC  Intake Air Temperature  Check Condition Engine Cranking or Running  Fault Condition-IAT Sensor Voltage less than 0.050  MIL-On during active fault  Adaptive-Disabled during active fault Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor.
Page 149 DTC 112-IAT Voltage Low Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On Intermittent  DST (Diagnostic Scan Tool) connected in problem Go to Step Go to Inter- System Data Mode mittent...
Page 150 Step Action Value(s)  Replace ECM. Refer to ECM replacement in the Engine Controls Section. 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.
Page 152 DTC 113-IAT Voltage High Conditions for Setting the DTC  Intake Air Temperature  Check Condition-Engine Running  Fault Condition-IAT Sensor Voltage greater than 4.95 volts  Adaptive-Disabled during active fault Circuit Description The TMAP is a combined IAT (Intake Air Temperature) and MAP (Manifold Absolute Pressure) sensor.
Page 153 DTC 113-IAT Voltage High Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On Intermittent  DST (Diagnostic Scan Tool) connected in problem Go to Step System Data Mode Go to Inter- mittent...
Page 154 Step Action Value(s)  Replace the ECM. Go to Step (11) Is the replacement complete?  Repair the Re-check wire harness and TMAP sensor circuit as ne- connector for damage corrosion or contami- cessary. nation Go to Step Refer to Wir- ing Repairs in Any problems found? Engine Elec-...
Page 156 DTC 116-ECT/CHT Higher Than Expected 1 Conditions for Setting the DTC ECT Sensor  Engine Coolant Temperature Resistance Scaling  Check Condition-Engine Running Ohms  Temp(deg F) Fault Condition-ECT greater than 230 F ±10%  MIL-On during active fault 248.0 ...
Page 157 DTC 116-ECT/CHT Higher Than Expected 1 Diagnostic Aid  Thoroughly inspect the entire cooling system and for any signs of coolant leakage including: coolant lines and hoses, water pump, engine block, radiator, etc.  Insure the radiator cap is in good repair and maintaining suitable cooling system pressure. ...
Page 158 DTC 117-ECT/CHT-Low Voltage Conditions for Setting the DTC  ECT Sensor Engine Coolant Temperature Resistance Scaling  Check Condition-Engine Running  Fault Condition-ECT sensor voltage less than 0.10 Ohms Temp(deg F)  ±10% MIL-On during active fault  Adaptive-Disabled during active fault 248.0 230.0 Circuit Description...
Page 159 DTC 117-ECT/CHT Low Voltage Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On Intermittent  DST (Diagnostic Scan Tool) connected in problem Go to Step System Data Mode Go to Inter- mittent...
Page 160 Step Action Value(s)  Replace ECM. Refer to ECM replacement in the Engine Controls Section. 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.
Page 162 DTC 118-ECT/CHT High Voltage Conditions for Setting the DTC ECT Sensor  Engine Coolant Temperature Resistance Scaling  Check Condition-Engine Running Ohms  Temp(deg F) Fault Condition-ECT sensor voltage exceeds 4.90 volts ±10%  MIL-On during active fault 248.0  Adaptive-Disabled 230.0 212.0...
Page 163 DTC 118-ECT/CHT Voltage High Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step Go to Inter- mittent...
Page 164 Step Action Value(s)  Jump the ECT connector CN5 signal circuit 137 at the ECT connector to engine ground Go to Step Go to Step (12) Does DST display ECT voltage of 0.10 or less?  Key OFF Repair the ...
Page 165 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 operate the vehicle to Go to OBD full operating temperature System OK...
Page 166 DTC 121-TPS 1 Lower Than TPS 2 C irc u it W ire E le c tro n ic T h ro ttle E C M C o lo r 1 8 0 D B W + M o to r 1 8 2 D B W - 1 4 7...
Page 167 DTC 121-TPS 1 Lower Than TPS 2 Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check Check? Section  Key ON, Engine OFF  Intermittent DST (Diagnostic Scan Tool) connected in Go to Step problem System Data Mode...
Page 168 Step Action Value(s)  Key OFF Repair the  Disconnect ECM wire harness connector open circuit as necessary.  Go to Step Using a DVOM check for continuity on the Refer to Wir- TPS 1 circuit 147 between throttle connector ing Repairs in CN3 and ECM connector CN1 Engine Elec-...
Page 170 DTC 122-TPS 1 Signal Voltage Low E le c tro n ic T h ro ttle C irc u it W ire E C M C o lo r 1 8 0 D B W + 1 8 0 M o to r 1 8 2 D B W - 1 8 2...
Page 171 DTC 122-TPS 1 Signal Voltage Low Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check Check? Section  Key ON, Engine OFF  DST (Diagnostic Scan Tool) connected in Go to Step DBW (Drive by Wire) throttle test mode Go to Step (3) Does the DST display TPS 1 voltage of 0.200...
Page 172 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 operate the vehicle to Go to OBD full operating temperature System OK...
Page 174 DTC 123-TPS 1 Signal Voltage High C irc u it W ire E le c tro n ic T h ro ttle E C M C o lo r 1 8 0 D B W + M o to r 1 8 2 D B W - 1 4 7...
Page 175 DTC 123-TPS 1 Signal Voltage High Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check Check? Section  Key ON, Engine OFF  DST (Diagnostic Scan Tool) connected Go to Step Go to Step (3) Does the DST display TPS 1 voltage of 4.800 volts or greater with the throttle closed?
Page 176 Step Action Value(s)  Key OFF Repair the  Disconnect ECM connector C001 circuit as ne-  Using a DVOM check for continuity on the cessary. Refer Go to Step sensor ground circuit 120 between the elec- to Wiring Re- tronic throttle connector CN3 and ECM pairs in connector CN1.
Page 178 DTC 127-IAT Higher Than Expected 2 Conditions for Setting the DTC  Intake Air Temperature  Check Condition-Engine Running  Fault Condition-Intake Air Temperature greater than 210 degrees F. with engine speed greater than 1000 rpm  MIL-On for active fault ...
Page 179 DTC 127-IAT Higher Than Expected 2 Diagnostic Aid  This fault will set when inlet air is much hotter than normal. The most common cause of high inlet air temperature is a problem with the inlet air system. Ensure that the air inlet is not obstructed, modified or damaged. ...
Page 180 DTC 129-BP Low Pressure Conditions for Setting the DTC  Barometric Pressure  Check Condition-Key On  Fault Condition-BP less than 8.30 psia  MIL-On for active fault  Adaptive-Disabled Circuit Description The BP (Barometric Pressure) is estimated from the TMAP sensor. The barometric pressure value is used for fuel and airflow calculations.
Page 181 DTC 129-BP Low Pressure Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On. Intermittent  DST (Diagnostic Scan Tool) connected in problem Go to Step System Data Mode Go to Inter- mittent...
Page 182 Step Action Value(s)  Probe TMAP connector signal circuit 123 with a test light connected to battery voltage Go to Step Go to Step (13) Does the DST display BP pressure of 16.00 psia or greater?  Key OFF Repair the ...
Page 183 Step Action Value(s) Repair the  Inspect ECM connector and wire harness circuit as ne- connector pins for corrosion, contamination cessary. Go to Step or mechanical damage Refer to Wir- (16) ing Repairs in Engine Elec- Any problems found? trical. ...
Page 184 DTC 134-EGO 1 Open/Inactive Conditions for Setting the DTC  Heated Oxygen Sensor  Check condition-Engine running  Fault condition-EGO 1 pre catalyst persistently cold for more than 55 seconds  MIL-On during active fault  Adaptive-Disabled during active fault ...
Page 185 DTC 134-EGO 1 Open/Inactive Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine Running  DST (Diagnostic Scan Tool) connected in Intermittent System Data Mode problem.
Page 186 Step Action Value(s) Correct the  Inspect wire harness connector CN5 pins problem as and CN1 pins for damage, corrosion or con- required see Go to Step tamination Electrical Section wire harness re- Did you find a problem? pair  Replace ECM Go to Step (11)
Page 188 DTC 154-EGO 2 Open/Inactive Conditions for Setting the DTC  Heated Oxygen Sensor  Check condition-Engine running  Fault condition-EGO 2 post catalyst sensor cold persistently more than 55 seconds  MIL-On during active fault  Adaptive-Disabled during active fault ...
Page 189 DTC 154-EGO 2 Open/Inactive Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine Running  DST (Diagnostic Scan Tool) connected in Intermittent System Data Mode problem.
Page 190 Step Action Value(s)  Replace ECM Go to Step (11) Is the replacement complete?  Key OFF  Disconnect ECM wire harness connector  Go to Step Repair open Using a DVOM check for continuity on circuit EGO 2 circuit 122 between EGO 2 connector CN12 and ECM connector CN1 Do you have continuity?
Page 192 DTC 171-Adaptive Learn High (Bi-Fuel/Gasoline Only) Conditions for Setting the DTC  Heated Oxygen Sensor  Check Condition-Engine Running  Fault Condition-Adaptive multiplier out of range greater than 30%  MIL-On Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas.
Page 193 DTC 171-Adaptive Learn High (Bi-Fuel/Gasoline Only) Step Action Value(s)  Perform the On-Board (OBD) System Check? Go to Step Go to Step Are any other DTCs present? Visually and physically check the following items:  The air intake duct for being collapsed or re- stricted ...
Page 194 Step Action Value(s) Repair the  Using a high impedance DVOM check for shorted circuit continuity between EGO 1 connector signal as necessary. ground circuit 120 and EGO 1 signal circuit Go to Step Refer to Wir- ing Repairs in Engine Elec- Do you have continuity? trical.
Page 196 DTC 172-Adaptive Learn Low Gasoline (Bi-Fuel/Gasoline Only) Conditions for Setting the DTC  Heated Oxygen Sensor  Check Condition-Engine Running  Fault Condition-Adaptive multiplier out of range greater than 30%  MIL-On Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas.
Page 197 DTC 172-Adaptive Learn Low Gasoline (Bi-Fuel/Gasoline Only) Step Action Value(s)  Perform the On-Board (OBD) System Check? Go to Step Go to Step Are any other DTCs present? Visually and physically check the following items:  The air intake duct for being collapsed or re- stricted ...
Page 198 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 operate the vehicle to full Go to OBD operating temperature System OK...
Page 200 DTC 182-FRT Voltage Low (Gasoline/Bi-Fuel Only) Conditions for Setting the DTC  Fuel Rail Temperature  Check Condition-Engine Running  Fault Condition-FT sensor voltage less than 0.050 volts Rail Sensor Temp Resistance  MIL-On in Ohms Degrees Degrees  Adaptive-Disabled (±...
Page 201 DTC 182-FRT Voltage Low (Gasoline/Bi-Fuel Only) Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On Intermittent  DST (Diagnostic Scan Tool) connected in problem Go to Step System Data Mode Go to Inter- mittent...
Page 202 Step Action Value(s)  Replace ECM. Refer to ECM replacement in the Engine Controls Section. 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.
Page 204 DTC 183-FRT Voltage High (Gasoline/Bi-Fuel Only) Conditions for Setting the DTC  Fuel Rail Temperature  Check Condition-Engine Running  Fault Condition-FT sensor voltage exceeds 4.90 Rail Sensor Temp Resistance  MIL-On in Ohms Degrees Degrees  Adaptive-Disabled during active fault (±...
Page 205 DTC 183-FT Voltage High (Gasoline/Bi-Fuel Only) Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On Intermittent  DST (Diagnostic Scan Tool) connected in problem Go to Step System Data Mode Go to Inter- mittent...
Page 206 Step Action Value(s)  Jump the fuel temperature sensor connector signal circuit 138 to engine ground Go to Step Go to Step (12) Does DST display FT voltage of 0.05 or less?  Key OFF Repair the  Disconnect ECM wire harness connector circuit as ne- cessary.
Page 207 Step Action Value(s)  Replace ECM Go to Step (14) Is the replacement complete?  Key OFF Repair the cir-  Disconnect ECM wire harness connector CN1 cuit as  Using a DVOM check for continuity between necessary. Go to Step (13) the fuel temperature connector CN16 signal Refer to Wiring circuit 138 and ECM connector circuit 138...
Page 208 DTC 187-LP Temp Voltage Low Conditions for Setting the DTC  LP Temperature  Check Condition-Engine Running  Fault Condition-FT sensor voltage less than 0.050 volts  MIL-On  Adaptive-Disabled Circuit Description LP Sensor Resistance The LP Temp (Fuel Temperature) sensor is a temperature sensi- Temperature in Ohms tive resistor located near the fuel outlet of the electronic pressure...
Page 209 DTC 187-LP Temp Voltage Low Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On Intermittent  DST (Diagnostic Scan Tool) connected in problem Go to Step System Data Mode Go to Inter- mittent...
Page 210 Step Action Value(s)  Replace ECM. Refer to ECM replacement in the Engine Controls Section. 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.
Page 212 DTC 188-LP Temp Voltage High Conditions for Setting the DTC  LP Temperature  Check Condition-Engine Running  Fault Condition-FT sensor voltage exceeds 4.90  MIL-On  Adaptive-Disabled during active fault Sensor Resistance Temperature in Ohms Circuit Description Degrees F. ( ±...
Page 213 DTC 188-LP Temp Voltage High Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On Intermittent  problem DST (Diagnostic Scan Tool) connected in Go to Step Go to Inter- System Data Mode mittent...
Page 214 Step Action Value(s)  Jump the fuel temperature sensor connector signal circuit 139 to engine ground Go to Step Go to Step (12) Does DST display FT voltage of 0.05 or less?  Key OFF Repair the  Disconnect ECM wire harness connector circuit as ne- cessary.
Page 215 Step Action Value(s)  Replace ECM Go to Step (14) Is the replacement complete?  Key OFF Repair the  Disconnect ECM wire harness connector circuit as ne- cessary.  Go to Step Using a DVOM check for continuity between Refer to Wir- (13) the fuel temperature connector CN14 signal...
Page 216 DTC 217-ECT/CHT Higher Than Expected 2 Conditions for Setting the DTC ECT Sensor Resistance  Engine Coolant Temperature Scaling  Check Condition-Engine Running Temp(deg F) Ohms ±10%  Fault Condition-ECT greater than 248 F 248.0  MIL-On during active fault 230.0 ...
Page 217 DTC 217-ECT/CHT Higher Than Expected 2 Diagnostic Aid  Thoroughly inspect the entire cooling system and for any signs of coolant leakage including: coolant lines and hoses, water pump, engine block, radiator, etc.  Insure the radiator cap is in good repair and maintaining suitable cooling system pressure.
Page 218 DTC 219-Max Govern Speed Override C irc u it W ire E le c tro n ic T h ro ttle E C M C o lo r 1 8 0 D B W + M o to r 1 8 2 D B W - 1 4 7 T P S 1 S ig n a l...
Page 219 DTC 219-Max Govern Speed Override Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF  Go to Step Go to Step DST connected Are any other DTC codes present with DTC 219? ...
Page 220 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 operate the vehicle to full Go to OBD operating temperature System OK...
Page 222 DTC 221-TPS 1 Higher Than TPS 2 C irc u it W ire E le c tro n ic T h ro ttle E C M C o lo r 1 8 0 D B W + M o to r 1 8 2 D B W - 1 4 7...
Page 223 DTC 221-TPS 1 Higher Than TPS 2 Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check Check? Section  Key ON, Engine OFF  Intermittent DST (Diagnostic Scan Tool) connected in Go to Step problem System Data Mode...
Page 224 Step Action Value(s)  Key OFF Repair the  Disconnect ECM wire harness connector open circuit as necessary.  Go to Step Using a DVOM check for continuity between Refer to Wir- throttle connector CN3 TPS 1 signal circuit ing Repairs in 147 and ECM connector CN1 circuit 147 Engine Elec- trical.
Page 226 DTC 222-TPS 2 Signal Voltage Low C irc u it W ire E le c tro n ic T h ro ttle E C M C o lo r 1 8 0 D B W + M o to r 1 8 2 D B W - 1 4 7...
Page 227 DTC 222-TPS 2 Signal Voltage Low Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check Check? Section  Key ON, Engine OFF  DST (Diagnostic Scan Tool) connected in Go to Step DBW (Drive by Wire) throttle test mode Go to Step (3) Does the DST display TPS 2 voltage of 0.200...
Page 228 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 operate the vehicle to Go to OBD full operating temperature System OK...
Page 230 DTC 223-TPS 2 Signal Voltage High C irc u it W ire E le c tro n ic T h ro ttle E C M C o lo r 1 8 0 D B W + M o to r 1 8 2 D B W - 1 4 7...
Page 231 DTC 223-TPS 2 Signal Voltage High Step Action Value(s) Did you perform the On-Board (OBD) System Go to OBD Go to Step Check? System Check Section  Key ON, Engine OFF  DST (Diagnostic Scan Tool) connected in Go to Step DBW (Drive by Wire) throttle test mode Go to Step (3) Does the DST display TPS 2 voltage of 4.800...
Page 232 Step Action Value(s)  Key OFF Repair the  Disconnect ECM connector CN1 circuit as ne-  cessary. Refer Using a DVOM check for continuity on the Go to Step to Wiring Re- sensor ground circuit 120 between throttle pairs in connector CN3 and ECM connector CN1 Engine Elec- trical.
Page 234 DTC 261 Injector Driver 1 Open or Low Side Short to Ground Conditions for Setting the DTC  Injector loop open or low side short to ground  Check Condition-key on and engine running  Fault Condition-System voltage greater than 9 volts and injector low side less than 4.0 volts for 10 injector firings ...
Page 235 DTC 261 Injector Driver 1 Open or Low Side Short to Ground Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem.
Page 236 Step Action Value(s)  Replace the 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. ...
Page 238 DTC 262-Injector Driver 1 Coil Shorted Conditions for Setting the DTC  Injector coil shorted  Check Condition-key on and engine running  Fault Condition-Battery voltage at ECM less than16 volts and injector on state low side greater than 4 volts for 10 injector firings ...
Page 239 DTC 262-Injector Driver 1 Coil Shorted Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step...
Page 240 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 operate the vehicle to Go to OBD full operating temperature System OK...
Page 242 DTC 264-Injector Driver 2 Open or Low Side Short to Ground Conditions for Setting the DTC  Injector loop open or low side short to ground  Check Condition-key on and engine running  Fault Condition-System voltage greater than 9 volts and injector low side less than 4.0 volts for 10 injector firings ...
Page 243 DTC 264-Injector Driver 2 Open or Low Side Short to Ground Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem.
Page 244 Step Action Value(s)  Replace the 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. ...
Page 246 DTC 265-Injector Driver 2 Coil Shorted Conditions for Setting the DTC  Injector coil shorted  Check Condition-key on and engine running  Fault Condition-Battery voltage at ECM less than16 volts and injector on state low side greater than 4 volts for 10 injector firings ...
Page 247 DTC 265-Injector Driver 2 Coil Shorted Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step...
Page 248 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 operate the vehicle to Go to OBD full operating temperature System OK...
Page 250 DTC 267-Injector Driver 3 Open or Low Side Short to Ground Conditions for Setting the DTC  Injector loop open or low side short to ground  Check Condition-key on and engine running  Fault Condition-System voltage greater than 9 volts and injector low side less than 4.0 volts for 10 injector firings ...
Page 251 DTC 267-Injector Driver 3 Open or Low Side Short to Ground Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem.
Page 252 Step Action Value(s)  Replace the 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. ...
Page 254 DTC 268-Injector Driver 3 Coil Shorted Conditions for Setting the DTC  Injector coil shorted  Check Condition-key on and engine running  Fault Condition-Battery voltage at ECM less than16 volts and injector on state low side greater than 4 volts for 10 injector firings ...
Page 255 DTC 268-Injector Driver 3 Coil Shorted Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step...
Page 256 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 operate the vehicle to Go to OBD full operating temperature System OK...
Page 258 DTC 270-Injector Driver 4 Open or Low Side Short to Ground Conditions for Setting the DTC  Injector loop open or low side short to ground  Check Condition-key on and engine running  Fault Condition-System voltage greater than 9 volts and injector low side less than 4.0 volts for 10 injector firings ...
Page 259 DTC 270-Injector Driver 4 Open or Low Side Short to Ground Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem.
Page 260 Step Action Value(s)  Replace the 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. ...
Page 262 DTC 271-Injector Driver 4 Coil Shorted Conditions for Setting the DTC  Injector coil shorted  Check Condition-key on and engine running  Fault Condition-Battery voltage at ECM less than 16 volts and injector on state low side greater than 4 volts for 10 injector firings ...
Page 263 DTC 271-Injector Driver 4 Coil Shorted Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step...
Page 264 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 operate the vehicle to Go to OBD full operating temperature System OK...
Page 266 DTC 336-Crank Sync Noise Conditions for setting the DTC  Crankshaft Position sensor  Check Condition Engine running  Fault Condition 1 invalid crank re-sync in less than 800 ms  MIL On during active fault  Adaptive Disabled Circuit Description The Crankshaft position sensor is a 5 volt powered sensor mounted to the lower front engine block.
Page 267 DTC 336-Crank Sync Noise Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion Repair the circuit as ne-  Check that the ECM ground terminal CN28 is cessary. clean, tight and in the proper location Go to Step Refer to Wir-...
Page 268 Step Action Value(s)  Replace CKP sensor Go to Step (10) Is the replacement complete?  Replace ECM Go to Step (11) Is the replacement complete?  Remove all test equipment except the DST.  Connect any disconnected components, fus- es, etc.
Page 270 DTC 337-Crank Loss Conditions for setting the DTC  Crankshaft position sensor  Check Condition Engine cranking  Fault Condition 6 cam pulse signals without crankshaft activity  MIL On during active fault  Adaptive Disabled Circuit Description The Crankshaft position sensor is a 5 volt powered sensor mounted to the lower front engine block.
Page 271 DTC 337-Crank Loss Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion Repair the circuit as  Check that the ECM ground terminal CN28 is necessary. clean, tight and in the proper location Go to Step Refer to Wir- ing Repairs...
Page 272 Step Action Value(s) Repair the circuit as ne-  Inspect the ECM connector CN1 for damage, cessary. corrosion or contamination Go to Step Refer to Wir- ing Repairs in Did you find a problem Engine Elec- trical.  Replace the CKP sensor Go to Step (10) Is the replacement complete?
Page 274 DTC 341-Camshaft Sensor Sync Noise Conditions for Setting the DTC  Camshaft position sensor  Check Condition-Cranking or Running  Fault Condition 1 invalid cam re-sync in 700ms or less  Adaptive learn disabled  MIL-On Circuit Description The CMP (Camshaft Position Sensor) is used to synchronize the fuel and ignition systems. This fault will set if the ECM detects erroneous pulses from the camshaft position sensor caus- ing invalid cam re-sync.
Page 275 DTC 341-Camshaft Sensor Sync Noise Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion Repair the circuit as ne-  Check that the ECM ground terminal CN28 is cessary.
Page 276 Step Action Value(s)  Replace CMP sensor Go to Step (10) Is the replacement complete?  Replace ECM Go to Step (11) Is the replacement complete?  Remove all test equipment except the DST.  Connect any disconnected components, fus- es, etc.
Page 278 DTC 342-Camshaft Sensor Loss Conditions for Setting the DTC  CMP (Camshaft Position Sensor)  Check Condition-Engine Cranking or Running  Fault Condition-No cam pulse in 2.5 cycles with engine speed greater than 1000 rpm  MIL-On for active fault ...
Page 279 DTC 342-Camshaft Sensor Loss Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion Repair the  Check that the ECM ground terminal CN28 is circuit as ne- clean, tight and in the proper location cessary.
Page 280 Step Action Value(s) Repair the circuit as ne-  Inspect the ECM connector terminals for cessary. damage, corrosion or contamination Go to Step Refer to wir- ing harness Did you find a problem? repair sec- tion.  Replace the CMP. Go to Step (10) Is the replacement complete?
Page 282 DTC 359-Fuel Run-out Longer Than Expected Conditions for Setting the DTC  LPG shut off valve  Check Condition Key OFF  Fault Condition Engine run down time greater than 20 seconds  MIL-On Circuit Description The LPG shut off valve is supplied system battery power from the VSW fused source. The ECM then provides a path to ground to turn the valve on.
Page 283 DTC 359-Fuel Run-out Longer Than Expected Step Action Value(s) Did you perform the On-Board (OBD) System Go to Step Check?  Disconnect the LPG shut off solenoid con- nector CN13  Using a DVOM check for power across ter- minals (circuits 177 and 821) while cranking System Vol- Go to Step Go to Step...
Page 284 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 operate the vehicle to Go to OBD full operating temperature System OK...
Page 286 DTC 420-Catalyst Monitor Test (Bi-Fuel/Gasoline Only) Conditions for Setting the DTC  Heated Oxygen Sensor  Check condition Engine running  Fault condition Catalyst monitor test failed  MIL On during active fault  Adaptive Disabled during active fault  Closed Loop Disabled during active fault Circuit Description The catalyst monitor test is run under certain operating conditions to determine if the catalyst is...
Page 287 DTC 420-Catalyst Monitor Test (Bi-Fuel/Gasoline Only) Diagnostic Aid  Inspect the exhaust system for visual signs of damage, leaks, or modification and repair if necessary.  Insure the pre catalyst and post catalyst oxygen sensors are mounted correctly and wiring is not damaged, melted, or corroded and repair if necessary. ...
Page 288 DTC 524-Oil Pressure Low Conditions for Setting the DTC  Engine Oil Pressure low  Check Condition-Engine running for 20 seconds or more with engine speed greater than 600 rpm  Fault Condition Open pressure switch circuit voltage equal to or greater than 2.50 volts ...
Page 289 DTC 524-Oil Pressure Low Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Verify that the engine has oil pressure using a mechanical oil pressure gauge before pro- Go to Step Repair faulty ceeding.
Page 290 Step Action Value(s) Repair the  Inspect the oil pressure switch connector circuit as ne- terminal and ECM connector for damage cor- cessary. Go to Step Refer to Wir- rosion or contamination ing Repairs in Engine Elec- Did you find a problem? trical.
Page 292 DTC 562-System Voltage Low Conditions for Setting the DTC  System Voltage to ECM  Check Condition-Key on with engine speed greater than 1000 RPM  Fault Condition-Battery voltage at ECM less than 9.0  MIL-On for active fault  Adaptive-Disabled Circuit Description The battery voltage powers the ECM and must be measured to correctly to properly operate in-...
Page 293 DTC 562 System Voltage Low Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem Go to Engine Go to Step System Data Mode...
Page 294 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 operate the vehicle to Go to OBD full operating temperature System OK...
Page 296 DTC 563-System Voltage High  Conditions for Setting the DTC  System Voltage to ECM  Check Condition-Cranking or Running  Fault Condition-System battery voltage at ECM greater than 16 volts  MIL-On for active fault  Adaptive-Disabled Circuit Description The battery voltage powers the ECM and must be measured to correctly operate injector driv- ers, trim valves and ignition coils.
Page 297 DTC 563-System Voltage High Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go To Step Go to Engine ...
Page 298 DTC 601-Flash Checksum Invalid Conditions for Setting the DTC  Engine Control Module  Check Condition Key on  Fault Condition Internal microprocessor error  MIL On  Adaptive Disabled for the remainder of the key-ON cycle  Power Derate level 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex- ecuted.
Page 299 DTC 601-Flash Checksum Invalid Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step Go to Inter- ...
Page 300 DTC 604-RAM Failure Conditions for Setting the DTC  Engine Control Module  Check Condition Key on  Fault Condition Internal microprocessor error  MIL On  Adaptive Disabled for the remainder of the key-ON cycle  Power Derate level 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex- ecuted.
Page 301 DTC 604-RAM Failure Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step Go to Inter- ...
Page 302 DTC 606-COP Failure Conditions for Setting the DTC  Engine Control Module  Check Condition Key on  Fault Condition Internal microprocessor error  MIL On  Adaptive Disabled Power Derate level 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex- ecuted.
Page 303 DTC 606-COP Failure Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step Go to Inter- ...
Page 304 DTC 627-Fuel Pump Relay Coil Open (Bi-Fuel/Gasoline Only) Conditions for Setting the DTC  Fuel pump relay check  Check Condition-Key ON  Fault Condition Relay coil open Circuit Description The fuel pump relay switches power out to the fuel pump for operation on gasoline fuel. This fault will set if the ECM detects an open circuit on the relay control output.
Page 305 DTC 627-Fuel Pump Relay Coil Open (Bi-Fuel/Gasoline Only) Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  DST connected and in the System Data Mode  Key OFF ...
Page 306 Step Action Value(s)  Replace the 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. ...
Page 308 DTC 628-Relay Control Ground Short (Bi-Fuel/Gasoline Only) Conditions for Setting the DTC  Fuel pump relay ground control  Check Condition-Key ON  Fault Condition Relay control shorted to ground Circuit Description The fuel pump relay switches power out to the fuel pump for operation on gasoline fuel. This fault will set if the ECM detects a short to ground on the relay control output.
Page 309 DTC 628-Relay Control Ground Short (Bi-Fuel/Gasoline Only) Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, DST connected in the System Data Intermittent Mode problem ...
Page 310 DTC 629-Relay Coil Short to Power (Bi-Fuel/Gasoline Only) Conditions for Setting the DTC  Fuel pump relay check  Check Condition-Key ON  Fault Condition Relay coil shorted to power Circuit Description The fuel pump relay switches power out to the fuel pump for operation on gasoline fuel. This fault will set if the ECM detects a short circuit to power on the relay control output.
Page 311 DTC 629-Relay Coil Short to Power (Bi-Fuel/Gasoline Only) Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  DST connected and in the System Data Mode  Key OFF ...
Page 312 Step Action Value(s)  Replace the 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. ...
Page 314 DTC 642-External 5 Volt Reference Low Conditions for Setting the DTC  External 5 volt reference  Check Condition-Engine cranking or running  Fault Condition-5 volt reference voltage lower than 4.60 volts  MIL-On during active fault  Adaptive-Disabled during active fault Circuit Description The external 5 volt supply powers many of the sensors and other components of the fuel sys- tem.
Page 315 DTC 642-External 5 Volt Reference Low Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem Go to Step System Fault Mode...
Page 316 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 operate the vehicle to Go to OBD full operating temperature System OK...
Page 318 DTC 643-External 5 Volt Reference High Conditions for Setting the DTC  External 5 volt reference  Check Condition-Engine cranking or running  Fault Condition-5 volt reference higher than 5.40 volts  MIL-On during active fault  Adaptive-Disabled during active fault Circuit Description The External 5 volt supply powers many of the sensors and other components in the fuel sys- tem.
Page 319 DTC 643-External 5 Volt Reference High Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine running Intermittent  DST (Diagnostic Scan Tool) connected in problem Go to Step System Data Mode...
Page 320 DTC 685-Relay Coil Open Conditions for Setting the DTC  Power relay check  Check Condition-Key ON  Fault Condition Relay coil open Circuit Description The power relay switches power out to various sensors, actuators and solenoids in the fuel system.
Page 321 DTC 685-Relay Coil Open Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  DST connected and in the system data mode  Key OFF  Remove the power relay from the fuse block Go to Step Go to Step ...
Page 322 Step Action Value(s)  Replace the 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. ...
Page 324 DTC 686-Relay Control Ground Short Conditions for Setting the DTC  Power relay ground control  Check Condition-Key ON  Fault Condition Relay control shorted to ground Circuit Description The power relay switches power out to various sensors, actuators and solenoids in the fuel system.
Page 325 DTC 686-Relay Control Ground Short Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, DST connected in the System Data Intermittent Mode problem  Go to Step Clear DTC 686 Go to Inter- ...
Page 326 DTC 687-Relay Coil Short to Power Conditions for Setting the DTC  Power relay check  Check Condition-Key ON  Fault Condition Relay coil shorted to power Circuit Description The power relay switches power out to various sensors, actuators and solenoids in the fuel system.
Page 327 DTC 687-Relay Coil Short to Power Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  DST connected and in the System Data Mode  Key OFF  Remove the power relay from the fuse block Go to Step Go to Step...
Page 328 Step Action Value(s)  Replace the 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. ...
Page 330 DTC 1111-Fuel Rev Limit C irc u it W ire E le c tro n ic T h ro ttle E C M C o lo r 1 8 0 D B W + M o to r 1 8 2 D B W - 1 4 7 T P S 1 S ig n a l...
Page 331 DTC 1111-Fuel Rev Limit Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF  DST in Active Fault Mode Go to Step Go to Step Are any other DTC codes present with DTC 1111? ...
Page 332 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 operate the vehicle to full Go to OBD operating temperature System OK...
Page 334 DTC 1112-Spark Rev Limit C irc u it W ire E le c tro n ic T h ro ttle E C M C o lo r 1 8 0 D B W + M o to r 1 8 2 D B W - 1 4 7 T P S 1 S ig n a l...
Page 335 DTC 1112-Spark Rev Limit Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF  DST connected Go to Step Go to Step Are any other DTC codes present with DTC 1112? ...
Page 336 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 operate the vehicle to full Go to OBD operating temperature System OK...
Page 338 DTC 1151-Closed Loop Multiplier High LPG Conditions for Setting the DTC  Heated Oxygen Sensor  Check Condition-Engine running  Fault Condition-Closed Loop multiplier out of range (greater than 35%)  MIL-ON Circuit description The EGO sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas.
Page 339 DTC 1151-Closed Loop Multiplier High LPG Step Action Value(s)  Perform the On-Board (OBD) System Check? Go to Step Go to Step Are any other DTCs present? Visually and physically check the following items:  The air intake duct for being collapsed or re- stricted ...
Page 340 Step Action Value(s) Repair the  Using a high impedance DVOM check for shorted circuit continuity at the EGO 1 connector CN11 be- as necessary. tween signal circuit 121 and sensor ground Go to Step Refer to Wir- circuit 120 ing Repairs in Engine Elec- Do you have continuity?
Page 342 DTC 1152-Closed Loop Multiplier Low LPG Conditions for Setting the DTC  Heated Oxygen Sensor  Functional Fault-Closed Loop multiplier out of range (at limit of-35%)  MIL Disabled Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas.
Page 343 DTC 1152-Closed Loop Multiplier Low LPG Step Action Value(s)  Perform the On-Board (OBD) System Check? Go to Step Go to Step Are any other DTCs present? Visually and physically check the following items:  The air intake duct for being collapsed or re- stricted ...
Page 344 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 operate the vehicle to full Go to OBD operating temperature System OK...
Page 346 DTC 1155-Closed Loop High (Bi-Fuel/Gasoline Only) Conditions for Setting the DTC  Heated Oxygen Sensor  Check Condition-Engine Running  Fault Condition-Closed Loop multiplier out of range greater than 35.0%  MIL-On Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas.
Page 347 DTC 1155-Closed Loop High (Bi-Fuel/Gasoline Only) Step Action Value(s)  Perform the On-Board (OBD) System Check Go to Step Go to Step Are any other DTCs present? Visually and physically check the following items:  The air intake duct for being collapsed or re- stricted ...
Page 348 Step Action Value(s)  Key OFF  Disconnect EGO 1 sensor wire harness con- Repair the nector CN11 shorted circuit  Disconnect ECM wire harness connector CN1 as necessary.  Go to Step Key ON Refer to Wir-  Using a high impedance DVOM check for ing Repairs in continuity between EGO 1 connector signal Engine Elec-...
Page 350 DTC 1156-Closed Loop Low (Bi-Fuel/Gasoline Only) Conditions for Setting the DTC  Heated Oxygen Sensor  Check Condition-Engine Running  Fault Condition-Closed loop multiplier out of range greater than-35%  MIL-On Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas.
Page 351 DTC 1156-Closed Loop Low (Bi-Fuel/Gasoline Only) Step Action Value(s)  Perform the On-Board (OBD) System Check? Go to Step Go to Step Are any other DTCs present? Visually and physically check the following items:  The air intake duct collapsed or restricted ...
Page 352 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 operate the vehicle to full Go to OBD operating temperature System OK...
Page 354 DTC 1161-Adaptive Learn High LPG Conditions for Setting the DTC  Heated Oxygen Sensor  Check Condition-Engine Running  Fault Condition-Adaptive multiplier out of range greater than 30%  MIL-On Circuit Description The EGO 1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas.
Page 355 DTC 1161-Adaptive Learn High LPG Step Action Value(s)  Perform the On-Board (OBD) System Check? Go to Step Go to Step Are any other DTCs present? Visually and physically check the following items:  The air intake duct for being collapsed or re- stricted ...
Page 356 Step Action Value(s)  Key OFF  Disconnect EGO 1 sensor wire harness con- Repair the nector CN11 shorted circuit  Disconnect ECM wire harness connector CN1 as necessary.  Go to Step Key ON Refer to Wir-  Using a high impedance DVOM check for ing Repairs in continuity between EGO 1 connector signal Engine Elec-...
Page 358 DTC 1162-Adaptive Learn Low LPG Conditions for Setting the DTC  Heated Oxygen Sensor  Check Condition-Engine running  Fault Condition-Adaptive multiplier out of range greater than-30%  MIL-On Circuit Description The EGO1 sensor is used to determine if the fuel flow to the engine is correct by measuring the oxygen content in the exhaust gas.
Page 359 DTC 1162-Adaptive Learn Low LPG Step Action Value(s)  Perform the On-Board (OBD) System Check? Go to Step Go to Step Are any other DTCs present? Visually and physically check the following items:  The air intake duct for being collapsed or re- stricted ...
Page 360 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 operate the vehicle to full Go to OBD operating temperature System OK...
Page 362 DTC 1165-Catalyst Monitor Test Conditions for Setting the DTC  Heated Oxygen Sensor  Check condition-Engine running  Fault condition-Catalyst monitor test failed  MIL-On during active fault  Adaptive-Disabled during active fault  Closed Loop-Disabled during active fault Circuit Description The catalyst monitor test is run under certain operating conditions to determine if the catalyst is functioning correctly.
Page 363 DTC 1165-Catalyst Monitor Test Diagnostic Aid  Inspect the exhaust system for visual signs of damage, leaks, or modification and repair if necessary.  Insure the pre catalyst and post catalyst oxygen sensors are mounted correctly and wiring is not damaged, melted, or corroded and repair if necessary. ...
Page 364 DTC 1171-EPR Pressure Higher Than Expected Conditions for Setting the DTC  EPR delivery pressure  Check condition-Engine running or cranking  MIL-On during active fault  Fault condition-EPR actual pressure greater than 1.0 inches above commanded pressure  Adaptive disabled Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer.
Page 365 DTC 1171-EPR Pressure Higher Than Expected Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion Did you run the fuel pressure diagnostic test in Go to Step Go to Step the fuel system diagnostic section with no prob- lems found? Follow the...
Page 366 DTC 1172-EPR Pressure Lower Than Expected Conditions for Setting the DTC  EPR delivery pressure  Check condition-Engine running or cranking  MIL-On during active fault  Fault condition-EPR actual pressure less than 1.0 inches below commanded pressure  Adaptive disabled Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer.
Page 367 DTC 1172-EPR Pressure Lower Than Expected Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion Did you run the fuel pressure diagnostic test in Go to Step the fuel system diagnostic section with no prob- Go to Step 3 lems found? Follow the...
Page 368 DTC1173-EPR Communication Lost Conditions for Setting the DTC  EPR CAN communication  Check condition-Engine running or cranking  MIL-On during active fault  Fault condition-No packets received within 500 ms  Adaptive disabled Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer.
Page 369 DTC 1173-EPR Communication Lost Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON Intermittent  DST (Diagnostic Scan Tool) connected in problem. Go the system data mode to Intermittent ...
Page 370 Step Action Value(s)  Key OFF Repair the  Disconnect the EPR connector CN15 open circuit  Disconnect the ECM connector CN1 as necessary. Go to Step  Using a DVOM check for continuity on the Refer to wir- CAN-circuit 115 between EPR connector ing repairs in CN15 and ECM connector CN1 engine elec-...
Page 371 Step Action Value(s)  Remove all test equipment and reconnect 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.  Go to Step Start the engine and operate the vehicle to System OK...
Page 372 DTC 1174-EPR Supply Voltage High Conditions for Setting the DTC  EPR supply voltage  Check condition-Engine running or cranking  MIL-On during active fault  Fault condition-internal EPR supply voltage too high  Adaptive disabled  Closed loop disabled Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer.
Page 373 DTC 1174-EPR Voltage Supply High Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  DST connected and in the System Data Mode Repair the  Go to Step Engine running charging sys- ...
Page 374 DTC 1175-EPR Supply Voltage Low Conditions for Setting the DTC  EPR supply voltage  Check condition-Engine running or cranking  MIL-On during active fault  Fault condition-EPR internal supply voltage low  Adaptive disabled Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer.
Page 375 DTC 1175-EPR Voltage Supply Low Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  DST connected and in the system data mode Repair the  Engine running Go to Step charging sys- ...
Page 376 Step Action Value(s)  Key OFF  Disconnect the ECM connector CN1 Repair the  Using a DVOM check continuity between the poor EPR EPR ground circuit 181 at EPR connector power ground CN15 and ECM connector CN1 circuits 181 circuit.
Page 378 DTC 1176-EPR Internal Actuator Fault Conditions for Setting the DTC  EPR internal actuator test  Check condition-Engine running or cranking  MIL-On during active fault  Fault condition-Failed actuator  Adaptive disabled Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer.
Page 379 DTC 1176-EPR Internal Actuator Fault Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  DST connected and in the system data mode  Check for any other current or active DTCs Go to Step Go to Step Does the DST show any other codes set?
Page 380 DTC 1177-EPR internal Circuitry Fault Conditions for Setting the DTC  EPR internal circuitry test  Check condition-Engine running or cranking  MIL-On during active fault  Fault condition-  Adaptive disabled Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer.
Page 381 DTC 1177-EPR Internal Circuitry Fault Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  DST connected and in the system data mode  Check for any other current or active DTCs Go to Step Go to Step Does the DST show any other codes set?
Page 382 DTC 1178-EPR Internal Communication Error Conditions for Setting the DTC  EPR internal communication test  Check condition-Engine running or cranking  MIL-On during active fault  Fault condition-  Adaptive disabled Circuit Description The EPR (Electronic Pressure Regulator) unit measures and controls the amount of fuel that is able to pass to the fuel mixer.
Page 383 DTC 1178-EPR Internal Communication Error Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  DST connected and in the system data mode  Check for any other current or active DTCs Go to Step Go to Step Does the DST show any other codes set?
Page 384 DTC 1612-RTI 1 Loss Conditions for Setting the DTC  Engine Control Module  Check Condition-Key on  Fault Condition-Internal microprocessor error  MIL-On  Adaptive-Disabled for the remainder of the key-ON cycle  Power Derate level 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex- ecuted.
Page 385 DTC 1612-RT 1 Loss Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step Go to Inter- ...
Page 386 DTC 1613-RTI 2 Loss Conditions for Setting the DTC  Engine Control Module  Check Condition- Key on  Fault Condition- Internal microprocessor error  MIL- On  Adaptive- Disabled for the remainder of the key-ON cycle  Power Derate level 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex- ecuted.
Page 387 DTC 1613-RTI 2 Loss Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step Go to Inter- ...
Page 388 DTC 1614-RTI 3 Loss Conditions for Setting the DTC  Engine Control Module  Check Condition-Key on  Fault Condition-Internal microprocessor error  MIL-On  Adaptive-Disabled for the remainder of the key-ON cycle  Power Derate level 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex- ecuted.
Page 389 DTC 1614-RTI 3 Loss Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step Go to Inter- ...
Page 390 DTC 1615-A/D Loss Conditions for Setting the DTC  Engine Control Module  Check Condition-Key on  Fault Condition-Internal microprocessor error  MIL-On  Adaptive-Disabled for the remainder of the key-ON cycle  Power Derate level 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex- ecuted.
Page 391 DTC 1615-A/D Loss Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step Go to Inter- ...
Page 392 DTC 1616-Invalid Interrupt Conditions for Setting the DTC  Engine Control Module  Check Condition-Key on  Fault Condition-Internal microprocessor error  MIL-On  Adaptive-Disabled for the remainder of the key-ON cycle  Power Derate level 2 Circuit Description The ECM has several internal checks that must be satisfied each time an instruction is ex- ecuted.
Page 393 DTC 1616-Invalid Interrupt Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step Go to Inter- ...
Page 394 DTC 1628-CAN Address Conflict Conditions for Setting the DTC  CAN Rx  Check Condition-Engine running  Fault Condition- 5 or more address conflict errors  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 395 DTC 1628-CAN Address Conflict Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On, Engine Running Intermittent  DST (Diagnostic Scan Tool) connected in problem System Data Mode Go to Step Go to Inter- ...
Page 396 DTC 2111-Unable To Reach Lower TPS C irc u it W ire E le c tro n ic T h ro ttle E C M C o lo r 1 8 0 D B W + M o to r 1 8 2 D B W - 1 4 7...
Page 397 DTC 2111-Unable To Reach Lower TPS Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check Check? Section  Key ON, Engine OFF  DST (Diagnostic Scan Tool) connected in Intermittent data stream mode Go to Step problem ...
Page 398 Step Action Value(s)  Check throttle for foreign object in bore Go to Step Go to Step (10) (11) Did you find a foreign object in the bore?  Remove foreign object Go to Step (13) Is the removal complete? Repair the ...
Page 400 DTC 2112-Unable To Reach Higher TPS C irc u it W ire E le c tro n ic T h ro ttle E C M C o lo r 1 8 0 D B W + M o to r 1 8 2 D B W - 1 4 7...
Page 401 DTC 2112-Unable To Reach Higher TPS Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check Check? Section  Key ON, Engine OFF  DST (Diagnostic Scan Tool) connected in Intermittent DBW data stream mode Go to Step problem ...
Page 402 Step Action Value(s) Repair the shorted to  Using a DVOM check for continuity between ground circuit throttle connector TPS 1 signal circuit 147 as necessary. Go to Step and engine ground Refer to Wir- (10) ing Repairs in Do you have continuity between them? Engine Elec- trical.
Page 404 DTC 2115-FPP1 Higher Than IVS Limit Conditions for Setting the DTC  Foot Pedal Position  Check Condition-Key On  Fault Condition-FPP 1 sensor voltage greater than 1.0 volt and IVS at-idle  MIL-On during active  Power derate level 2 Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on pedal position.
Page 405 DTC 2115-FPP 1 Higher Than IVS Limit Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF  DST (Diagnostic Scan Tool) connected in System Data Mode Greater than Go to Step...
Page 406 Step Action Value(s)  Replace ECM Go to Step (11) 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. ...
Page 408 DTC 2122-FPP 1 High Voltage Conditions for Setting the DTC  Foot Pedal Position  Check Condition-Key On  Fault Condition-FPP1 sensor voltage exceeds 4.00 volts  MIL-On during active fault  Low rev limit  Force idle Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on pedal position.
Page 409 DTC 2122-FPP 1 Voltage High Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF  DST (Diagnostic Scan Tool) connected in Greater than Go to Step Go to Step System Data Mode...
Page 410 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 operate the vehicle to Go to OBD full operating temperature System OK...
Page 412 DTC 2123-FPP 1 Low Voltage Conditions for Setting the DTC  Foot Pedal Position  Check Condition-Key On  Fault Condition-FPP sensor voltage less than 0.300  MIL-On during active  Low rev limit  Force idle Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on pedal position.
Page 413 DTC 2123-FPP 1 Low Voltage Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF  DST (Diagnostic Scan Tool) connected in System Data Mode 0.300 volts Go to Step Go to Step...
Page 414 Step Action Value(s) Repair the signal shorted  Key ON to ground cir-  Using a DVOM check for continuity between cuit as Go to Step ECM connector circuit153 and engine ground required. See (10) wiring har- Do you have continuity? ness repair section Repair the...
Page 416 DTC 2135-TPS 1/2 Voltages Out Of Range C irc u it W ire E le c tro n ic T h ro ttle E C M C o lo r 1 8 0 D B W + M o to r 1 8 2 D B W - 1 4 7...
Page 417 DTC 2135-TPS 1/2 Out Of Range Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check Check? Section  Key ON, Engine OFF  DST (Diagnostic Scan Tool) connected in Intermittent DBW (Drive By Wire) test mode Go to Step problem ...
Page 418 Step Action Value(s) Repair circuit  120 as neces- Using a DVOM check continuity on circuit sary. Refer to 120 between connector CN1 and CN3 Go to Step Wiring Re- pairs in Do you have continuity? Engine Elec- trical.  Replace throttle Go to Step Is the replacement complete?
Page 420 DTC 2139-FPP 1 Lower Than IVS Limit Conditions for Setting the DTC  Foot Pedal Position  Check Condition-Key On  Fault Condition-FPP 1 voltage less than 0.850 volts and IVS off-idle  MIL-On during active  Power derate Circuit Description The Foot Pedal Position sensor uses a variable resistor to determine signal voltage based on pedal position.
Page 421 DTC 2139-FPP 1 Lower Than IVS Limit Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF  DST (Diagnostic Scan Tool) connected in Greater than Go to Step Go to Step...
Page 422 Step Action Value(s)  Replace FPP/IVS sensor Go to Step (10) Is the replacement complete?  Replace ECM Go to Step (11) Is the replacement complete?  Remove all test equipment except the DST.  Connect any disconnected components, fus- es, etc.
Page 424 DTC 2229-BP High Pressure Conditions for Setting the DTC  Barometric Pressure  Check Condition-Key On  Fault Condition-BP greater than 16 psia  MIL-On for active fault  Adaptive-Disabled Circuit Description The BP (Barometric Pressure) is estimated from the TMAP sensor. The barometric pressure value is used for fuel and airflow calculations.
Page 425 DTC 2229-BP High Pressure Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key On Intermittent  DST (Diagnostic Scan Tool) connected in problem  Go to Step System Data Mode Go to Inter- mittent...
Page 426 DTC 2300-Primary Loop Open/Low Side Short to Ground Conditions for Setting the DTC  Ignition Control Check  Check condition-Engine running or cranking  Fault condition-Adaptive dwell greater than 2.0ms or total dwell greater than 14.0ms  MIL-On during active fault ...
Page 427 DTC 2300-Primary Loop Open/Low Side Short to Ground Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF Intermittent  DST (Diagnostic Scan Tool) connected in problem.
Page 428 Step Action Value(s)  Replace the ignition module Go to Step (10) 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.
Page 430 DTC 2301-Primary Coil Shorted to Voltage Conditions for Setting the DTC  Ignition Control Check  Check condition-Engine running or cranking  Fault condition-Adaptive dwell less than-2.0ms or total dwell less than 4.0ms  MIL-On during active fault  Adaptive-Disabled ...
Page 431 DTC 2301-Primary Coil Shorted to Voltage Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF Intermittent  DST (Diagnostic Scan Tool) connected in problem.
Page 432 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 operate the vehicle to Go to Step full operating temperature System OK...
Page 434 DTC 2303-Primary Loop Open/Low Side Short to Ground Conditions for Setting the DTC  Ignition Control Check  Check condition-Engine running or cranking  Fault condition-Adaptive dwell greater than 2.0ms or total dwell greater than 14.0ms  MIL-On during active fault ...
Page 435 DTC 2303-Primary Loop Open/Low Side Short to Ground Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF Intermittent  DST (Diagnostic Scan Tool) connected in problem.
Page 436 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 operate the vehicle to full operating temperature Go to Step System OK...
Page 438 DTC 2304-Primary Coil Shorted to Voltage Conditions for Setting the DTC  Ignition Control Check  Check condition-Engine running or cranking  Fault condition-Adaptive dwell less than-2.0ms or total dwell less than 4.0ms  MIL-On during active fault  Adaptive-Disabled ...
Page 439 DTC 2304-Primary Coil Shorted to Voltage Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF Intermittent  DST (Diagnostic Scan Tool) connected in problem.
Page 440 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 operate the vehicle to Go to Step full operating temperature System OK...
Page 442 DTC 2306-Primary Loop Open/Low Side Short to Ground Conditions for Setting the DTC  Ignition Control Check  Check condition-Engine running or cranking  Fault condition-Adaptive dwell greater than 2.0ms or total dwell greater than 14.0ms  MIL-On during active fault ...
Page 443 DTC 2306-Primary Loop Open/Low Side Short to Ground Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF Intermittent  DST (Diagnostic Scan Tool) connected in problem.
Page 444 Step Action Value(s)  Replace the ignition module Go to Step (10) 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.
Page 446 DTC 2307-Primary Coil Shorted to Voltage Conditions for Setting the DTC  Ignition Control Check  Check condition-Engine running or cranking  Fault condition-Adaptive dwell less than-2.0ms or total dwell less than 4.0ms  MIL-On during active fault  Adaptive-Disabled ...
Page 447 DTC 2307-Primay Coil Shorted to Voltage Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF Intermittent  DST (Diagnostic Scan Tool) connected in problem.
Page 448 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 operate the vehicle to Go to Step full operating temperature System OK...
Page 450 DTC 2309-Primary Loop Open/Low Side Short to Ground Conditions for Setting the DTC  Ignition Control Check  Check condition-Engine running or cranking  Fault condition-Adaptive dwell greater than 2.0ms or total dwell greater than 14.0ms  MIL-On during active fault ...
Page 451 DTC 2309-Primary Loop Open/Low Side Short to Ground Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF Intermittent  DST (Diagnostic Scan Tool) connected in problem.
Page 452 Step Action Value(s)  Replace the ignition module Go to Step (10) 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.
Page 454 DTC 2310-Primary Coil Shorted to Voltage Conditions for Setting the DTC  Ignition Control Check  Check condition-Engine running or cranking  Fault condition-Adaptive dwell less than-2.0ms or total dwell less than 4.0ms  MIL-On during active fault  Adaptive-Disabled ...
Page 455 DTC 2310-Primary Coil Shorted to Voltage Step Action Value(s) Go to OBD Did you perform the On-Board (OBD) System Go to Step System Check? Check Sec- tion  Key ON, Engine OFF Intermittent  DST (Diagnostic Scan Tool) connected in problem.
Page 456 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 operate the vehicle to Go to Step full operating temperature System OK...
Page 457: Servicing The Fuel System
Servicing the Fuel System...
Page 458 PROTECTION OF ELECTRICAL COMPONENTS INSTALLATION PROCEDURE IMPORTANT The ECM is calibrated for each engine. Verify you have the correct controller by noting the P/N on the To prevent permanent damage to the ECM ECM label. The calibration number can also be and/or other electrical components, follow- found by connecting the DST and finding the calibra- ing the steps listed below...
Page 459 IV. FUEL TEMPERATURE (FT) SENSOR 9. Start the vehicle and let run until it reaches normal operating temperature. REPLACEMENT (LPG ONLY) If a DTC code is found, refer to the Electrical Section for further diagnosis. III. LPG FUEL SYSTEM PRESSURE RELIEF Fuel Temperature Sensor The LPG fuel system operates at pressure up to 21.5 bar (312 psi).
Page 460 Contamination of the HEGO sensor can re- sult from the use of an inappropriate RTV sealer or silicone spray products. Do not use silicone sprays or hoses which are as- sembled using silicone lubricants. Always use “oxygen sensor safe” RTV sealant for repair procedures.
Page 461 5. Remove the sensor. INSTALLATION PROCEDURE 1. Apply a minimal amount of Loctite 962T or equivalent sealer to threads on the Engine Coo- lant Temperature Sensor. Remove any excess sealer on the sensor threads. Install Engine Coolant Temperature Sensor. Torque to 10.8-14.5 ft.lbs.
Page 462 Install Oxygen Sensor. Torque to 36.2-43.4 ft. lbs. (49.0-58.8 Nm) Reconnect electrical connector to the Oxygen Sensor. Contamination of the HEGO sensor can re- 3. Reconnect the negative battery cable. sult from the use of an inappropriate RTV 4. Start the vehicle and let run until it reaches sealer or silicone spray products.
Page 463  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 fol- lowing problems:  Rough Idle  Stalling Testing the PCV Action ...
Page 464 2. Relieve the LPG fuel system pressure. Refer IMPORTANT to III. LPG Fuel System Pressure Relief. Verify that the quad seals rest flat against the neck 3. Remove the air intake duct. of the Throttle Body with no twists. 4. Remove the retaining pin holding the fuel hose fitting and remove fuel hose.
Page 465 3. Refer to the Fuel Injection Pressure Tester kinked. Owner’s Manual supplied in the IMPCO Test Kit 4. Reconnect negative battery cable. for instructions on relieving gasoline fuel pres- 5. Open valve on the LPG tank.
Page 466 XVII. ELECTRONIC PRESSURE REGULATOR (EPR) REMOVAL PROCEDURE Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel 1. Disconnect the negative battery cable. system to reduce the risk of personal injury. 2. Relieve the LPG fuel system pressure. Refer to After you relieve the fuel system pressure, a III.
Page 467 Contamination of the HEGO sensor can result from the use of an inappropriate RTV sealer or silicone spray products. Do not use silicone sprays or hoses which are assembled using silicone lubricants. Always use “oxygen sen- sor safe” RTV sealant for repair procedures. Silicon contamination will cause a high but false HEGO signal voltage (rich exhaust indi- cation).
Page 468 XVIII. ELECTRONIC PRESSURE REGULATOR NOTE (EPR) The Repair Kit consists of nine parts which are not available separately. These are the only serviceable A Repair Kit is available to service and replace the components of the EPR. Any attempt to service following components in the Spectrum III Electron- other components may damage or cause the EPR to ic Pressure Regulator (EPR):...
Page 469 NOTE 11. Turn the Regulator over and remove the Be sure to identify the type of screw and its loca- seven screws from the face of the Regulator. tion during each stage of disassembly to ensure Remove cover. proper placement during reassembly. 12.
Page 470 over the valve pin and install C-clip or retain- face. Torque screws to 40 in. lbs. (4.5 ing clip. Nm). 4. Place a new secondary body gasket ensur- ing the small hole in the gasket is aligned Optional: with the small hole in the body cover. Place If hoses and O-rings were removed during the body cover and gasket on the front of Regu- Removal Procedure, then follow the additional...
Page 471 23. Turn Key to the ON position for several XX. SHUT-OFF VALVE REPLACEMENT seconds, then turn back to OFF. Using a REMOVAL PROCEDURE liquid or electronic leak detection tool, in- spect the EPR, fuel hoses and all serviced 1. Disconnect the negative battery cable. fittings for leaks.
Page 472 3. Remove ECM (Refer to I. Engine Control 4. Remove ECM/Mixer Bracket (Refer to XXII. Module). EPR/ECM Mounting Bracket). 4. Remove EPR (Refer to XVIII Electronic 5. Remove the TMAP (Refer to VI. Tempera- Pressure Regulator). ture Manifold Absolute Pressure Sensor). 5.
Page 473 2. Install the exhaust manifold cover with three screws. Torque to 10.8-14.5ft.lbs. (14.7- 19.6Nm). XXIV. RESTRICTED EXHAUST SYSTEM DIAGNOSIS PROCEDURE: 1. Carefully remove the HEGO 2(Refer to VIII. Heated Exhaust Gas Oxygen Sensor). 2. Install Exhaust Back Pressure Test Gauge (J35314-A) in place of the HEGO 3.
Page 474 INSTALLATION PROCEDURE IMPORTANT The Catalytic converter is speciﬁcally designed to meet the emission control of the certiﬁed en- gine. Use only the OEM speciﬁed part. Install the Catalytic Converter using the OEM end product processes. 1. Start engine 2. Check for any DTC codes and clear 3.
Page 475: Definitions
Definitions...
Page 476 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.
Page 477 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...
Page 478 LPG: Liquiﬁed Petroleum Gas. content of the exhaust gas. (See Lambda Sen- M85: A blend of gasoline and methanol consisting sor). of 85% methanol and 15% gasoline. Oxygenate: Oxygenates (such as MTBE, ethanol MSV: (Abbreviated MSV). Refers to the manually and methanol) added to gasoline to increase the operated valve on the LPG tank.
Page 479 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- USB: Universal Serial Bus. A plug or interface sup- ber.
Page 481 TOOL KIT & ACCESSORIES...
Page 482 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...
Page 483: Appendix
Appendix...
Page 484 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 485 Ignition System Specifications Firing Order 1-3-4-2 Hyundai 27410-23400 Spark Plug Type NGK PFRN6N Champion RC8PYPB Spark Plug Gap .028-.031 in (0.7-0.8mm)