2011 LPG30 LLiu Gong Impco

2011 Emission Certified
LPG Fuel System

3.0L GM Engine
for LiuGong
Parts & Service Manual

Including Labor Time Guide
Revision B/May, 2011
2011 Emission Certified

LPG Fuel System
3.0L GM Engine for LiuGong
Parts & Service Manual
Table of Contents
General Information................................................................................................ 5
An overview of this Service Manual
Maintenance ........................................................................................................... . 9
General maintenance and maintenance interval information
Fuel System........................................................................................................... 17
An overview of the LPG fuel system and its components
LPG Fuel System Diagnosis ................................................................................ 27
How to identify a general problem
LPG Symptom Diagnostics .................................................................................. 35
How to correct a specific problem
Electrical Section .................................................................................................. 51
Diagnostic Scan Tool ...................................................................................... 53
Using the DST for testing and trouble shooting
Wire Schematic...................................................................................................81
Engine wiring schematics
Engine Wire Harness Repair .............................................................................85
Repairing a wire harness on the vehicle
Diagnostic Trouble Codes (DTCs) ....................................................................89
Application, schematic and DTC specific code information
Servicing the Fuel System .................................................................................... 237
Step by step instructions on how repair and/or replace fuel related Components
LPG Parts Diagram ................................................................................................ 255
Illustrations and part views
Labor Time Guide .................................................................................................. 299
The labor reimbursed by IMPCO for warrantable service and repairs
Definitions .............................................................................................................. 317
Definitions of phrases and acronyms used throughout this Service Manual
Appendix ............................................................................................................... . 323
Supplemental charts and tables
General Information
INTRODUCTION
Fuel other than HD-5 or HD-10 may cause harm

to the engines emission control system and a
warranty claim may be denied on this basis if operators can readily find the proper fuel.* Use of
any other fuel may result in your engine no longer
operating in compliance with CARB or EPA emissions requirements.
This service manual supplement has been developed to provide the service technician with the
basic understanding of the IMPCO certified fuel
and emission systems for the 3.0L GM engine.
This manual should be used in conjunction with
the base engine manual and the OEM service
manual when diagnosing fuel or electrical problems.
*Not Applicable in the state of California.

FUEL LINE CONNECTIONS
HOW TO IDENTIFY THE ENGINE YEAR

Loctite 567 is recommended for all NPT connections.
The emission label on the engine will identify the

specific model year.
SERVICING YOUR EMISSIONS
CERTIFIED ENGINE
Do not use Teflon tape to seal any fuel fittings. Fragments of the tape may enter into
the fuel system, causing damage or malfunction of critical fuel system components.
Any maintenance and repair should be performed

by trained and experienced service technicians.
Proper tools and equipment should be used to
prevent injury to the servicing technician and
damage to the vehicle or components. Service
repairs should always be performed in a safe environment and the technician should always wear
protective clothing to prevent injury.
AIR FILTRATION REQUIREMENTS

Dry filtration is required with maximum recommended 4 W.C. restriction @ 75 cfm. IMPCO
strongly recommends the use of OEM or factory
replacement parts.
For parts or labor to be reimbursed under the

IMPCO Technologies Inc. emission warranty, only
work performed by IMPCO or OEM trained technicians using only IMPCO specified parts will qualify
for reimbursement. Refer to the IMPCO Labor
Time Guide for additional information.
WASHING
Caution should be used when pressure washing
near or on an engines electrical system. Avoid
direct pressure spray on the system electrical
connectors. The electrical connectors are splash
resistant, but if high pressure water or steam is
sprayed directly at the connectors, moisture can
become trapped behind the connector seal and
cause serious system problems, many of them
showing up as intermittent.
For parts or labor not reimbursed under warranty, a

repair shop or person of the owners choosing may
maintain, replace, or repair emission-control
devices and systems. It is highly recommended
that any replacement parts used for maintenance
or for the repair of emission control systems be
new OEM replacement parts. The use of other
than genuine IMPCO replacement parts may impair the effectiveness of emission control systems,
therefore, the owner should assure that such parts
are warranted by their manufacturer to be equivalent to genuine IMPCO OEM parts in performance
and durability.
FUEL QUALITY
LPG engines and fuel systems are designed to
operate on HD-5 or HD-10 specification LPG fuel.
FUEL SYSTEM CAUTIONS
Unlike gasoline or propane vapors that

sink downward. Highly flammable
air/fuel mixtures may be present and
can be ignited causing personal injury.
Always work in well ventilated areas.
Do not use Teflon tape to seal any fuel

fittings. Fragments of the tape may enter into the fuel system, causing
damage or malfunction of critical fuel
system components.
WARNINGS, CAUTIONS AND NOTES

This manual contains several different Warnings,
Cautions, and Notes that must be observed to
prevent personal injury and or damage to the engine, the fuel system or personal property.
Do not smoke, carry lighted tobacco or

use a lighted flame of any type when
working on or near any fuel related
component. Highly flammable air-fuel
mixtures may be present and can be
ignited causing personal injury.
A WARNING is an advisement that by performing a process or procedure listed in this manual

improperly may result in serious bodily injury,
death and/or serious damage to the engine or
property.
Typical Warning Label:
Do not allow LPG to contact the skin.

LPG is stored in the fuel tank as a liquid. When LPG contacts the
atmosphere, it immediately expands into a gas, resulting in a refrigeration
effect that can cause severe burns to
the skin.
A WARNING is an advisement that

by performing a process or procedure
listed in this manual improperly may
result in serious bodily injury, death
and/or serious damage to the engine
or property.
A CAUTION label or statement is used when it
has been determine that by performing a process
or procedure defined in the manual improperly a
less severe result may occur. It could however,
result in serious bodily injury, and or serious damage to the engine or property damage.
Do not allow LPG to accumulate in areas below ground level such as in a

service pit or underground ventilation
systems. LPG is heavier than air and
can displace oxygen, creating a dangerous condition.
Less severe than WARNING but has the

potential to cause injury or damage.
Also used to notify of situations that
could lead to eventual failure, injury or
damage.
Do not make repairs to the fuel system

if you are not familiar with or trained to
service Propane fuel systems. Contact
the dealer who sold you the engine to
locate a repair facility with trained
technicians to repair your fuel system.
This caution label may also appear in area of this

manual that applies to service and repair proce-
dures. In addition it may also be used to indicate

a failure to observe which may influence the terms
of the warranty.
An IMPORTANT statement generally denotes a
situation that requires strict adherence to the assembly, tightening, or service procedure. Failure
to observe this procedure could result in an unsafe condition or improper performance of the
engine or a component.
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 damage.
A NOTE statement applies to a specific item or

procedure that is to be followed during the servicing of the engine or its components.
PROPER USE OF THIS SERVICE MANUAL,
TOOLS AND EQUIPMENT
To reduce the potential for injury to the technician
or others and to reduce damage to the engine during service repairs the technician should observe
the following Steps:
The service procedures defined in this manual, when followed, have been found to be a
safe and efficient process to repair the fuel
system. In some cases special tools may be
required to perform the necessary procedures
to safely remove and replace a failed component.
Tools identified in this manual with the prefix
J or BT can be procured through SPX in
Warren, Michigan.
IMPCO tools identified in this manual with a
prefix ITK can be acquired through OEM
Parts Distribution.
IMPORTANT
It is important to remember that there may be a
combination of Metric and Imperial fasteners used
in the installation of the IMPCO fuel system.
Check to insure proper fit when using a socket or
wrench on any fastener to prevent damage to the
component being removed or injury from slipping
off the fastener.
The fuel system utilizes fuel lines and hoses with
high pressure connectors. Always use a wrench
of the proper size and torque to the correct value.
For hoses with swivel fittings, be sure not to turn
the fixed fitting which may cause a twisting or
kinking of the hose, possibly resulting in fuel line
restriction and/or leak.
Maintenance
MAINTENANCE
SERPENTINE BELT SYSTEM
The maintenance of an engine and related components are critical to its operating performance
and lifespan. Industrial engines operate in environments that often include hot and cold
temperatures and extreme dust. The recommended maintenance schedule is listed in this
section, however, environmental operating conditions and additional installed equipment may
require more frequent inspection and servicing.
The owner and/or service agent should review the
operating conditions of the equipment to determine the inspection and maintenance intervals.
Serpentine belts utilize a spring-loaded tensioner

to keep the belt properly adjusted. Serpentine
belts should be checked according to the maintenance schedule in this section.
IMPORTANT:
The use of belt dressing or anti-slipping
agents on belts is not recommended.
COOLING SYSTEM
It is important that the cooling system of the engine be maintained properly to ensure proper
performance and longevity.
When performing maintenance on the engine,

turn the ignition OFF and disconnect the battery negative cable to avoid injury or damage
to the engine.
Alcohol or Methanol based anti-freeze or

plain water are not recommended for use
in the cooling system at anytime.
ENGINE BELTS
The engine installed in this equipment uses a serpentine drive belt configuration that drives the
water pump, alternator and additional pumps or
devices. It is important to note that the drive belt
is an integral part of the cooling and charging system and should be inspected according to the
maintenance schedule in this section. When inspecting the belts check for:
Cracks
Chunking of the belt
Splits
Material hanging loose from the belt
Glazing, hardening
If any of these conditions exist the belt should be

replaced with the recommended OEM replacement belt.
Do not remove the cooling system pressure cap (radiator cap) when the engine is
hot. Allow the engine to cool and then
remove the cap slowly to allow pressure
to vent. Hot coolant under pressure may
discharge violently.
NOTE that the LPG vaporizer is connected to the
cooling system and the fuel system may be adversely affected by low coolant levels and
restricted or plugged radiator cores. Therefore,
the cooling system must be maintained according
to the recommend maintenance schedule in this
section and also include:
Alcohol or Methanol based anti-freeze or

plain water are not recommended for use in
the cooling system at anytime.
10
The regular removal of dust, dirt and debris

from the radiator core and fan shroud.
Inspection of coolant hoses and components
for leaks, especially at the radiator hose connections. Tighten hose clamps if necessary.
Check radiator hoses for swelling, separation,
hardening, cracks or any type of deterioration.
If any of these conditions exist the hose

should be replaced with a recommended OEM
replacement part.
Inspect the radiator cap to ensure proper sealing.
COOLANT
Check coolant level in coolant recovery tank and
add coolant as required. Add 50/50 mixture of
GM Dexcool antifreeze and water or coolant per
engine manufacturers instructions. Do not add
plain water. Replace coolant per the recommended schedule.
Verify that any additional electrical services

installed by the owner are properly installed in
the system.
Verify that the MIL, charging, and oil pressure
lights illuminate momentarily during engine start.
ENGINE CRANKCASE OIL
OIL RECOMMENDATION
Select an engine oil viscosity that will best match
the prevailing daytime temperature:
IMPORTANT:
The manufacturers of the engine and fuel system
do not recommend the use of stop leak additives
to repair leaks in the cooling system. If leaks are
present the radiator should be removed and repaired or replaced.
ENGINE ELECTRICAL SYSTEM MAINTNANCE
The engines electrical system incorporates computers to control various related components. The
electrical system connections and ground circuits
require good connections. Follow the recommended maintenance schedule in this section to
maintain optimum performance. When inspecting
the electrical system check the following:
Check Positive and Negative cables for corrosion, rubbing, chafing, burning and to ensure
tight connections at both ends.
Check battery for cracks or damage to the
case and replace if necessary.
Inspect engine wire harness for rubbing, chafing, pinching, burning, and cracks or breaks in
the wiring.
Verify that engine harness connectors are correctly locked in by pushing in and then pulling
the connector halves outward.
Inspect ignition coil wire for hardening, cracking, arcing, chafing, burning, separation, split
boot covers.
Check spark plug wires for hardening, cracking, chafing, arcing or burning, separation, and
split boot covers.
Replace spark plugs at the required intervals
per the recommended maintenance schedule.
Verify that all electrical components are securely mounted to the engine or chassis.
The oil must meet GM specification 9986231. Motor oils meeting this spec receive the API
(American Petroleum Institute) starburst symbol:
ILSAC GF-4 oils are highly recommended. Oils

meeting the SL-4 spec are improved over the previous generation GF-3 oils in many ways
11
Reduced Phosphorous levels (20%) for reduced catalyst poisoning

Improved oxidation resistance (4X oxidation
inhibitor treat level = 100% improvement)
Improved hi temp deposit control (1.5X detergents = 25% improvement)
It is noted that the GF-4 oils are also backward

compatible and are equal or better than previous
grades of oil in all aspects.
OEMs may opt for higher viscosity oils based on
their application experience however GF-4 oils
may not be available in these viscosity ranges. In
this case it is recommended the OEM utilize high
quality oil (API rating SM).
Engine Oil Dip Stick (Typical)
CAUTION: Do not to operate your engine with an
oil level below the normal operating range. Severe engine damage could occur.
SYNTHETIC OILS
Synthetic oils have been available for use in industrial engines for a relatively long period of
time and may offer advantages in cold and hot
temperatures. However, it is not known if synthetic oils provide operational or economic
benefits over conventional petroleum-based oils
in industrial engines. Use of synthetic oils does
not permit the extension of oil change intervals.
CHECKING/FILLING ENGINE OIL LEVEL
IMPORTANT:
Care must be taken when checking engine oil level. Oil level must be maintained between the
ADD mark and the FULL mark on the dipstick.
To ensure that you are not getting a false reading,
make sure the following steps are taken before
checking the oil level.
1. Stop engine.
2. Allow approximately five minutes for the oil to
drain back into the oil pan.
3. Remove the dipstick. Wipe with a clean cloth
or paper towel and reinstall. Push the dipstick
all the way into the dipstick tube.
4. Remove the dipstick and note the amount of
oil on the dipstick. The oil level must be between the FULL and ADD marks.
5. If the oil level is below the ADD mark reinstall

the dipstick into the dipstick tube and proceed
to Step 6.
6. Remove the oil filler cap from the valve cover.
7. Add the required amount of oil to bring the
level up to, but not over, the FULL mark on
the dipstick. Reinstall the oil filler cap to the
valve rocker arm cover and wipe any excess
oil clean.
CHANGING THE ENGINE OIL
IMPORTANT:
When changing the oil, always change the oil
filter.
1. Start the engine and run until it reaches normal operating temperature.
An overfilled crankcase (oil level being too

high) can cause an oil leak, a fluctuation
or drop in oil pressure. When overfilled,
the engine crankshafts splash and agitate
the oil, causing it to aerate or foam.
IMPORTANT:
Change oil when engine is warm and the old oil
flows more freely.
2. Stop engine
12
Engine oil will be hot. Use protective

gloves to prevent burns. Engine oil contains chemicals which may be harmful to
your health. Avoid skin contact.
3. Remove drain plug and allow the oil to drain.
4. Remove and discard oil filter and its sealing
ring.
5. Coat sealing ring on the new filter with clean
engine oil, wipe the sealing surface on the filter
mounting surface to remove any dust, dirt or
debris. Tighten filter securely (follow filter manufacturers instructions). Do not over tighten.
6. Check sealing ring on drain plug for any damage, replace if necessary, wipe plug with clean
rag, wipe pan sealing surface with clean rag
and re-install plug into the pan. Tighten to the
OEM specification.
7. Fill crankcase with oil.
8. Start engine and check for oil leaks.
9. Dispose of oil and filter in a safe and responsible manner.
FUEL SYSTEM INSPECTION AND
MAINTENANCE
LPG FUEL SYSTEM
The LPG fuel system installed on this industrial
engine has been designed to meet the emission
standard applicable for the 2011 model year. To
ensure compliance to these standards, follow the
recommended maintenance schedule contained in
this section.
INSPECTION AND MAINTENANCE OF THE
FUEL STORAGE CYLINDER
The fuel storage cylinder should be inspected
daily or at the beginning of each operational shift
for any leaks, external damage, adequate fuel
supply and to ensure the manual service valve is
open. Fuel storage cylinders should always be
securely mounted, inspect the securing straps or
retaining devices for damage ensure that all locking devices are closed and locked. Check to
ensure that the fuel storage cylinder is positioned
with the locating pin in the tank collar on all horizontally mounted cylinders this will ensure the
proper function of the cylinder relief valve.
When refueling or exchanging the fuel cylinder,

check the quick fill valve for thread damage. Also
verify O-ring is in place and inspect for cracks,
chunking or separation. If damage to the o-ring
is found, replace prior to filling. Check the service line quick coupler for any thread damage.
IMPORTANT:
When refueling the fuel cylinder, wipe both the
female and male connection with a clean rag prior
to filling to prevent dust, dirt and debris from being
introduced to the fuel cylinder.
INSPECTION OF THE FUEL FILTER
The LPG system on this emission certified engine
utilizes an in-line replaceable fuel filter element.
This element should be replaced, at the intervals
specified in the recommended maintenance
schedule. When inspecting the fuel filter check
the following:
Check for leaks at the inlet and outlet fittings,

using a soapy solution or an electronic leak
detector and repair if necessary.
Check to make sure filter is securely mounted.
Check filter housing for external damage or
distortion. If damaged replace fuel filter.
AIR FUEL MIXER/THROTTLE CONTROL

DEVICE MAINTENANCE AND INSPECTION
IMPORTANT:
The Air Fuel Mixer components have been
specifically designed and calibrated to meet the
fuel system requirements of the emission certified
engine. The mixer should not be disassembled or
rebuilt. If the mixer fails to operate or develops a
leak the mixer should be replaced with the OEM
recommended replacement parts.
When inspecting the mixer check for the following
items:
13
Leaks at the inlet fitting.

Fuel inlet hose for cracking, splitting or chaffing, replace if any of these condition exist.
Ensure the mixer is securely mounted.
Inspect air inlet hose connection and clamp.
Also inspect inlet hose for cracking, splitting or
chafing. Replace if any of these conditions exist.
Inspect Air cleaner element according to the

Recommended Maintenance Schedule found
in this section.
Check Fuel lines for cracking, splitting or chafing. Replace if any of these conditions exist.
Verify Throttle body return action to ensure
throttle shaft is not sticking. Repair if necessary.
Check for leaks at the throttle body and intake
manifold.
The measurement of oxygen in the exhaust

stream is measured in voltage and sent to the
ECM. The ECM then makes corrections to the
fuel air ratio to ensure the proper fuel charge and
optimum catalytic performance. Therefore, it is
important that the exhaust connections remain
secured and air tight.
PRESSURE REGULATOR MAINTENANCE AND

INSPECTION
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 sensor safe RTV sealant for repair
procedures. Silicon contamination will cause
a high but false HEGO signal voltage (rich
exhaust indication). The ECM will then reduce the amount of fuel delivery to the
engine, causing a severe driveability problem. If silicone contamination is suspected,
remove and visually inspect the sensor element. If contaminated, the portion of the
sensor exposed to the exhaust stream will
have a white powdery coating. Always be
sure to eliminate the cause of contamination
before replacing the sensor.
IMPORTANT:
The Pressure Regulator components have been
specifically designed and calibrated to meet the
fuel system requirements of the emission certified
engine.
If the Regulator fails to operate or develops a
leak, it should be repaired or replaced with the
OEM recommended replacement parts. When
inspecting the regulator check for the following
items:
Check for any fuel leaks at the inlet and outlet

fittings.
Check for any fuel leaks in the regulator body.
Check the inlet and outlet fittings of the coolant supply lines for water leaks.
Check the coolant supply lines for hardening,
cracking, chafing or splits. If any of these conditions exist replace coolant lines.
Check coolant supply hose clamp connections, ensure they are tight.
Check to ensure the Regulator is securely
mounted and the mounting bolts are tight.
Check the Regulator for external damage.
Check the Regulator electrical connections to
ensure the connector is seated and locked.
EXHAUST SYSTEM AND CATALYTIC

CONVERTER INSPECTION AND
MAINTENANCE
IMPORTANT:
The exhaust system on this emission certified engine contains Heated Exhaust Gas Oxygen
Sensors (HEGOs) which provide feedback to the
ECM on the amount of oxygen present in the exhaust stream after combustion.
When inspecting the Exhaust system check the

following:
14
Exhaust manifold at the cylinder head for

leaks and that all retaining bolts and shields (if
used) are in place.
Manifold to exhaust pipe fasteners to ensure
they are tight and that there are no exhaust
leaks repair if necessary.
HEGO electrical connector to ensure connector is seated and locked, check wires to ensure
there is no cracking, splits chafing or burn
through. Repair if necessary.
Exhaust pipe extension connector for leaks
tighten if necessary.
Visually inspect converter to ensure muffler is
securely mounted and tail pipe is properly
aimed.
Check for any leaks at the inlet and outlet of
the converter.
LPG CERTIFIED ENGINE MAINTENANCE REQUIREMENTS

For maintenance or other work that is not performed under warranty, maintenance, replacement, or repair of the
emission control devices and systems may be performed by any engine repair establishment or individual.
Perform the following maintenance on the engine at the hours indicated and at equivalent hour intervals thereafter.
This maintenance schedule represents the manufacturers recomInterval Hours
mended maintenance intervals to maintain proper engine/equipment
function. Federal, State, or Local regulations may require additional or
Daily 1000 1500 2000 2500 3000 3500 4000 4500 5000
more frequent inspection or maintenance intervals than those specified above. Check with the authority having jurisdiction for details.
General Maintenance Section

Visual check for fluid leaks
X
Check engine oil level
X
Check coolant level
X
Every 100 hours or 60 days of operation
Change engine oil and filter
Check LPG system for leaks
Prior to any service or maintenance activity
Inspect accessory drive belts for cracks, breaks, splits or glazing
X
X
X
X
X
Inspect electrical system wiring for cuts, abrasions or corrosion
X
X
Inspect all vacuum lines and fittings for cracks, breaks or hardening
X
X
Engine Coolant Section
Clean debris from radiator core
Change coolant--GM 6277M specification (Dexcool) 50-50
Every 5000 hours or five years
mixture with distilled water
Inspect coolant hoses for cracks, swelling or deterioration
X
X
X
X
X
Every 2,000 hours or two years, whichever occurs first
Replace coolant hoses and accessory drive belt
Engine Ignition System
Inspect Battery case for leaks or damage
X
X
X
X
X
Inspect battery cables for damage corrosion or contamination
X
X
X
X
X
Check all electrical connector retainer locks
X
X
X
X
X
Replace spark plugs
X
X
X
Inspect crank sensor timing wheel for debris or damage
Clean ignition coil
X
X
X
X
X
Check spark plug wires for cuts abrasions or hardening
X
Replace distributor cap and rotor
X
Replace spark plug wires
X
Fuel System Maintenance
Every 200 hours, or every 100 hours in dusty environment
Inspect air cleaner
Replace fuel filters
X
X
X
X
X
Inspect Shut-off Valve for leaks and closing
X
X
Leak check fuel lines, regulator, fuel rail and injectors
X
X
Check air induction and intake manifold for leaks
X
X
Check manifold for vacuum leaks
X
X
Drain Regulator oil build up
Engine Exhaust System
Inspect exhaust manifold for leaks
X
X
Inspect exhaust piping for leaks
X
X
Check HEGO sensor connectors and wires for burns, cuts or damage
X
X
Inspect catalyst for mechanical damage
X
X
Note that propane engines are designed to operate on HD5 or HD10 specification LPG fuel. Fuel other than HD5 or HD
10 may cause harm to the engines emission control system and a warranty claim may be denied on this basis if operators
can readily find the proper fuel*. Use of any other fuel may result in your engine no longer operating in compliance with CARB
or EPA emissions requirements. * Not Applicable in the state of California.
15
16
LPG Fuel System
17
LPG FUEL SYSTEM OPERATION
--
Tank Pressure
Regulated Pressure
Injected Gas
Intake Air
Exhaust Gas
Engine Control
Module
Air Cleaner
FPP
Catalytic Muffler
18
DESCRIPTION AND OPERATION OF THE FUEL

SYSTEMS
LPG FUEL SYSTEM
The primary components of the LPG fuel system are
the fuel storage tank, regulator, throttle control
device, fuel injectors, engine control module (ECM),
catalytic converter and Heated Exhaust Gas Oxygen (HEGO) Sensor.
Typical LPG Cylinder

1. Liquid Outage Fill Check Valve
2. Pressure Relief Valve
3. Liquid Outage valve w/quick disconnect coupling
4. Filler Valve
5. Fuel Gauge
6. Vapor Withdrawal Tube (when applicable)
7. 80% Limiter Tube
8. Fuel Level Float
9. Liquid Withdrawal Tube
LPG FUEL TANK

LPG is stored in the fuel tank as a liquid. The approximate pressure of the fuel in the tank is 16.5
bar (240 psi) when the tank is full at an ambient
temperature of 27 C (81F). The boiling point,
(temperature at which the liquid fuel becomes vapor) is approximately -40 C (-40 F). When the
fuel changes from liquid to vapor the fuel expands
and creates pressure inside the tank. When the
tank service valve is opened the pressure inside
the tank forces the liquid fuel out though the pickup
tube located near the bottom of the fuel cylinder.
SERVICE LINE
LPG flows from the fuel tank to the Regulator via
the service line connected to the tank utilizing a
quick coupler. The other end of the service line is
connected to a bulkhead connector, allowing for a
safe means of passing through the sheet metal
and into the engine compartment. The service
line is made of high pressure hose with special
material or possibly tubing which is compatible
with the LPG fuel and should always be replaced
with an OEM supplied part.
The service valve mounted in the end of the cylinder controls the flow of fuel from the tank. By
turning the handle to its open position, fuel flows
out of the tank and into the service line. The service valve is also equipped with a safety feature
called an excess flow check valve. This feature
reduces the flow from the service valve in the event
of a rupture of the fuel line or any downstream fuel
transport components. A safety valve is built into
the tank. Normally set at 25.8 bar (375 psi), it will
release pressure to prevent tank rupture due to
over-pressurization of the cylinder
The bulkhead assembly should never be

removed. Never run a service line through
the sheet metal.
FUEL FILTER
LPG, fuel like all other motor fuels is subject to
contamination from outside sources. Refueling of
the equipment tank and removal of the tank from
the equipment can inadvertently introduce dirt,
rust and other foreign matter into the fuel system.
It is therefore necessary to filter the fuel prior to
entering the fuel system components downstream
19
of the tank. A replaceable, high pressure, inline

fuel filter is built into regulator and another is in
line between the regulator and fuel rail. Maintenance of the filters is critical to proper operation
of the fuel system and should be replaced according to the maintenance schedule or more
frequently under severe operating conditions.
connection with the throttle and there is no direct

mechanical (cable) connection between the pedal
and the throttle shaft.
The ECM monitors the foot pedal position sensor
when the engine is running. When the operator
depresses or releases the foot pedal, the ECM
sends an electrical signal to the motor on the
electronic throttle to increase or decrease the angle of the throttle blade thereby increasing or
decreasing the volume of air delivered to the engine. Two internal Throttle Position Sensors
(TPSs) provide feedback to the ECM indicating
the position of the throttle shaft and blade. Defaults programmed into the ECM software ensure
correct speed, load and emission control for all
throttle ranges.
REGULATOR
The Regulator is a combination vaporizer and pressure regulating device with a built-in LPG shut-off
solenoid valve. The fuel shutoff is a normally
closed valve on the vaporizer, controlled by the
ECM. The valve is opened is opened momentarily
when the ignition is first turned on to allow the system to pressurize and when the engine is running.
When open, LPG passes into the regulator and any
liquid LPG is vaporized by heat provided by the engine coolant. The fuel vapor pressure is then
reduced to approximately 88 kPa (12.6 psi) and
delivered to the fuel rail and fuel injectors. The outlet fuel pressure is referenced to the manifold
pressure for a more stable idle.
A throttle related failure will cause a LIMP

HOME mode of operation, where the engine has
no response to the pedal.
THREE WAY CATALYTIC CONVERTER
The Catalytic Converter is a component of the
emissions system which is designed and calibrated to meet the emission standards in effect for
2011 model year.
Regulator
The exhaust gases pass through the honeycomb

catalyst which is coated with a mixture of metals
(such as platinum, palladium, and rhodium) to
oxidize and reduce CO, HC and NOx emission
gases.
The regulator and some of components are serviceable.

THROTTLE CONTROL DEVICEDRIVE BY
WIRE
Speed control is maintained by the amount of pressure applied to the foot pedal located in the engine
compartment, however, in this Drive By Wire
(DBW) application, the foot pedal has an electronic
20
Engine Control Module (ECM)
Three Way Catalytic Converter
The ECM also performs diagnostic functions on

the fuel system and notifies the operator of engine malfunctions by turning on a Malfunction
Indicator Light (MIL) mounted in the dash. Malfunctions in the system are identified by a
Diagnostic Trouble Code (DTC) number. In addition to notifying the operator of the malfunction in
the system, the controller also stores the information about the malfunction in its memory. A
technician can than utilize a computerized diagnostic scan tool to retrieve the stored diagnostic
code and by using the diagnostic charts in this
manual to determine the cause of the malfunction. In the event a technician does not have the
computerized diagnostic tool.
ENGINE CONTROL MODULE

To obtain maximum effect from the catalyst and
accurate control of the air fuel ratio, the emission
certified engine is equipped with an onboard
computer or Engine Control Module (ECM). The
ECM is a controller which receives input data
from sensors mounted to the engine and fuel system and then outputs various signals to control
engine operation.
HEATED EXHAUST GAS OXYGEN SENSOR

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

(HEGO) is an emissions control component. In the event of a failure, the HEGO
should only be replaced with the recommended OEM replacement part. The
HEGO is sensitive to silicone based products and can become contaminated.
Avoid using silicone sealers or air or fuel
hoses treated with a silicone based lubricant.
The Heat Exhaust Gas Oxygen (HEGO) Sensor
TMAP SENSOR
The Air Temperature/Manifold Absolute Pressure
or TMAP sensor is a combination of two sensors:
1) A variable resistor used to monitor the difference in pressure between the intake manifold
and outside or atmospheric pressure. The
ECM monitors the resistance of the sensor to
determine engine load (the vacuum drops
when the engine is under load or at wide
open throttle) and may alter the fuel mixture
to improve performance and emissions.
HEGO voltage output.
2) The Manifold Air Temperature (MAT or IAT)
sensor is a variable resistance thermistor located in the air intake passage which measures
the temperature of the incoming air. The ECM
uses the resistance value to monitor incoming
air temperature and calculate the engines
airflow requirement. The ECM provides a
voltage divider circuit so that when the air is
cool, the signal reads a higher voltage, and
lower when warm. On cold starts, the ECM
richens the fuel/air mixture.
22
IGNITION SYSTEM
TMAP Sensor
COOLANT TEMPERATURE SENSOR
The Engine Coolant Temperature sensor or ECT is
a variable resistance thermistor that changes resistance as the engine's coolant temperature
changes. The sensor's resistance 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.
The ignition system spark system uses a Crank

Position and Camshaft Position sensor for engine
timing. A coil assembly contain an ignition coil
and an ignition module supplies the ignition spark
for the system. The coil is fired for each cylinder
over two engine revolutions. The distributor
routes each spark event to the appropriate cylinder spark plug. The plug is fired near the top of
the compression stroke to ignite the fuel and air
mixture.
CAM SENSOR
In the 2011 engine the CAM sensor and a cam
signal wheel are incorporated into the ignition distributor mounted on the side of the engine block.
Coolant Temperature Sensor

OIL PRESSURE SENDER
CRANK SENSOR
The Engine Oil Pressure Sender is designed to ensure adequate lubrication throughout the engine. It
is monitored by the ECM. If the pressure drops, a
MIL will occur.
Crank Sensor
The crank position sensor is a Hall effect sensor
that is triggered by a reluctor wheel on the crankshaft. Two missing teeth are used to determine
Oil Pressure Sender
23
engines rotational position. The crank sensor is the

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

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

The 2011 saturated drive injectors operate on a two
24
LPG Closed Loop Schematic
25
26
LPG System Diagnosis
27
LPG FUEL SYSTEM DIAGNOSIS
Regulator Assembly
FUEL SYSTEM DESCRIPTION
The Engine Control Module (ECM) receives

information from various engine sensors in
order to control the operation of the engine.
LPG is stored in the tank as a liquid and delivered under pressure up to 21.5 BAR (312
psi). At Key ON the Regulator allows LPG to
flow from the tank through the fuel filter and
inside, where fuel is vaporized and reduced in
pressure.
Verify the manual shut off valve on the

LPG tank is fully opened.
Verify that the excess flow valve has not
been activated.
Inspect fuel tank to ensure it is properly
mounted and rotated to the correct position.
Inspect the hoses leading from the tank
ensuring they are properly connected and
do not have any kinks or damage.
TOOLS REQUIRED:
DIAGNOSTIC AIDS
This procedure is intended to diagnose a vehicle operating on LPG. If the vehicle will not
continue to run refer to Hard Start for preliminary checks. Before starting this procedure,
complete the following tasks to verify that liquid fuel is being delivered to the EPR:
PRESSURE GAUGES
7/16 Open end wrench (for test port

plugs)
Test port adapter
DST
Inspect fuel tank to verify it has a sufficient

amount of fuel.
28
Diagnostic Scan Tool (DST)
0-15 PSI Gauge
FUEL SYSTEM DESCRIPTION

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

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

Step
1
Action
Value(s)
Were you referred to this procedure by a DTC diagnostic

Chart?
Connect the Diagnostic Scan Tool (DST) to the ECM Data Link
Connector (DLC) and check for any DTCs.
Are any DTCs present in the ECM?
Perform the following visual and physical preliminary checks:
Check all ECM system fuses and circuit breakers (refer to
Engine Wiring Schematic).
Check the ECM grounds for being clean, tight and in their
proper locations (refer to Engine Wiring Schematic).
Check the vacuum hoses for damage, splits, kinks and proper connections.
Check the fuel system for any type of leak or restriction from
the supply tank.
Check for air leaks at all mounting areas of the intake manifold sealing surfaces.
Check for air leaks at all intake ducting between intake manifold and air cleaner.
Check air cleaner and all vehicle intake ducting for restrictions.
Check exhaust system for flow obstructions or leaks.
Yes
No
Go to Step
(3)
Go to
Step (2)
Go to applicable DTC
Table
Go to
Step (3)
Correct
the faulty
condition
and Go to
Step 20
Go to
Step (4)
Go to Step
(9)
Go to
Step (5)
Correct
the faulty
condition
and Go to
Step 20
Go to
Step (6)
Check the ignition wires for the following conditions:

Cracking or hardening
Proper routing
Bare or shorted wires
Carbon tracking
Check the wiring harness for the following conditions:
Proper connections
Pinches
Cuts or abrasions
Were any faulty conditions found in the preliminary checks?
4
Does the vehicle start and run?

Check the fuel system for the following conditions:
Verify the LPG fuel tank is at least full.
Verify the manual fuel shut-off valve is open and operating
correctly.
Verify the high-flow valve has not tripped.
Verify the quick disconnect is fully engaged and there are no
kinks or obstructions in the high pressure LPG supply hose.
Verify the LPG fuel filter is clean and unobstructed.
Were any faulty conditions found in the fuel supply system?
30
Step
Action
Value(s)
Yes
Connect a calibrated 0-5 PSI pressure gauge to the primary pressure test port of the Regulator.
Make sure the manual shut-off valve is open and turn the
ignition to ON.
Crank the engine and observe the pressure gauge.
6
Does the pressure gauge indicate the proper primary fuel

pressure?
No
If NO
pressure
was indicated, Go
to Step
(14)
2.04.0
PSI
Go to Step
If LOW or
(7)
HIGH
pressure
was indicated,
Go to
Step
(15)
LPG is a gaseous fuel and requires higher secondary ignition voltages than gasoline fueled engines. Check the
ignition system for proper ignition secondary voltage output
with J 26792 or equivalent.
Remove the spark plugs and check for the following:

Correct plug type for LPG application.
Wet electrodes (oil fouling)
Cracks
Wear
Improper gap
Burned electrodes
Heavy deposits
Correct
the faulty
condition
and
Go to Step
(20)
Go to
Step (8)
Go to Step
(12)
Repair
the engine as
necessary and
Go to
Step
(20)
Go to Step
(16)
Go to
Step
(10)
Were any faulty conditions found in the ignition system

check?
Perform a leak-down test on the engine.
Are all cylinder leak-down test results within specification?
<10%
leakage
Turn OFF the manual fuel shut-off valve.

Start the engine and let it run until it dies.
Remove the LPG Temperature Sensor from the Regulator (DO NOT disconnect the electrical connector).
Inspect the inside of the low-pressure fuel supply hose
for heavy-end deposits.
Are there any deposits built-up in the low-pressure fuel supply hose?
31
Step
Action
10
11
12
13
14
15
Values
Yes
No
Remove the FAP sensor from the Fuel Rail and insert the
Pressure Test Adapter and connect to 103 kPa (15 PSI)
pressure gauge.
Connect the DST to the vehicle DLC connector and open the
DST software.
Turn the manual shut-off valve ON. Start the engine and
allow it to reach operating temperature.
Compare the gauge secondary pressure reading to the actual

pressure on the DST.
+/-15 kPa
(2.2 PSI)
Is the gauge secondary pressure within the specified percentage of the actual pressure indicated on the DST?
Turn OFF the manual shut-off valve and let the engine run
until it dies.
Turn the ignition OFF.
Go to Step Go to
19
Step (11)
Go to Step Go to
(14)
Step (13)
If turned OFF, turn ON the manual shut-off valve.

Disconnect the Lock-off valve electrical connector.
Apply 12V to the lock-off valve terminals and observe the
pressure gauge.
Does the pressure gauge indicate pressure?
Repair or replace the Shut Off Valve (refer to Repair Instructions).
Is the action complete?
32
Above
1.0 PSI
Go to Step
17
Go to
Step 18
Go to Step
20
NA
Step
Action
Values
Yes
No
Go to Step
20
NA
Go to Step
20
NA
Go to Step
20
NA
Go to Step
20
NA
-15% to
+15%
Go to Step
21
Go to
Step 24
-15% to
+15%
Go to Step
22
Go to
Step 24
-15% to
+15%
Go to Step
23
Go to
Step 24
-15% to
+15%
Go to Step
29
Go to
Step 24
Inspect the following for heavy-end deposits:

16
Pressure Regulator. Inspect, clean and/or repair as necessary (refer to Regulator Repair Instructions).
Are all actions complete?
Replace the ECM.
17
Replace the Shut Off Valve.
18
19
20

System working correctly at this time. Vehicle may have
intermittent electrical connection conditions.
Return vehicle to original condition (but leave the diagnostic
equipment connected).
Start the engine and wiggle test the harness while observing
the DST Faults Screen and the pressure gauge readings.
Repair any conditions encountered.
Clear any active or historic DTCs (DST Service or Faults
Screen).
Clear Adaptive from memory (DST Service Screen).
Return the vehicle to original condition.
Operate the vehicle under all load and driving conditions for
at least 10 minutes.
Park the vehicle with the engine running and connect the
DST to the vehicles DLC connector.
Open the DST software and switch to the Faults Screen.
Let the vehicle idle with no load for at least 30 seconds and
observe the Adaptive 1 fuel correction.
Did the Adaptive 1 fuel correction remain within the specified
values?
With engine still idling, apply a load with the hydraulic system
for at least 10 seconds and observe the Adaptive 1 value.
21
22
23
Did the Adaptive 1 fuel correction remain within the specified

values?
Raise the engine rpms to 75-90% of maximum full governed
speed with no load for at least 10 seconds and observe the
Adaptive 1 fuel correction.
Did the Adaptive 1 fuel correction remain within specified values?
With the engine still running at 75-90% of full governed
speed, apply a moderate load with the hydraulic system.
Observe the Adaptive 1 fuel correction.
Did the Adaptive 1 fuel correction remain within specified values?
33
Step
Action
Values
Yes
No
24
Was the Adaptive 1 fuel correction less than -15%?
Go to Step Go to
(26)
Step (25)
25
Was the Adaptive 1 fuel correction more than +15%?
Go to Step
(27)
NA
Go to Step
(28)
NA
Go to Step
(28)
NA
NA
NA
NA
NA
26
Engine is running RICH (system is trying to compensate by decreasing the amount of fuel). Check the following for any
condition which may cause the engine to run RICH:
Ignition system (See Step 7).
Air cleaner and intake system (including vehicle intake
ducting) for airflow obstructions.
Exhaust system for flow obstructions.
HEGO for correct switching characteristics.
Engine is running LEAN (system is trying to compensate by
increasing the amount of fuel). Check the following for any
condition which may cause the engine to run LEAN:
Intake manifold for leaks.
All throttle body gaskets or o-rings for leaks.
All vacuum hoses and fittings for leaks.
Exhaust system for leaks
27
NOTE: Exhaust system leaks allow for excess O2 to dilute the

HEGO sensor giving a false reading. Engine may exhibit signs
of a rich running condition but the Adaptive 1 corrections will
indicate an excessive positive fuel adjustment.
HEGO for correct switching characteristics.

28
Repeat Step 20.
29
Remove all test equipment except the DST.

Connect any disconnected components, fuses, etc.
Using the DST clear DTC information from the ECM.
Turn the ignition OFF and wait 30 seconds.
Start the engine and operate the vehicle to full operating
temperature
Observe the MIL
Observe engine performance and driveability
Does the engine operate normally with no stored codes?

Remove all diagnostic equipment and return vehicle to original
condition. Return vehicle to customer.
34
Fuel Symptom Diagnostics
35
FUEL SYMPTOM DIAGNOSTICS

Checks
Action
Before using this section, you should have performed On Board Diagnostic
(OBD) Check and determined that:
Before Using This

Section
1. The ECM and MIL are operating correctly.

2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists
but without a MIL.
Several of the following symptom procedures call for a careful visual and
physical check. These checks are very important as they can lead to prompt
diagnosis and correction of a problem.
1.
2.
3.
4.
Fuel System Check
Verify the customer complaint.

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

Check the ECM ground for being clean, tight and in its proper location.
Check the vacuum hoses for splits, kinks and proper connections.
Check thoroughly for any type of leak or restriction.
Check for air leaks at all the mounting areas of the intake manifold sealing
surfaces.
Check for proper installation and leakage around the Regulator and Throttle body.
Check the ignition wires for the following conditions:
Visual and Physical
Checks
Cracking
Hardening
Proper routing
Carbon tracking
Check the wiring for the following items: proper connections, pinches or
cuts.
The following symptom tables contain groups of possible causes for each
symptom. The order of these procedures is not important. If the DST readings do not indicate a problem, then proceed in a logical order, easiest to
check or most likely to cause the problem.
36
INTERMITTENT
Checks
Action
DEFINITION: The problem may or may not turn ON the (MIL) or store a Diagnostic Trouble Code
(DTC).
Preliminary Checks
Do not use the DTC table if a fault is an intermittent, the use of the DTC tables with this condition may result in the replacement of good parts.
Faulty electrical connections or wiring can cause most intermittent problems.
Check the suspected circuit for the following conditions:
Faulty Electrical Connections or Wiring
Operational Test
Faulty fuse or circuit breaker, connectors poorly mated, terminals not fully
seated in the connector (backed out). Terminals not properly formed or
damaged.
Wire terminals poorly connected.
Terminal tension is insufficient.
Carefully remove all the connector terminals in the problem circuit in order to ensure the proper contact tension.
If necessary, replace all the connector terminals in the problem circuit in
order to ensure the proper contact tension (except those noted as Not
Serviceable). See section Wiring Schematics.
Checking for poor terminal to wire connections requires removing the
terminal from the connector body.
If a visual and physical check does not locate the cause of the problem, operate the engine with the DST connected. When the problem occurs, an
abnormal voltage or scan reading indicates a problem circuit.
The following components can cause intermittent MIL and no DTC(s):
Intermittent MIL
Illumination
A defective relay.
Switch that can cause electrical system interference. Normally, the problem will occur when the faulty component is operating.
The improper installation of add on electrical devices, such as lights, 2way radios, electric motors, etc.
The ignition secondary voltage shorted to a ground.
The MIL circuit or the Diagnostic Test Terminal intermittently shorted to
ground.
The MIL wire grounds.
To check for the loss of the DTC Memory:
Loss of DTC Memory
1. Disconnect the TMAP sensor.

2. Run engine under no load until the MIL illuminates.
3. The ECM should store a TMAP DTC which should remain in the memory
when the ignition is turned OFF. If the TMAP DTC does not store and
remain, the ECM is faulty.
37
NO START
Checks
Action
DEFINITION: The engine cranks OK but does not start.

Preliminary Checks
None
Use the DST to :
ECM Checks
Check for proper communication with both the ECM

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

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

Cracks.
Wear.
Improper gap.
Burned electrodes.
Heavy deposits.
Check for bare or shorted ignition wires.
Check for loose ignition coil connections at the coil.
38
Checks
Action
Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel system.
Check for the following:
Engine Mechanical
Checks
Manifold vacuum leaks.

Venturi vacuum leaks.
Engine Vacuum leaks.
Improper valve timing.
Low compression.
Improper valve clearance.
Worn rocker arms.
Broken or weak valve springs.
Worn camshaft lobes.
Check the exhaust system for a possible restriction:

Exhaust System Checks
Inspect the exhaust system for damaged or collapsed pipes.

Inspect the muffler for signs of heat distress or for possible internal failure.
39
HARD START
Checks
Action
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run,
or may start but immediately dies.
Preliminary Checks
Make sure the engines operator is using the correct starting procedure.
Sensor Checks
Check the Engine Coolant Temperature sensor with the DST. Compare
the engine coolant temperature with the ambient air temperature on a
cold engine. If the coolant temperature reading is more than 10 degrees
greater or less than the ambient air temperature on a cold engine, check
for high resistance in the coolant sensor circuit. Check the cam/crank
sensors.
Check the Throttle Position (TPS) and Foot Pedal Position (FPP) sensor
connections.
Important: A closed LPG manual fuel shut off valve will create a no start
condition.
Fuel System Checks
Check Venturi assembly for proper installation and leakage.

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

Cracks.
Wear.
Burned electrodes.
Heavy deposits.
Check for bare or shorted ignition wires.
Check for moisture in the distributor cap.
Check for loose ignition coil connections.
Important:
1. If the engine starts but then immediately stalls, check the cam/crank sensor.
2. Check for improper gap, debris or faulty connections.
40
Checks
Action
Important: The LPG Fuel system is more sensitive to intake manifold leakage than the gasoline fuel supply system.
Check for the following:
Engine Mechanical
Checks
Engine vacuum leaks

Venturi Vacuum Leaks
Improper valve timing-how?
Low compression
Worn rocker arms
Broken or weak valve springs

Check for possible plugged catalytic converter. Refer to Restricted Exhaust
System Diagnosis.
41
CUTS OUT, MISSES

Checks
Action
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load
increases, but normally felt below 1500 rpm. The exhaust has a steady spitting sound at low speed, or hard
acceleration for the fuel starvation that can cause the engine to cut-out.
Preliminary Checks
None
1.
2.
3.
4.
Start the engine.

Check for proper ignition output voltage with spark tester J 26792.
Check for a cylinder misfire.
Remove the spark plugs and check for the following conditions:
Insulation cracks.
Wear.
Improper gap.
Burned electrodes.
Heavy deposits.
Visually/Physically inspect the secondary ignition for the following:
Ignition wires for arcing and proper routing.

Cross-firing.
Ignition coils for cracks or carbon tracking.
Perform a cylinder compression check. Check the engine for the following:
Engine Mechanical
Checks
Fuel System Checks
Additional Check

Worn rocker arms.
Check the intake and exhaust manifold passages for casting flash.
Check the fuel system:
Plugged fuel filter (if equipped).

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

Checks
Action
DEFINITION: The engine has a momentary lack of response when accelerating the engine. The condition can occur at any engine speed. The condition may cause the engine to stall if its severe enough.
Preliminary Checks
None.
Fuel System Checks
Check the fuel pressure. Refer to Fuel System Diagnosis.

Check for low fuel pressure during a moderate or full throttle acceleration. If the fuel pressure drops below specification, there is possibly a
faulty low pressure regulator or a restriction in the fuel system.
Check the TMAP sensor response and accuracy.
Check Shut-Off electrical connections.
Check the Regulator, Venturi and Throttle body for proper installation
and leakage.
NOTE: Natural Gas and Propane require higher secondary ignition system
voltages for the equivalent gasoline operating conditions.
Additional Check
Check for the proper ignition voltage output with J 26792 or the equivalent. Verify that the spark plugs are the correct type and properly gapped.
Check for faulty spark plug wires.
Check for oil fouled spark plugs.
Check for manifold vacuum or air induction system leaks.

Check the alternator output voltage.
43
BACKFIRE
Checks
Action
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping
noise.
Preliminary Check
None.
NOTE: LPG requires higher secondary ignition system voltages for the
equivalent gasoline operating conditions.
Check for the proper ignition coil output voltage using the spark tester
J26792 or the equivalent.
Check the spark plug wires by connecting an ohmmeter to the ends of
each wire in question. If the meter reads over 30,000 ohms, replace the
wires.
Check the connection at ignition coil.
Check for deteriorated spark plug wire insulation.
Remove the plugs and inspect them for the following conditions:

Cracks.
Wear.
Improper gap.
Burned electrodes.
Heavy deposits.
Important! The LPG Fuel system is more sensitive to intake manifold

leakage than a gasoline fuel supply system.
Check the engine for the following:
Engine Mechanical
Check
Fuel System Checks

Engine compression.
Intake manifold gaskets.
Sticking or leaking valves.
Exhaust system leakage.
Check the intake and exhaust system for casting flash or other restrictions.
Perform a fuel system diagnosis. Refer to Fuel System Diagnosis.
44
LACK OF POWER, SLUGGISHNESS, OR SPONGINESS

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

Check for possible plugged catalytic converter.
Check the engine for the following:

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

Checks
Action
DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected.
Also, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by
refueling records.
Preliminary Checks
Fuel System Checks

Sensor Checks
Ignition System
Checks
Check the air cleaner element (filter) for dirt or being plugged.
Visually check the vacuum hoses for splits, kinks, and proper connections.
Properly inflated tires.
Check the operators driving habits for the following:

Excessive idling or stop and go driving.
Carrying of very heavy loads.
Rapid acceleration.
Suggest to the owner to fill the fuel tank and to recheck the fuel economy
and/or suggest that a different operator use the equipment and record the
results.
Check the Regulator fuel pressure. Refer to Fuel System Diagnosis.
Check the fuel system for leakage.
Check the TMAP sensor.

Cracks.
Wear.
Improper gap.
Burned electrodes.
Heavy deposits.
Check the ignition wires for the following items:
Cooling System
Checks
Cracking.
Hardness.
Proper connections.
Check the engine thermostat to see if it is stuck open or for the wrong heat
range.
46
ROUGH, UNSTABLE, OR INCORRECT ENGINE SPEED, STALLING

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

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

and accuracy.
Fuel System Checks
Check for rich or lean symptom that causes the condition.

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

Cracks.
Wear.
Improper gap.
Burned electrodes.
Blistered insulators.
Heavy deposits.
Check the spark plug wires by connecting an ohmmeter to the ends of each
wire in question. If the meter reads over 30,000 ohms, replace the wires.
Important: The LPG Fuel system is more sensitive to intake manifold leakage
than the gasoline fuel supply system.
Additional Checks
Check for vacuum leaks. Vacuum leaks can cause poor engine performance.
Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor readings to be skewed resulting
in poor engine performance.
47
Checks
Action
Check the engine for:
Engine Mechanical Check
Broken motor mounts.

Low compression.
Worn rocker arms.
48
SURGES/CHUGGLES
Checks
Action
DEFINITION: The engine has a power variation under a steady throttle. The engine feels as if it speeds
up and slows down with no change to the throttle.
Preliminary Checks
Sensor Checks
None.
Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance.
Fuel System Checks
Check for Rich or Lean symptom that causes the condition.

Run the engine at the speed of the complaint. Monitoring the oxygen sensor will help identify the problem.
Check the fuel pressure while the condition exists. Refer to Fuel System
Diagnosis.
Verify proper fuel control solenoid operation.
Verify that the LPG manual shut-off valve is fully open.
Check the in-line fuel filter for restrictions.
Check for the proper ignition output voltage using the spark tester J26792 or
the equivalent.
Ignition System
Checks

Cracks.
Wear.
Improper gap.
Burned electrodes.
Heavy deposits.
Check the Crankshaft Position (CKP) sensor.
Additional Check
Check the vacuum hoses for kinks or leaks.
Check Transmission
49
CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS

RESULTS OF INCORRECT OPERATION
A plugged positive crankcase ventilation (PCV) orifice or hose may cause the following conditions:
Rough or unstable engine speed

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

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

Inspect the PCV orifice in the valve cover for debris or blockage.
50
Electrical Section
51
52
DST (Diagnostic Scan Tool)
53
DST (Diagnostic Scan Tool)

Software Installation Instructions
Installation of the USB to CAN adapter driver and utility.

Installation of the Spectrum series IV DST software program.
Software login and password functionality.
DST INSTALLATION INSTRUCTIONS

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

NOTE: Close any open applications prior to installing the DST.
Insert the Ifak CD included with your USB to CAN adapter and open the file folder.
For users with restricted rights using Windows 7 or Windows Vista, select Run as administrator as shown above.
For all others, select the Setup file. You may receive a Windows message asking you to confirm the installation
request by an unknown publisher. You must select Yes to continue the installation.
55
Select the Next box to continue with the installation.
Enter your company name or organization and click the Next box. Follow the next steps using the recommended
defaults.
56
Click the Finish box to complete the installation. It is now recommended you re-boot your computer.
Connect the Ifak adapter to an available USB port. You may see a message confirming you wish to make changes
to the computer from an unknown publisher. If so, you must select the Yes box to continue the installation. Windows will now install the Ifak driver to your computer. You should see a message confirming the driver was
successfully installed as shown above.
57
Open the Start menu. You should see the is CAN Configuration utility confirming the utility installation. Select the
is CAN Configurator.
Click the Add box.
58
Select the USB button, then click the OK box.
Click on the Search attached device box.
59
When the Ifak device serial number is shown, click the Select box, then click the OK box. The Ifak driver and utility
installation is now complete. If you had problems during this installation please see the additional information and
test instructions for your Ifak adapter included with your service test kit.
60
Spectrum Series IV DST Software Installation:

In most instances the OEM manufacturer will have supplied you the DST software installation files. The installation files may have been provided to you by internet download, CD or other media storage. Regardless of the
delivery system, please follow the instructions to install the DST software below. If the files were supplied to you in
a .zip file format it is strongly recommended that the files are first unzipped before proceeding with the DST software installation.
Insert the CD, USB flash drive, other storage media or find the location where the DST software has been saved on
your computer.
Open the Spectrum_Series_IV_DST file folder.
61
For users with restricted rights using Windows 7 or Windows Vista, it may be necessary to select the Run as
administrator box similar to the Ifak USB driver installation. For all others, click the Spectrum Engine Monitor.msi file. You may receive a Windows message asking you to confirm the installation request by an unknown
publisher. If so, you must select the Yes box to continue the installation.
Click the Next box.
62
Follow the on screen prompts that will guide you through the installation.
The Spectrum 4 logo shortcut is placed on the desktop confirming the installation is complete. It is now recommended that you re-boot your computer.
63
Connecting the DST:
Connect the Diagnostic Link Connector or DLC to the Ifak adapters connector. Connect the other end of the DLC
connector to the engine harness (3 pin connector).
Click on the Spectrum 4 shortcut to open the DST software program. Turn the engine ignition power ON.
64
Click on the S3000 tab at the lower left of the Spectrum Engine Monitor page.
On the S3000 data stream page, pull down the Settings menu and click on Connection Settings
65
The Select CAN Device & Channel dialog box will appear. Select the Ifak device, and then click the OK box.
Under the Connection drop down menu, select Connect
66
When connected, the live data stream appears in the Value column.
67
Using the Spectrum DST

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

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

In field updates (or reflashing) are possible with the S3000 ECM using the DST. Always check first to be sure
the ECM has been programmed with the latest calibration before attempting any diagnostic or service repair procedure. Calibration files are supplied in the .s37 file format. These files may be supplied to you by the OEM along with
a password unique to that particular s.37 file. You will need the password to complete the re-programming
procedure. Before re-programming the ECM, shut down any other programs running on your PC including wireless
and e-mail programs. The PC must be dedicated to the re-programming process at this time. Be sure your PC battery is adequately charged. Failure to follow these instructions may render the ECM not usable in the field.
Under the Tools drop down menu, select Reprogram S3000 Engine Control Unit. Turn ignition power ON.
The S3000 Flash Upgrade Wizard dialog box will appear. Select the Next box.
69
Use the Browse box to navigate to the location of the calibration file.
Enter the password that was supplied with the calibration file.
70
Select the Next box.
The progress bar shows the status updating.
Any interruption during the re-programming

process may render the ECM unusable in
the field.
71
Please wait until you receive a message confirming the update is complete.
Turn the ignition power OFF. Wait 10 seconds and select Finish.
Turn the ignition ON. Verify the calibration updated with the new file number in the ECM Part Number data stream
shown above. The reprogramming process is now complete.
72
Graphic Display Interface
Shown as the monitor page in the DST, the above page is the default entry page that opens with the DST program. It provides a graphical interface for important engine parameters. Graphics shown in gray are not available
for the specific application the DST may be connected to as shown above. This function is controlled by the ECM
calibration file and cannot be changed by the service technician.
73
Display DTC (Diagnostic Trouble Codes)
DTC codes can be read by clicking on the Diagnostics tab at the bottom of the monitor page. The source of
the DTC stream can be set manually for the MEFI ECM or the S3000 ECM, or left in the default All position for auto
detection of the DTC codes from either MEFI or the S3000 ECM. Codes that can be viewed are set in two categories, active and historic. Active codes are codes that are set and the fault that is causing the code to set is
constant. Historic codes are codes that have set in the past, but the fault that caused them has been corrected
such as with an intermittent problem. This function is selectable by choosing the Active or Historic, as shown in
the above image. Codes can be cleared by clicking the Clear box. The DTC set code list may also be saved by
clicking the Save box shown above. The file will be saved in a convenient HTML file compatible with Windows Internet Explorer and will provide a browse function to save the file to a location of choice for the service technician.
74
Data Stream:
The fuel and emissions service manual will refer to the DST and asked that it be connected in the data stream
mode. This simply means it is first connected and that data is shown on the S3000 data stream page as shown
above. The data stream page can be accessed by selecting the S3000 tab shown at the lower left above.
Plot Data:
Data stream information may also be selected for a trace plot. This page is available by clicking the Plot tab at the
lower page center as shown above.
75
The custom parameters of the plot can be selected by clicking on the plot icon just below the Settings menu item
at the top left of the page shown above. To save the custom settings select OK.
76
Diagnosing Intermittent Problems

Intermittent fuel system problems can prove to be the most challenging to diagnose. It is of the upmost
important when diagnosing intermittent problems to operate the engine system while monitoring with the
DST and pressure gauge set. An example of this would be if the DST showed a lean fuel mixture at full
load. One of the first things to look at would be the fuel pressure. The fuel pressure would need to be monitored while the engine is operating at full load, not at low or no load because the leaning effect does not
occur until full load. Electrical problems should be treated in a similar same way. One excellent tool for
finding intermittent electrical problems is the DST plot function. Set up the plot for the sensor code that sets.
An example of this would be if an intermittent IAT code set, tag the IAT voltage and watch the plot. While
watching the plot, agitate the electrical wire connection at the sensor and ECM connector. The resolution
of the plot screen is such that you will be able to see any unstable voltages that you may not see with a
standard DVOM.
Caution should be used when pressure washing the under hood of any electrical system. Avoid direct
pressure spray on the system electrical connectors. The connectors are splash proof but if high pressure
water or steam is sprayed directly at the connector moisture can become trapped behind the connector seal
and cause serious system problems, many of them showing up as intermittents. Extra care must be taken
when probing electrical pins and terminals. Do not bend or spread these terminals as this can also be a
source of intermittent problems cause by improper handling of these low voltage connectors and terminals.
When running electrical diagnostics avoid back probing the wire connectors as this may damage the wire
seal. When running the continuity checks use a wire probe to only touch the wire terminal. Forc- ing the
electrical probe into the terminal may cause the terminal to spread leading to permanent damage. More
Intermittent diagnostic information can be found on the Fuel Symptom Diagnostics, Intermittent Diag- nostic
Charts.
Fuel System Checks

This system has OBD (Onboard Diagnostics) for many sensors, relays and monitors, but not all malfunctions have a DTC code available to alert the service technician to a problem. A good example of this
would be the engine ignition system. If a spark plug, cap, rotor or wire fails a DTC code may not be set. The
DST provides advanced diagnostic capabilities, but some items are still left to the basics of general engine
mechanics. Following the recommended maintenance schedule is the best way to prevent this type of
problem for which a DTC code does not exist. Many times the basics are overlooked and can be at- tributed
to improper maintenance. Some general rules to follow are:
Check to be sure the ECM is programmed with the latest calibration file
Check general engine tune up items such as spark plugs, distributor cap and rotor, spark plug wires,
air, and fuel filters if equipped with such.
Check that the charging system is working correctly.
Check block heaters, battery heaters, battery terminals and fuel supply systems for proper operation.
77
78
INTERMITTENT PROBLEMS
Intermittent fuel system problems can prove to be the most challenging to repair. It is most important to
remember when looking to find the cause of these problems, to operate the system in the condition when
and where the problem occurs. An example of this would be, if the DST showed a lean fuel mixture at full
load, one of the first things to look at would be the fuel pressure. The fuel pressure would need to be
monitored while the machine is operating at full load, not at idle because the leaning effect does not occur
at idle. Electrical problems should be treated the same way. One excellent tool for finding
intermittent electrical problems is the DST plot/log function. Set up the plot for the code that sets. An example of this would be if an intermittent IAT code set, tag the IAT voltage and watch the plot. While
watching the plot, agitate the electrical wire connection at the sensor and ECM connector. The resolution
of the plot screen is such that you will be able to see any unstable voltages that you would otherwise not
see with a standard DVOM.
Caution should be used when pressure washing the under hood of any electrical system. Avoid direct
pressure spray on the system electrical connectors. They are splash proof, but if water is sprayed directly at the connector moisture can become trapped behind the connector seal and cause serious system
problems.
Extra care must be taken when probing electrical pins and terminals. Do not bend or spread these terminals as this can also be a source of intermittent problems cause by improper handling of these
connectors.
79
80
Engine Wire Schematic
81
2011 3.0L GM Engine IMPCO Emission Certified LPG Fuel System

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82
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Engine Wire Harness Repair
85
ON-VEHICLE SERVICE
WIRE HARNESS REPAIR
REPAIRING TWISTED/SHIELDED CABLE
The ECM harness electrically connects the

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

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

system, so it is important that the best possible
bond at all wire splices be made by soldering the
splices.
3. Untwist conductors, strip insulation as
necessary.
CONNECTORS AND TERMINALS

Use care when probing a connector or replacing
terminals in them to prevent shorting opposite
terminals and damage certain components. Always use jumper wires between connectors, for
circuit checking. Do not probe through the
Weather-Pack seals with oversized wire probes.
Use tachometer adapter J 35812 (or equivalent)
which provides an easy hook up of the tach lead.
The connector test adapter kit J 35616 (or
equivalent), contains an assortment of flexible
connectors used to probe terminals during diagnosis. Fuse remover and test tool BT 8616, or
equivalent, is used for removing a fuse and to
adapt fuse holder, with a meter, for diagnosis. Do
not solder oxygen sensor wire terminals as these
wire ends are used for the sensors oxygen
reference.
4. Splice wire using splice clips and rosin

core solder. Wrap each splice to insulate.
5. Wrap with Mylar and drain wire (uninsulated) wire.
6. Tape over entire juncture and secure.
Open circuits are often difficult to locate by sight

due to dirt, oxidation, or terminal misalignment.
Merely wiggling a connector on a sensor, or in
the wiring harness, may correct the open circuit
condition. This should always be considered,
when an open circuit, or failed sensor is indicated. Intermittent problems may also be caused by
oxidized or loose connections.
Before making a connector repair, be certain of
the type of connector. Weather-Pack and Compact Three connectors look similar, but are
serviced differently.
86
REPAIRING TWISTED LEADS
METRI-PACK
Some connectors use terminals called MetriPack Series 150. They are also called Pull-ToSeat 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 into the connector to seat it
in place.
1. Locate Damaged Wire.

2. Remove insulation as required.
3. Splice two wires together suing splice

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

other wires.
5. Retwist as before and tape with electrical
tape and hold in place.
MICRO-PACK
Refer to Figure 2 and repair procedure for replacement of a Micro-Pack terminal.
Metri-Pack Series 150 Terminal Removal

1. Slide the seal back on the wire.
2. Insert tool BT-8518, or J 35689, or equivalent, as shown in insert A and B to release
the terminal locking tab (2).
3. Push the wire and terminal out through the
connector. If reusing the terminal, reshape
the locking tab (2).
WEATHER-PACK
A Weather-Pack connector can be identified by a
rubber seal, at the rear of the connector. The
connector is used in the engine compartment to
protect against moisture and dirt that may oxidize and/or corrode the terminals. Given the low
voltage and current levels found in the electronic
system, this protection is necessary to ensure a
good connection.
Micropack Connector
1.
2.
3.
4.
Cable
Terminal
Locking Tang
Tool J33095/BT8234-A
87
WEATHER-PACK TERMINAL REPAIR
backup, or secondary locking feature for the

connector. They are used to improve the connector reliability by retaining the terminals, if the
small terminal lock tabs are not positioned
properly.
Weather-Pack connections cannot be replaced
with standard connections. Additional instructions are provided with Weather-Pack connector
and terminal packages.
1. Open secondary lock hinge on connector.
2. Remove terminal using tool.
3. Cut wire immediately behind cable seal
4. Replace terminal.
a. Slip new seal onto wire
b. Strip 5 mm (.2) of insulation from wire.
c. Crimp terminal over wire and seal.
5. Push terminal and connector and engage
locking tangs.
6. Close secondary lock hinge.
Use tool J M28742, or BT8234-A or equivalent to
remove the pin and sleeve terminals. If the removal is attempted with an ordinary pick, there is
a good chance that the terminal will be bent, or
deformed. Unlike standard blade type terminals,
these terminals cannot be straightened once
they are bent.
Verify that the connectors are properly seated
and all of the sealing rings in place, when connecting leads. The hinge type flap provides a
88
Diagnostic Trouble
Codes (DTCs)
89
Ignition Control System Diagnostics
Before using the Ignition Control Diagnostic chart be sure to check the following items:
Spark plug wires:
Be sure spark plug wires are in good condition. Check for cuts, breaks, burns, hardness or swelling.
LPG fuel requires much higher peak firing voltages compared to gasoline. Check spark plug electrical
continuity using a DVOM. Wires should ohm out to no more than 1,000 ohms per foot of wire length.
Distributor cap and rotor:
Check the cap and rotor assembly for moisture, corrosion or carbon tracking. The ignition timing is not
adjustable. Turning the distributor assembly will not change the ignition timing, but will alter the rotor
phase. Wipe away dust and debris from the ignition coil tower.
System power fuses:
Check the system power fuses. These sources supply the ignition coil and module system power.
Check that the power and ground terminals are clean and in the proper location.
90
Ignition Control System Diagnostic Chart

Step
Action
Did you perform the On-Board (OBD) System

Check?
DST connected and in the system data mode.

Crank the engine and observe the engine
speed signal on the DST
Is the value greater than the specified value?

Check the DST for historical code sets.
(Always diagnose and repair codes with the
lowest numerical value first).
Value(s)
Yes
No
Go to Step
(2)
Go to OBD System Check

Section
~125 RPM
Go to Step
(5)
Go to Step (3)
Go to Step
(16)
Go to Step (4)
Go to Step
(16)
Go to Step (5)
Go to Step(6)
Go to Step (10)
Go to Step
(7)
Repair the system power

circuit. Check
all system fuses
and power relay
connections
Go to Step
(8)
Go to Step (13)
Go to Step
(9)
Repair the system power

circuit. Check
all system fuses
and power relay
connections
Go to Step
(16)
Did you find and correct the problem?

Run the diagnostic chart for DTC 522752
Did you find and correct the problem?
Disconnect the ignition module connector
C035
Using an LED type test lamp check for a signal between the ignition module connector
pin B and battery positive
Crank the engine
Does the LED test lamp flash while cranking the
engine?
Using a DVOM check for power between the
ignition module connector pin A and engine
ground
System
voltage
Do you have power?
Disconnect the ignition coil connector C035

Using a digital LED test lamp check for a signal between the ignition coil connector pin B
and battery positive
Crank the engine
Does the LED test lamp flash while cranking the
engine?
Using a DVOM check for voltage between the
ignition coil connector pin A and engine
ground
System
voltage
Does the DVOM show voltage?

Replace the ignition coil
9
Is the replacement complete?
91
Step
10
Action
Value(s)
Key OFF
Disconnect the connector ECU-C
Using a DVOM check for continuity between
ignition module connector pin B and ECM
connector pin K1
Do you have continuity between them?
ignition module connector pin B and engine
ground
11
Replace ECM
12
13

Disconnect coil. Using a DVOM check for
continuity between the ignition module connector pin C and engine ground
14
Do you have continuity?

the ignition module connector pin D and ignition coil connector pin B
Replace the ignition module.
15
16

Using the DST clear DTC information from
the ECM.
Start the engine and operate the vehicle to
full operating temperature
Observe the MIL
After operating the engine check for any
stored codes.
Does the engine operate normally with no stored
codes?
92
Yes
No
Go to Step
(11)
Repair the open

ignition control
circuit. See wiring harness
repair section.
Repair the
shorted to
ground ignition control
circuit. See
wiring harness
repair section.
Go to Step (12)
Go to Step
(16)
Go to Step
(14)
Go to Step
(15)
Repair the open

ignition module
ground circuit.
See wiring harness repair.
Repair the open
ignition module
circuit. See wiring harness
repair.
Go to Step
(16)
System OK
Go to OBD System Check
93
DTC 51 ETC TPS 1 Range
Conditions for Setting the DTC
Electronic Throttle Control

Check Condition-Ignition ON
Fault Condition-TPS 1 voltage below 0.2 TPS 2 voltage greater than 4.95
MIL-On during active fault
Circuit Description
The electronic throttle body has two throttle position sensors TPS1 and TPS2. The voltage from these
sensors is used to determine the percentage throttle opening. The TPS sensors have a nominal output
range of 0.2 to 4.95 volts. From the throttle body itself TPS1 ranges from 0.2 to 4.95 volts as the throttle is
opened, TPS2 ranges from 4.95 to 0.2 volts for this same closed to open travel. The ECM rectifies TPS2
signal so both signals on the diagnostic monitor read from 0.2 to 4.95 as the throttle is opened. The travel
of the throttle plate from the fully closed to the fully open mechanical stops may not use this entire range of
voltages. The ECM learns the actual range of voltages used and adjusts the THROTTLE POSITION reading to range from 0 to 100% over this used range of voltages. The system looks at both TPS signals and if
the readings are outside of the upper and lower limits or do not agree with each within limits a code will be
set. The following failure combinations and resulting outcomes are possible:
a) TPS1 fails open or shorted: MIL illuminated, ECM uses TPS2, normal engine operation
b) TPS2 fails open or shorted: MIL illuminated, ECM uses TPS1, normal engine operation
c) TPS1 & 2 fail open or shorted: MIL illuminated, ECM stops controlling throttle, throttle goes to limp
home position and is non- responsive, engine will high idle or allow truck to move slowly.
d) TPS1 & 2 do not match: MIL illuminated, ECM will use the higher of the two TPS readings resulting in
normal or less than normal engine power.
94
Typical TPS and Throttle Position Readings (assumes 5.00 supply voltage):
Actual
Throttle
Position
Fully
closed
Open
Open
Fully Open
TPS1
reading at
Throttle
TPS2
reading at
Throttle
TPS1
reading
on Monitor
TPS2
reading
on Monitor
Throttle
Position
on Monitor
0.32
4.70
0.32
0.30
1.32
3.32
4.32
3.70
1.70
0.70
1.32
3.32
4.32
1.30
3.30
4.30
25
75
100
CONDITIONS FOR SETTING THE DTC

DTC 51 will set if TPS1 and TPS2 disagree by greater than 5.96%
A short circuit code will set if the TPS1 (as shown on the diagnostic monitor) is greater than 99.02%
of the 5 Volt Power Supply 1 (approx. 4.95 volts)
A short circuit code will set if the TPS2 (as shown on the diagnostic monitor) is greater than 99.8% of
the 5 Volt Power Supply 1 (approx. 4.99 volts)
An open circuit code will set if the TPS1 (as shown on the diagnostic monitor) is less than 4% of the 5
Volt Power Supply 1 (approx. 0.2 volts)
95

Step
Action
Value(s)
Yes
No
Go to Step
(2)
Go to OnBoard Diagnostics
System
Check/Malfun
ction indicator
lamp.
TPS 1
<0.2V
TPS 2
>4.99V
Go to Step
(3)
Intermittent
problem. Go
to Preliminary
and Intermittent Checks
Between
4.8-5.2V
Go to Step
(5)
Go to Step (4)
Verify that
there are no
codes for the
5 volt supply
before proceeding.
Replace the
ECU. Go to
Step (9)
Repair the
circuit as necessary. Refer
to Wire Harness Repair.
Go to Step (9)
Did you perform the On-board diagnostics

(OBD) system check?
1
NOTE: If the 5 volt reference Supply 1 is shorted

to ground, various codes may set, including
Throttle, Pedal 1, Oil Pressure, Cam and 5 Volt
Power Supply Codes. If multiple codes are set,
refer to diagnostics for codes 524261 to verify 5
volt reference.
With the monitor connected, Key ON, read
both throttle position sensors 1 and 2 voltages.
Is either reading below 0.2 volts
Is the TPS 1 voltage above 9.95 volts or is
TPS 2 voltage above 4.99
2
Is the higher voltage minus the lower voltage divided by 5 then multiplied by 100 greater than 6.
NOTE: this is the formula the ECU uses to determine if the TPS readings are within the
specifications
Key OFF, disconnect C017 from the throttle
body.
Key ON, measure the voltage from C017 pin
6 to pin 2
Is the voltage between 4.8 and 5.2 volts?
Key OFF, disconnect ECU-B
Measure the resistance from C017 pin 2 to
ECU B pin G2
ECU B pin G4
Is the resistance less than 5?
NOTE: Do not probe wires without proper service tool. Permanent harness damage may
result.
96
Step
Action
Value(s)
With C017 disconnected, measure the resistance from pin 6 to pin 1 of the throttle
body.
Push the throttle plate to the fully closed position, and then observe the resistance sweep
while moving the throttle to the fully open
position
Repeat the test across pin 6 to pin 4.
Is the resistance change smooth with no observed glitches, and does the resistance vary
from 800 to 1500 for pin 6 to 1 and from 1400
to 300 for pin 6 to 4 as the throttle is moved from
fully closed to fully open?
ECU-B pin G3
ECU-B pin D3
Remove all test equipment except the monitor.

Using the monitor, reset the adaptive learn.
Using the monitor, clear DTC information
from the ECM.
full operating temperature.
Observe the MIL.
Observe engine performance and driveability.
After operating the engine within the test parameters of code, check for any stored
codes.
codes?
97
<5
Yes
No
Go to Step
(6)
Replace the
throttle body
assembly. Go
to Step (7)
NOTE: Verify
that there are
no codes for
the 5 volt
supply before
proceeding.
Replace the
ECU. Got to
step 7
Repair the
Go to Step
(7).
System OK.
Go to On-Board
Diagnostics
System
Check/Malfuncti
on Indicator
lamp.

Code
91-2
522712-3
522712-4
522713-3
5227132-4
Pedal Position Voltage Table

Definition
Condition
Pedal Sensor 1 to Pedal Sensor 2
Differ by more
Coherence
Then
Pedal Sensor 1 Short to Ground
Less then
Pedal Sensor 1 Short to High
Greater Then
Less then
Greater Then
Limit
12 to
25 %
0.09
4.97
0.09
2.49
Comment
Varies with Pedal
Position
volts
volts
volts
volts
Circuit Description
There are two pedal position sensors on the electronic foot pedal to signal to the ECU exactly how much
throttle the driver has requested. The sensors are Hall Effect type not variable resistance sensors. The two
sensors are provided as a safety feature in case one sensor fails. While the system looks at both sensors,
sensor 1 is used to operate the system. The diagnostic tool allows the technician to monitor three signals
which relate to the foot pedal. The first is pedal position, the system automatically scales the full travel of the
pedal to equal 0 to 100 percent pedal position. The second and third signals are sensor 1 and sensor 2
voltages. Sensor 1 voltage can range from 0.66 to 4.95 volts but will usually be in the range of 1.0 to 3.6
volts. Sensor 2 voltage can range from 0.33 to 2.48 volts but will usually be in the range of 0.5 to 1.8 volts.
(Sensor 2 should read of sensor 1).
98

Step
Action
Value(s)
Yes
Did you perform the On-board diagnostics (OBD)

system check?
Go to Step
(2).

both pedal position sensor voltages.
See Pedal Position Voltage Table
Slowly depress the pedal while observing the
monitor
Intermittent
problem. Go
to Preliminary
and Intermittent Checks.
Are the readings within the specifications and is

the sweep smooth without any glitches?
Check pedal position sensor
Disconnect VIC 1
Key ON, measure voltage from VIC 1 pins S
and R.
Key ON, measure voltage from VIC 1 pins M
and L.
Go to Step
(5)
Go to Step (4)
Refer to the
vehicle wiring
diagram and
check ground
back to ECU,
repair as
necessary.
Refer to the
vehicle wiring
diagram and
repair the
power supply
problem between here
and ECU.
Check for
possible ECU
5 volt problem. Refer to
codes 524260
and 524261
for diagnostic
aids.

Key ON, measure the voltage from VIC 1
pins S and M to ground
Between 4.8
and 5.2V
99
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
If there is a
glitch in the
sweep, replace the
pedal position
sensor. Otherwise, go to
Step (3).
Step
Action
Value(s)
Check pedal sensor

Key OFF, disconnect VIC 1. Remove pins K
and J from the connector.
Reconnect VIC 1. Key ON.
Measure the voltage from each wire to engine ground while slowly depressing the
pedal.
Sweep, watch for glitch
Repeat on other side
NOTE: Pin J will show the voltage of pin K.

This is normal operation
>0.09 and
<4.97 V
Does the voltage sweep with no glitches from

greater than 0.09 volts to less than 4.97 volts on
pin A and from greater than 0.09 to less than
2.49 volts on pin B?
result.
Key OFF, disconnect ECU-A
Measure the resistance from VIC 1 pin K to
ECU-A pin H2 and VIC 1 pin J to ECU-A pin
F3.
Connect the ECU-A and VIC 1 connectors.
With the monitor or DST connected, wiggle
the ECU-A connector.
Are any glitches observed while wiggling the
connector?
100
<5
Yes
No
Reinstall the
pins to the
proper positions in the
connector.
Go to step 6
Reinstall the
pins to the
connector.
Replace pedal
position sensor. Go to
step 8.
Go to Step
(7)
Repair the
open in the
harness. Go
to Step (8)
Repair or replace the

harness. Go
to Step (8)
Replace the
ECU. Go to
Step (8).
101
DTC 100 Oil Pressure Low/High/High at Stall

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

Step
1
Action
Value(s)

Check?
Verify that the engine has oil pressure using a

mechanical oil pressure gauge before proceeding with this chart. Oil pressure must remain
above 6 psi.
Does the engine have oil pressure above 6 psi?
Ignition ON, Engine Running DST connected
in system Data Mode
Clear DTC 100
Warm the engine by idling until the ECT
temperature is above 160 degrees F. and
has been running for at least one minute
Increase engine speed above 500 RPM
Does DTC 100 reset?
Clear DTC 100
Key OFF
Disconnect oil pressure switch connector
C012 and isolate the connector from engine
ground.
Start and run the engine
Does DTC 100 reset?
Replace oil pressure switch

Ignition OFF
Disconnect C012
the oil pressure switch connector and engine
ground
Does the DVOM show continuity?
Inspect ECU-B connector pin C1 for damage
corrosion or contamination
Did you find a problem?
103
Yes
No
Go to Step
(2)
Go to OBD
System.
Check Section
6 PSI
Go to Step
(3)
Repair faulty
Oiling System
Go to Step
(4)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(6)
Go to Step
(5)
Go to Step
(9)
Repair the
shorted to
ground oil
pressure circuit as
necessary.
Refer to Wiring Repairs.
Repair the
circuit as
necessary.
Refer to Wiring Repairs in
Engine Electrical.
Go to Step
(7)
Go to Step
(8)
Step
Action
Value(s)
Replace ECM
8

the ECM.
Start the engine and run to full operating
temperature
Observe the MIL
Observe engine performance
After operating the engine within the test parameters of DTC 100 check for any stored
codes.
codes?
104
Yes
No
Go to Step
(9)
System OK
Go to OBD
System
Check
105
DTC 105 MAT Short to High/Ground/Open
Key ON
Manifold Air Temp Short Circuit to High, MAT voltage greater than 4.95 V.
Manifold Air Temp Short Circuit to Ground, MAT voltage less than 0.05 V
Manifold Air Temp Open Circuit, MAT voltage greater than 4.88V but less than 4.94V
Circuit Description
The TMAP is a combined manifold air temperature (MAT) and manifold absolute pressure (MAP) sensor. A
temperature-sensitive resistor is used in the TMAP Sensor located in the intake manifold of the engine. It is
used to monitor incoming air temperature and pressure; and the output, in conjunction with other sensors,
is used to determine the airflow to the engine. The ECU provides a voltage divider circuit so that when the
air is cool, the signal reads higher voltage, and lower when warm.
106
DTC 105 MAT Short to High/Ground/Open

Step
Action
Value(s)
Yes
No
Go to Step
(2)
Perform OBD
System check
Go to Step
(3)
Intermittent
problem. Go
to Preliminary
Go to Step
(4)
Go to Step
(5). If the 5
volt supply 2
is grounded,
an open code
will be set.
Replace the
ECU. Go to
step last
Replace the
TMAP sensor. Go to
step last
<5
Go to Step
(6)
Repair the
circuit as
necessary
>30M
Repair short
circuit as
necessary
Go to Step
(7)

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

to ground, various codes may set, including Pedal 2, and 5 Volt Power Supply Codes, as well
as ignition system malfunctions. If multiple
codes are set, refer to diagnostics for code
524260 to verify 5 volt reference.
Key ON.
Monitor MAT PID.
2
Does Monitor display MAT at the default value of
214 degrees?
Key OFF.
Disconnect the TMAP sensor connector J8
from the TMAP sensor.
Key ON, measure the voltage across pins 1
and 2
3
Between 4.8
and 5.2V
result
Key OFF.
Measure the resistance across the TMAP
sensor pins 1 and 2.
4
Is the resistance correct for the temperature as

shown in the temperature/ resistance chart
above?
Key OFF.
Disconnect the ECU wire harness connector
ECU-B.
Measure the resistance from TMAP sensor
connector C011 pin 2 and ECU-B pin E2.
Measure the resistance from TMAP sensor
connector pin 1 and ECU-B pin H4.
Disconnect the ECU wire harness connector.
Measure the resistance between TMAP sensor connector ground circuit pins 1 and 2.
Is the resistance greater than 30M?
107
Step
Action
Value(s)
Recheck wire harness and TMAP sensor

connectors for damage corrosion or contamination.
Were any problems found?

Replace the ECU.
Yes
No
Repair the
circuit as
necessary
Go to Step
(8)
Go to Step
(9)
8
108
109
DTC 106 MAP/Low/High/Short/Open
Key ON, engine RPM equals zero

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

PSIa
5
10
15
20
25
30
35
40
45
50
kPa
5
10
15
20
25
30
35
40
45
kPa
34.47
68.94757
103.4214
137.8951
172.3689
206.8427
241.3165
275.7903
310.2641
344.7379
PSIa
0.725189
1.450377
2.175566
2.900754
3.625943
4.351131
5.07632
5.801508
6.526697
50 7.251885
PSIa
55
60
65
70
75
80
85
90
95
100
kPa
379.2116
413.6854
448.1592
482.633
517.1068
551.5806
586.0543
620.5281
655.0019
689.4757
PSIa
105
110
115
120
125
130
135
140
145
150
kPa
723.9495
758.4233
792.8971
827.3708
861.8446
896.3184
930.7922
965.266
999.7398
1034.214
kPa
55
60
65
70
75
80
85
90
95
100
PSIa
7.977074
8.702262
9.427451
10.15264
10.87783
11.60302
12.3282
13.05339
13.77858
14.50377
kPa
105
110
115
120
125
130
135
140
145
150
PSIa
15.22896
15.95415
16.67934
17.40452
18.12971
18.8549
19.58009
20.30528
21.03047
21.75566
MAP Output Voltage

120
100
MAP in kPa
80
60
40
20
0
0
3
Voltage
111
DTC 106 MAP/Low/High/Short/Open

Step
Action
Value(s)
Yes

system check?
1
Go to Step (2)
Key ON, engine off.

Monitor the MAP reading.
Does the monitor display MAP reading of 508

kPa on the digital display?
Key OFF, disconnect C011 from the TMAP
sensor
Key ON, measure the voltage across the
C011 connector, pins 1 and 3.
No
System
Check/Malfun
ction indicator
lamp.
Intermittent
problem. Go
to Preliminary
508 kPa
Go to Step (3)
Between
4.8 and
5.2V
Go to Step (4)
Go to Step (5)
Go to Step (7)
Go to Step (5)
<5
Go to Step (6)
Repair open
in the wiring
and Go to
Step (7)
Between
4.8 and
5.2V
Go to Step (7)
Replace the
ECU. Go to
Step (7)
Is voltage between 4.8 and 5.2 volts?

Replace known good MAP sensor and retest.
Is everything OK?
4
result.
Check resistance between C011 pin 1 and
ECU-B pin H4, C011 pin 3 and ECU-B pin
H2, and C011 pin 4 and ECU-B pin H3.
Is resistance less than 5?
Refer to diagnostics for 5 volt reference voltage. See codes DTC 524260
Retest for 5 volts at Co11 pins 1 and 3
Is voltage now between 4.8 and 5.2 volts?
112
Step
Action
Value(s)

from the ECM.
Observe the MIL.
codes.

codes?
113
Yes
No
System OK.
System
Check/Malfun
ction Indicator
lamp.
DTC 110-ECT/Low/High/Short/Open
ECT sensor voltage less than 0.059.

ECT sensor voltage greater than 4.888.
ECT sensor voltage greater than 4.99.
MIL - on during active fault and for 2 seconds after active fault.
Circuit Description
The Coolant Temperature Sensor is a Negative Coefficient (as the temperature rises, the resistance drops) temperature sensitive resistor located in the Cylinder Head.
The ECM uses the reading to determine temperature related operating condition requirements for the engine. Five volts is applied across the sensor and voltage drop is
measured to determine the temperature.
114
Temp
(deg F)
242.4
231.9
211.6
201.4
181.9
163.1
144.9
127.4
102.4
78.9
49.9
23.5
-5.7
-21.2
-30.8
-40.0
Ohms
101
121
175
209
302
434
625
901
1,556
2,689
5,576
11,562
28,770
49,715
71,589
99,301
DTC 110-ECT/Low/High/Short/Open
Step
Action
No
Intermittent
fault. See wiring
schematics
and check
circuits from
C034 to ECUB for possible
short to
ground.
Go to step2
Go to Step
(3)
Go to Step
(4)
Between 4.8
and 5.2 V
Replace the
sensor. Go
to Step (5)
Go to Step
(4)
<5 and
>30M
Replace the
ECU. Go to
Step (5)
Repair fault in
harness. Go to
Step (5)
From Diagnostic tool, monitor ECT.

Is the displayed temperature reading estimated engine temperature
Disconnect connector C034
From monitor, does temperature read 214 C?

(Default)
With C034 disconnected, measure the voltage across C034 pins A and B
Yes
Key ON, ECT should reflect engine temperature?
Value(s)
result.
With C034 and ECU-B disconnected, measure the resistance from C034 pin 1 to ECU-B
pin F2, C034 pin 2 to ECU-B pin F4 and
across C034 pins 1 and 2.
Is the resistance less than 5 ohms from C034 to
ECU-B and greater than 30M across C034?
115
DTC 135 FRP Open/Short/High
FRP Sensor
Check Condition-Key ON
Fault Condition-FRP voltage greater than 4.94 volts
Fault Condition-FRP voltage less than 0.25 volts
MIL-ON
Circuit Description
The FRP (Fuel Rail Pressure) is a sensor that monitors the state of the LP fuel in the fuel rail. A pressure
sensor located on the fuel rail monitors the fuel pressure. The output in conjunction with other sensors is
used to determine the appropriate injector pulse to deliver the fuel. A lower output voltage indicates a lower pressure, and higher voltage for higher pressure. This fault will set if the signal voltage is less than 0.25
or greater than 4.94 volts.
116
DTC 135 FRP Open/Short/High

Step
1
Action
Value(s)
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Less than
0.20 volts?
Go to Step
(4)
Go to Step
(3)
Greater
than 4.90
volts
Go to Step
(6)
Go to Step
(5)
Repair the
circuit as
necessary.
See wire
harness repair section.
Go to Step
(5)

Check?
Key ON
DST (Diagnostic Scan Tool) connected
with the Voltages and Service windows
displayed.
Does the DST display FRP (Fuel Rail Pressure) voltage less than 0.20 volts?
Key OFF
Disconnect the FRP sensor connector
C016 from the wiring harness.
Jump the 5 volt reference B and FRP signal circuit C together.
Key ON
Does the DST display FRP voltage greater
than 4.90 volts?
Inspect FRP connector and pins for corrosion,
contamination or mechanical damage.
Any problems found?
Replace FRP Sensor.

5
Go to Step
(12)
Key ON
Using a DVOM check for voltage between
FRP connector 5 volt reference ECU-B J2
and sensor ground pin A.
Does the DVOM display a voltage greater

than 4.90 volts?
Key OFF
Disconnect ECU-B connector
Check for continuity between FRP sensor
connector C and ECM signal pin J3.
117
Greater
than 4.90
volts
Repair the 5
volt reference circuit
as necessary. See
wire harness
repair section
Go to Step
(7)
Go to Step
(8)
Repair the
open signal
circuit. See
wire harness
repair section.
Step
Action
Value(s)
Using a DVOM check for continuity between FRP sensor connector signal A
and sensor ground K2.
8
Using a DVOM check for continuity between FRP sensor connector B and
engine ground.
9
Inspect ECM connector and wire harness

connector terminals for corrosion, contamination or mechanical damage.
10
Any problems found?
11
12
No
Go to Step
(9)
Go to Step
(10)
Go to Step
(11)
Replace ECM.
Go to Step
(12)
Yes
Repair the
shorted to
ground signal circuit.
See wire
Repair the
shorted to
ground signal circuit.
See wire
Repair harness and
connector as
necessary.
See wire
Remove all test equipment except the

DST.
Connect any disconnected components,
fuses, etc.
the ECM.
full operating temperature
Observe the MIL
Does the engine operate normally with no

stored codes?
118
System OK
Go to OBD
System
Check
119
DTC 168 System Voltage Low/High
System Voltage
Voltage high: battery voltage above 18.5 volts with the Key ON.
Voltage low: battery voltage below 5.29 volts while the engine is running
MIL-On
Circuit Description
The system monitors battery voltage and will set a code if the voltage is out of range.
120
DTC 168 System Voltage Low/High

Step
Action
Value(s)
Was a fault found?

result.
Key OFF, disconnect connector ECU-B.
Using the proper tools, ground ECU-B pin
D4.
Measure voltage from ECU-B M2 to M1.
Is voltage within range?
Measure voltage from ECU-B M2 to engine
ground.
3
No
Repair as
necessary
Go to step 2
Intermittent
problem. Go
to Preliminary
Go to Step
(3)
Check all
grounds and
repair as
necessary.
Go to Step
(7)
Go to Step
(4)
Go to Step
(6)
Go to Step
(5)
Replace the
power latch
relay. Go to
Step (7).
Repair open
in harness as
necessary.
Refer to Wire
Harness
Repair. Go to
Step (7).
Perform charging system diagnostics.
Yes

Remove Component Power Relay.
Measure voltage from pins E8 and D8 to engine ground.
Key OFF
Disconnect ECU-B
Measure the resistance from: ECU-B pin M2
to Component Power Relay pin C9 and ECUB pin D4 to Component Power Relay pin A9
121
System
Voltage
DTC 628 Cal Memory Failure
Engine Control Module

Fault Condition-Internal microprocessor error
MIL-On
Circuit Description
The ECM has several internal checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. This diagnostic applies
to internal microprocessor integrity conditions within the engine control module (ECM). This diagnostic also addresses if the ECM is not programmed or the program checksum does not match or has become
corrupted. Always verify that the ECM was flashed with the proper calibration files before using the following diagnostic chat.
122
DTC 628 Cal Memory Failure

Step
Action
Value(s)
Reprogram or replace the ECU as required.
No
Go to step 2
System
Check/Malfun
ction indicator
lamp.

(OBD) system check?
Yes
Is the repair completed?

from the ECM.
Observe the MIL.
codes.
codes?
123
Go to Step
(3)
System OK.
System
Check/Malfun
ction Indicator
lamp.
DTC 630 ECU Checksum Error

MIL-On
Circuit Description
124
DTC 630 ECU Checksum Error

Step
Action
Value(s)
No
Go to step 2
System
Check/Malfun
ction indicator
lamp.

(OBD) system check?
Yes

from the ECM.
Observe the MIL.
codes.
codes?
125
Go to Step
(3)
System OK.
System
Check/Malfun
ction Indicator
lamp.
DTC 651 Injector Short/Open
Short to B+
Open Circuit
Short to Ground
Circuit Description
The ECU injector circuit drives the LPG system.
126

Step
Action
Value(s)
No
Go to Step
(2)
System
Check/Malfun
ction indicator
lamp.

(OBD) system check?
Yes
For DTC 651-3 short to B+, Go to Step (3)

For DTC 651-5 Open Circuit, Go to Step (5)
For DTC 651-6 Short to Ground, Go to Step
(11)
Disconnect injector connector
Key OFF
Disconnect ECU-B
Is resistance between pin Measure voltage
from pin injector pin 2 to ground.
>0V
Go to Step
(4)
Is voltage greater than zero?

Key ON, measure voltage from pin 2 to
ground.
>0V
Replace
ECU. Go to
Step (14)

For affected cylinder, disconnect injector
connector, Key ON
Measure voltage from pin 1 to ground.
Repair short
to power in
the harness.
Go to step14
Battery
Voltage
Go to Step
(8)
Go to Step
(6)
Is battery voltage present?

With C007 disconnected, Key ON
Measure voltage at C007 pin 2
6
Battery
Voltage
Key OFF, disconnect ECU-B.

Measure resistance from C007 pin 1 to ECUB pin A1
<5
Measure resistance of affected injector.
2 .5
8
Is resistance 2 .5?
127
Repair open
in harness
between
C007 and injector
connector.
Go to Step
(14)
Refer to the
wiring diagram for your
truck and repair power
supply problem. Go to
Step (14)
Go to Step
(9)
Go to Step
(7)
Repair open
in the harness. Go to
Step (14)
Replace injector. Go to
Step (14)
Step
Action
Key OFF, C007 disconnected

Measure the resistance of the control circuit.
See table above.
10

Key OFF, ECU-B disconnected
Measure the resistance of the control circuit
from C007 to ECU-B.
11
Is the resistance less than 5 ?

With the affected cylinder disconnected,
measure the resistance if the injector.
12
Is resistance 2 .5?
Measure resistance from the injector connector pin 1 of the affected cylinder to
ground.
13

Measure the resistance from the control circuit to ground.
14

from the ECM.
Observe the MIL.
codes.
codes?
128
Value(s)
Yes
No
<5
Go to Step
(10)
Repair open
Step (14)
<5
Replace
ECU. Go to
Step (14)
Repair open
Step (14)
2 .5
Go to Step
(12)
Replace the
injector. Go to
Step (14)
>30
Replace the
ECU. Go to
Step (14)
Go to Step
(13)
>30
Repair the
short to
ground in the
harness. Go
to Step (14)
Replace the
ECU. Go to
Step (14)
System OK.
System
Check/Malfun
ction Indicator
lamp.
129
Short to B+
Open Circuit
Short to Ground
Circuit Description
130

Step
Action
Value(s)
No
Go to Step
(2)
System
Check/Malfun
ction indicator
lamp.

(OBD) system check?
Yes

(11)
Key OFF
Disconnect ECU-B
Measure voltage from injector pin 2 to
ground.
>0V
Go to Step
(4)

ground.
>0V
Replace
ECU. Go to
Step (14)

connector, Key ON
Repair short
to power in
the harness.
Go to
Step(14)
Battery
Voltage
Go to Step
(8)
Go to Step
(6)

6
Battery
Voltage

<5
2 .5
8
Is resistance 2 .5?
131
Repair open
in harness
between
C008 and injector
connector.
Go to Step
(14)
Refer to the
Step (14)
Go to Step
(9)
Go to Step
(7)
Repair open
Step (14)
Step (14)
Step
Action

See table above.
10

from C007 to ECU-B pin 2.
11

12
Is resistance 2 .5?
ground.
13

14

from the ECM.
Observe the MIL.
codes.
codes?
132
Value(s)
Yes
No
<5
Go to Step
(10)
Repair open
Step (14)
<5
Replace
ECU. Go to
Step (14)
Repair open
Step (14)
2 .5
Go to Step
(12)
Replace the
injector. Go to
Step(14)
>30
Replace the
ECU. Go to
Step (14)
Go to Step
(13)
>30
Repair the
short to
ground in the
harness. Go
to Step (14)
Replace the
ECU. Go to
Step (14).
System OK.
System
Check/Malfun
ction Indicator
lamp.
133
Short to B+
Open Circuit
Short to Ground
Circuit Description
134

Step
Action
Value(s)
No
Go to Step
(2)
System
Check/Malfun
ction indicator
lamp.

(OBD) system check?
Yes

(11)
Key OFF
Disconnect ECU-B
>0V
Go to Step
(4)

ground.
>0V
Replace
ECU. Go to
Step (14)

connector, Key ON
Repair short
to power in
the harness.
Go to step14
Battery
Voltage
Go to Step
(8)
Go to Step
(6)

6
Battery
Voltage

<5
2 .5
8
Is resistance 2 .5?
135
Repair open
in harness
between
C009 and injector
connector.
Go to Step
(14)
Refer to the
Step (14)
Go to Step
(9)
Go to Step
(7)
Repair open
Step (14)
Step (14)
Step
Action
Value(s)

See table above.
10

from C009 to ECU-B.
11

12
Is resistance 2 .5?
ground.
13

14

from the ECM.
Observe the MIL.
codes.
codes?
136
Yes
No
Go to Step
(10)
Repair open
Step (14)
<5
Replace
ECU. Go to
Step (14)
Repair open
Step (14)
<5
Go to Step
(12)
Replace the
injector. Go to
step14
2 .5
Replace the
ECU. Go to
Step (14)
Go to Step
(13)
>30
Repair the
short to
ground in the
harness. Go
to Step (14)
Replace the
ECU. Go to
Step (14).
System OK.
System
Check/Malfun
ction Indicator
lamp.
>30
137
Short to B+
Open Circuit
Short to Ground
Circuit Description
138

Step
Action
Value(s)
No
Go to Step
(2)
System
Check/Malfun
ction indicator
lamp.

(OBD) system check?
Yes

(11)
Key OFF
Disconnect ECU-B
>0V
Go to Step
(4)

ground.
>0V
Replace
ECU. Go to
Step (14)

connector, Key ON
Repair short
to power in
the harness.
Go to step14
Battery
Voltage
Go to Step
(8)
Go to Step
(6)

6
Battery
Voltage

<5
2 .5
8
Is resistance 2 .5?
139
Repair open
in harness
between
C010 and injector
connector.
Go to Step
(14)
Refer to the
Step (14)
Go to Step
(9)
Go to Step
(7)
Repair open
Step (14)
Step (14)
Step
Action

See table above.
10

from C010 to ECU-B.
12

Is resistance 2 .5?
ground.
13

11
14

from the ECM.
Observe the MIL.
codes.
codes?
140
Value(s)
Yes
No
<5
Go to Step
(10)
Repair open
Step (14)
<5
Replace
ECU. Go to
Step (14)
Repair open
Step (14)
2 .5
Go to Step
(12)
Replace the
injector. Go to
step14
>30
Replace the
ECU. Go to
Step (14)
Go to Step
(13)
>30
Repair the
short to
ground in the
harness. Go
to Step (14)
Replace the
ECU. Go to
Step (14).
System OK.
System
Check/Malfun
ction Indicator
lamp.
141
DTC 1635 Code vs. Cal Version

MIL-On
Circuit Description
142
DTC 1635 Code vs. Cal Version

Step
1
Action
Value(s)

Check?
Ignition ON
DST (Diagnostic Scan Tool) connected in
System Data Mode
Clear system fault code
Ignition OFF
Ignition ON
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
Does DTC 1635 reset with the Ignition ON?

Check ECM power and ground connections
at ECU-B pins M2, M1, L1 and C001.
3
Did the power and ground circuits check OK?
Re-flash the ECM with the correct calibration

file
Repeat all in step (2).
Does DTC 1635 still set?

Replace ECM
5

the ECM
Turn the Ignition OFF and wait 30 seconds.
temperature
Observe the MIL
After operating the engine within the test parameters of DTC 1635 check for any stored
codes
codes?
143
DTC 522545 MIL (Malfunction Indicator Lamp) Open
Circuit Description
The Spectrum Fuel system is equipped with OBD (On-Board Diagnostics). The system has a
dash mounted MIL (Malfunction Indicator Lamp). The MIL serves as notification of an emissions related problem. It will display DTCs that have been stored due to a possible system
malfunction. The following DTC charts in this manual will instruct the technician to perform the
OBD system check. This simply means to verify the operation of the MIL. The lamp should
illuminate when the key is in the ON position, and the engine is not running. This feature
verifies that the lamp is in proper working order. If the lamp does not illuminate with the
vehicle Key ON and engine OFF, repair it as soon as possible. Once the engine is in start or
run mode, the lamp should go off. If the lamp stays on while the engine is in the start or run
mode, a current diagnostic trouble code may be set or a problem may exist with the MIL electrical wiring. The electrical schematic above shows the MIL power source supplied to the
lamp. The ECM completes the circuit to ground to turn the lamp ON.
144
145
DTC 522614 Throttle Failed to Enter Limp Home

Fault Condition-Throttle return spring test
Circuit Description
Dual throttle position sensors (TPS) are used with the electronic throttle control (ETC) to determine
throttle plate position. The TPS values are used by the ECM to determine if the throttle is opening and
closing as commanded. The ECM runs several checks at ignition on to validate the working condition of
the ETC. This fault will set if the ECM detects a problem with the ETC internal return spring.
146
DTC 522614 Throttle Failed to Enter Limp Home

Step
1
Action
Value(s)

Check?
Ignition ON
data stream mode.
Clear DTC 522614
Ignition OFF
Ignition ON
Does DTC 522614 re-set?

Check the electronic throttle for a foreign object
in the throttle bore or damaged throttle bore or
fly assembly.
3
Did you find damage or a foreign object in the
bore?
Ignition OFF
Disconnect electronic throttle connector
C017
Disconnect ECM wire harness connector
ECU-B
all electronic throttle connector pins and engine ground

electronic throttle connector pin 1 and ECU-B
connector pin G3.

electronic throttle connector pin 2 1 and ECU-B
connector pin G2.

connector pin M3.
147
Yes
No
Go to Step
(2)
Go to OBD
System Check
Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Remove the
foreign object
or replace the
throttle if
damage is
found. Go to
Step (17)
Go to Step (4)
Repair the
shorted to
ground TPS
circuit as
necessary.
Refer to Wiring Repairs
Go to Step (5)
Go to Step
(6)
Go to Step
(7)
Go to Step
(8)
Repair the
open circuit as
necessary.
Repair the
open circuit as
necessary.
Repair the
open circuit as
necessary.
Step
Action
Value(s)

connector pin D3.
8

connector pin M4.
9

connector pin G4.
10
Replace electronic throttle

11
12

the ECM.
temperature.
Observe the MIL
Observe engine performance.
After operating the engine within the test parameters of DTC 522614 check for any
stored codes.
codes?
Replace the ECM
13
148
Yes
Go to Step
(9)
Go to Step
(10)
Go to Step
(11)
No
Repair the
shorted TPS
circuit to
ground as
necessary.
Repair the
shorted TPS
circuit to
ground as
necessary.
Repair the
shorted TPS
circuit to
ground as
necessary.
Go to Step
(12)
System OK
Go to Step
(13)
Go to Step
(14)
Step
Action
14
Value(s)

the ECM.
temperature.
Observe the MIL
stored codes.

codes?
149
Yes
No
System OK
Go to OBD
System Check
DTC 522616 Throttle Actual vs. Commanded Error

Fault Condition-TPS 1 and 2 calculated values exceed 10%
Circuit Description
throttle plate position. Although the actual voltage values between them are inverse, the calculated position
values should remain very close. The TPS values are used by the ECM to determine if the throttle is opening and closing as commanded. This fault will set if the ECM detects more than a 10% difference in
calculated values between TPS 1 and TPS 2.
150
DTC 522616 Throttle Actual vs. Commanded Error

Step
1
Action
Value(s)

Check?
Ignition ON
data stream mode.
Clear DTC 522616
Ignition OFF
Ignition ON

fly assembly.
3
bore?
Ignition OFF
C017
ECU-B

connector pin G3.

connector pin G2.

connector pin M3.
151
Yes
No
Go to Step
(2)
Go to OBD
System Check
Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Remove the
foreign object
or replace the
throttle if
damage is
found. Go to
Step (17)
Go to Step (4)
Repair the
shorted to
ground TPS
circuit as
necessary.
Go to Step (5)
Go to Step
(6)
Go to Step
(7)
Go to Step
(8)
Repair the
open circuit as
necessary.
Repair the
open circuit as
necessary.
Repair the
open circuit as
necessary.
Step
Action
Value(s)

connector pin D3.
8

connector pin M4.
9

connector pin G4.
10

11
12

the ECM.
temperature.
Observe the MIL
stored codes.
codes?
Replace the ECM
13
152
Yes
Go to Step
(9)
Go to Step
(10)
Go to Step
(11)
No
Repair the
shorted TPS
circuit to
ground as
necessary.
Repair the
shorted TPS
circuit to
ground as
necessary.
Repair the
shorted TPS
circuit to
ground as
necessary.
Go to Step
(12)
System OK
Go to Step
(13)
Go to Step
(14)
Step
Action
14
Value(s)

the ECM.
temperature.
Observe the MIL
stored codes.

codes?
153
Yes
No
System OK
Go to OBD
System Check
DTC 522617 Throttle Failed to Fully Open/Close

Fault Condition-TPS 1 and 2 calculated values exceed 10%
Circuit Description
throttle plate position. Although the actual voltage values between them are inverse, the calculated position
values should remain very close. The TPS values are used by the ECM to determine if the throttle is opening and closing as commanded. This fault will set if the ECM detects more than a 10% difference in
calculated values between TPS 1 and TPS 2.
154
DTC 522617 Throttle Failed to Fully Open/Close

Step
1
Action
Value(s)

Check?
Ignition ON
data stream mode.
Clear DTC 522617
Start the engine

fly assembly.
3
bore?
Ignition OFF
C017
ECU-B

connector pin G3.

connector pin G2.

connector pin M3.
connector pin D3.
8
155
Yes
No
Go to Step
(2)
Go to OBD
System Check
Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Remove the
foreign object
or replace the
throttle if
damage is
found. Go to
Step (17)
Go to Step (4)
Repair the
shorted to
ground TPS
circuit as
necessary.
Go to Step (5)
Go to Step
(6)
Go to Step
(7)
Go to Step
(8)
Go to Step
(9)
Repair the
open circuit as
necessary.
Repair the
open circuit as
necessary.
Repair the
open circuit as
necessary.
Repair the
shorted TPS
circuit to
ground as
necessary.
Step
Action
Value(s)

connector pin M4.
9

connector pin G4.
10

11
12

the ECM.
temperature.
Observe the MIL
stored codes.
codes?
Replace the ECM
13
156
Yes
Go to Step
(10)
Go to Step
(11)
No
Repair the
shorted TPS
circuit to
ground as
necessary.
Repair the
shorted TPS
circuit to
ground as
necessary.
Go to Step
(12)
System OK
Go to Step
(13)
Go to Step
(14)
Step
Action
14
Value(s)

the ECM.
temperature.
Observe the MIL
stored codes.

codes?
157
Yes
No
System OK
Go to OBD
System Check
DTC 522630 Oxygen Sensor Failure to Switch Lean, Bank 1

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

Step
Action
Value(s)
Yes

system check?
Go to Step
(2)
Is the O2 sensor switching from rich to lean, and

is the short term correction less than 25%?
With the engine at operating temperature,

monitor the O2 sensor voltage and the short
term fuel trim
Check all problems listed in the diagnostic

aids.
For the O2 sensor, also refer to DTC 522730
diagnostics.
For MAP diagnostics, refer to DTC 106
For ECT diagnostics, refer to DTC 110
Verify proper maintenance and condition of
the ignition system.
Verify engine condition with a compression
test.
Were any faults found?

Monitor connected with the engine running,
monitor the engine RPM.
One at a time, disconnect each injector and
observe the drop in engine speed.
Do one or more injectors not drop the engine
speed when disconnected?
NOTE: the engine speed will only drop momentarily as the ECU corrects the engine speed.
Check the fuel pressure.
Is the pressure 88 kPa (12.8 PSI) above atmospheric pressure, engine off 15 kPa (2.2
PSI) holding steady?
Checking injectors
One at time, connect a noid light across
each injector connector.
With the engine running, does the noid light
flash at the connector of the failed injector
connector?
159
No problems
at this time.
Intermittent
problem. Go
to Preliminary
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
Go to Step
(3)
Repair as required. Go to
step last
Go to Step
(4)
Go to Step
(6)
Go to Step
(5)
Go to Step
(6)
Replace the
Regulator, Go
to Step (8).
Replace
faulty injector
Go to Step
(8)
Repair circuit
to the injector. Go to
step last
Step
7
Action
Value(s)
Check pressure drop

Check manifold vacuum supply to regulator
Is the pressure within specifications?

from the ECM.
Observe the MIL.
codes.
codes?
160
System OK.
Yes
No
Replace the
regulator. Go
to Step (8)
Verify the filter is OK. Go

to Step (8).
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
161
DTC 522631 Oxygen Sensor Failure to Switch Rich, Bank 1

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

Step
Action
Value(s)
Yes

system check?
Go to Step
(2)


term fuel trim

aids.
diagnostics.
test.

PSI) and holding steady?
Checking injectors
connector?
163
No problems
at this time.
Intermittent
problem. Go
to Preliminary
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
Go to Step
(3)
step last
Go to Step
(4)
Go to Step
(6)
Go to Step
(5)
Go to Step
(6)
Replace the
vaporizer, Go
to Step (8).
Replace
faulty injector
Go to Step
(8)
Repair circuit
step last
Step
7
Action
Value(s)
Check pressure drop


from the ECM.
Observe the MIL.
codes.
codes?
164
System OK.
Yes
No
Replace the
regulator. Go
to Step (8)

to Step (8).
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
165
DTC 522635 Short Term Fuel Lean, Bank 1

Circuit Description
Diagnostic Aids
Low fuel pressure
Defective O2 sensor
Faulty MAP sensor
166

Step
Action
Value(s)
Yes

system check?
Go to Step
(2)


term fuel trim

aids.
diagnostics.
test.

Checking injectors
connector?
167
No problems
at this time.
Intermittent
problem. Go
to Preliminary
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
Go to Step
(3)
step last
Go to Step
(4)
Go to Step
(6)
Go to Step
(5)
Go to Step
(6)
Replace the
Regulator, Go
to Step (8).
Replace
faulty injector
Go to Step
(8)
Repair circuit
step last
Step
7
Action
Value(s)
Check pressure drop


from the ECM.
Observe the MIL.
codes.
codes?
168
System OK.
Yes
No
Replace the
regulator. Go
to Step (8)

to Step (8).
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
169
DTC 522636 Short Term Fuel Lean, Bank 1

Circuit Description
Diagnostic Aids
Low fuel pressure
Defective O2 sensor
Faulty MAP sensor
170

Step
Action
Value(s)
Yes

system check?
Go to Step
(2)


term fuel trim

aids.
diagnostics.
test.

Checking injectors
connector?
171
No problems
at this time.
Intermittent
problem. Go
to Preliminary
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
Go to Step
(3)
step last
Go to Step
(4)
Go to Step
(6)
Go to Step
(5)
Go to Step
(6)
Replace the
Regulator.
Go to Step
(8).
Replace
faulty injector
Go to Step
(8)
Repair circuit
step last
Step
7
Action
Value(s)
Check pressure drop


from the ECM.
Observe the MIL.
codes.
codes?
172
System OK.
Yes
No
Replace the
regulator. Go
to Step (8)

to Step (8).
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
173
DTC 522690 Bus Failure
CAN Rx
Check Condition-Engine running
Fault Condition-CAN error packets lost, not received or corrupt
MIL-ON
Circuit description
The CAN bus (controller area network) is used by the ECM to communicate with other digital devices
used throughout the fuel system. Information is sent over the CAN bus in digital information packets that
contain information for various control functions. This fault will set if the ECM detects continuous CAN
communications hardware errors or CAN policy violations.
174
DTC 522690 Bus Failure

Step
Action
Value(s)

(OBD) system check?
Go to Step
(2)
Yes

from the ECM.
Observe the MIL.
codes.
codes?
175
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
Go to Step
(3)
System OK.
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
DTC 522691 Redundant Check Failure

MIL-On
Circuit Description
176
DTC 522691 Redundant Check Failure

Step
1
Action
Value(s)

Check?
Ignition ON
System Data Mode
Ignition OFF
Ignition ON

Check ECU-B power and ground connections at M1, L1 and M2. Also check C001,
C005, C003 and C015.
3

file
Repeat all in Step (2).

Replace ECM
5

the ECM
temperature
Observe the MIL
stored codes
codes?
177
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
DTC 522692 Redundant General Conversion Failure

MIL-On
Circuit Description
178

Step
1
Action
Value(s)

Check?
Ignition ON
System Data Mode
Ignition OFF
Ignition ON

C005, C003 and C015.
3

file

Replace ECM
5

the ECM
temperature
Observe the MIL
stored codes
codes?
179
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
DTC 522694 Memory Checksum Error

MIL-On
Circuit Description
180
DTC 522694 Memory Checksum Error

Step
1
Action
Value(s)

Check?
Ignition ON
System Data Mode
Ignition OFF
Ignition ON

C005, C003 and C015.
3
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check

file

Replace ECM
5

the ECM
temperature
Observe the MIL
stored codes
codes?
181

MIL-On
Circuit Description
182

Step
1
Action
Value(s)

Check?
Ignition ON
System Data Mode
Ignition OFF
Ignition ON

C005, C003 and C015.
3

file

Replace ECM
5

the ECM
temperature
Observe the MIL
stored codes
codes?
183
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
DTC 522698 Redundant Clock Failure

MIL-On
Circuit Description
184
DTC 522698 Redundant Clock Failure

Step
1
Action
Value(s)

Check?
Ignition ON
System Data Mode
Ignition OFF
Ignition ON

C005, C003 and C015.
3

file

Replace ECM
5

the ECM
temperature
Observe the MIL
stored codes
codes?
185
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
DTC 522699 Redundant Watchdog Failure

MIL-On
Circuit Description
186
DTC 522699 Redundant Watchdog Failure

Step
1
Action
Value(s)

Check?
Ignition ON
System Data Mode
Ignition OFF
Ignition ON

C005, C003 and C015.
3

file

Replace ECM
5

the ECM
temperature
Observe the MIL
stored codes
codes?
187
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check
DTC 522700 Redundant SDF Timeout

MIL-On
Circuit Description
188
DTC 522700 Redundant SDF Timeout

Step
1
Action
Value(s)

Check?
Ignition ON
System Data Mode
Ignition OFF
Ignition ON
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(4)
Repair the
circuit as
necessary.
Engine Electrical.
Go to Step
(5)
Go to Step
(6)
Go to Step
(5)
System OK
Go to OBD
System
Check

Check ECM power and ground connections
at C001 pins E and F, C002, C012 and C016
3

file

Replace ECM
5

the ECM
temperature
Observe the MIL
stored codes
codes?
189

Circuit Description
a) TPS1 fails open or shorted, - MIL illuminated, ECM uses TPS2, normal engine operation
b) TPS2 fails open or shorted, - MIL illuminated, ECM uses TPS1, normal engine operation
c) TPS1 & 2 fail open or shorted, - MIL illuminated, ECM stops controlling throttle, throttle goes to limp
home position and is non-responsive, engine will high idle or allow truck to move slowly.
d) TPS1 & 2 do not match, - MIL illuminated, ECM will use the higher of the two TPS readings resulting in
190
Actual
Throttle
Position
Fully
closed
Open
Open
Fully Open
TPS1
reading at
Throttle
TPS2
reading at
Throttle
TPS1
reading
on Monitor
TPS2 reading
on Monitor
Throttle
Position on
Monitor
0.32
4.70
0.32
0.30
1.32
3.32
4.32
3.70
1.70
0.70
1.32
3.32
4.32
1.30
3.30
4.30
25
75
100
Also see DTC 51.
191

Step
Action
Value(s)
Yes
No
Go to Step
(2)
System
Check/Malfun
ction indicator
lamp.
Go to Step
(3)
Intermittent
problem. Go
to Preliminary
Go to Step
(5)
Go to Step (4)
Verify that
there are no
codes for the
5 volt supply
before proceeding.
Replace the
ECU. Go to
Step (9)
Repair the
Go to Step (9)

system check?

Power Supply Codes .If multiple codes are set,
volt reference.
2
Is the higher voltage minus the lower voltage divided by 5 then multiplied by 100 greater than 6?
NOTE: this is the formula the ECU uses to determine if the TPS readings are within the
specifications
body.
6 to pin 2
ECU B pin G2
ECU B pin G4
4
result.
192
Step
Action
Value(s)
body.
position
ECU-B pin G3
ECU-B pin D3

from the ECM.
Observe the MIL.
codes.
codes?
193
Yes
No
Go to Step
(6)
Replace the
throttle body
assembly. Go
to Step (7)
NOTE: Verify
that there are
no codes for
the 5 volt
supply before
proceeding.
Replace the
ECU. Go to
Step (7)
Repair the
Go to Step
(7).
System OK.
Go to On-Board
Diagnostics
System
Check/Malfuncti
on Indicator
lamp.

Circuit Description
a) TPS1 fails open or shorted, - MIL illuminated, ECM uses TPS2, normal engine operation
b) TPS2 fails open or shorted, - MIL illuminated, ECM uses TPS1, normal engine operation
c) TPS1 & 2 fail open or shorted, - MIL illuminated, ECM stops controlling throttle, throttle goes to limp
home position and is non-responsive, engine will high idle or allow truck to move slowly.
d) TPS1 & 2 do not match, - MIL illuminated, ECM will use the higher of the two TPS readings resulting in
194
Actual
Throttle
Position
Fully
closed
Open
Open
Fully Open
TPS1
reading at
Throttle
TPS2
reading at
Throttle
TPS1
reading
on Monitor
TPS2 reading
on Monitor
Throttle
Position on
Monitor
0.32
4.70
0.32
0.30
1.32
3.32
4.32
3.70
1.70
0.70
1.32
3.32
4.32
1.30
3.30
4.30
25
75
100

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

Step
Action
Value(s)
Yes
No
Go to Step
(2)
System
Check/Malfun
ction indicator
lamp.
Go to Step
(3)
Intermittent
problem. Go
to Preliminary
Go to Step
(5)
Go to Step (4)
Verify that
there are no
codes for the
5 volt supply
before proceeding.
Replace the
ECU. Go to
Step (9)
Repair the
Go to Step (9)

(OBD) system check?
1

Power Supply Codes .If multiple codes are set,
volt reference.
Is the higher voltage minus the lower voltage
divided by 5 then multiplied by 100 greater
than 6.
result.
body.
6 to pin 2
ECU B pin G2
ECU B pin G4
4
result.
196
Step
Action
Value(s)
body.
position
ECU-B pin G3
ECU-B pin D3

from the ECM.
Observe the MIL.
codes.
codes?
197
Yes
No
Go to Step
(6)
Replace the
throttle body
assembly. Go
to Step (7)
NOTE: Verify
that there are
no codes for
the 5 volt
supply before
proceeding.
Replace the
ECU. Go to
Step (7)
Repair the
Go to Step
(7).
System OK.
System
Check/Malfunc
tion Indicator
lamp.
Code
91-2
522712-3
522712-4
522713-3
5227132-4

Definition
Condition
Differ by more
Coherence
Then
Less then
Greater Then
Less then
Greater Then
Limit
12 to
25 %
0.09
4.97
0.09
2.49
Comment
Varies with Pedal
Position
volts
volts
volts
volts
Circuit Description
198

Step
Action
Value(s)
Yes

system check?
Go to Step
(2).

monitor

Disconnect VIC 1
Key ON, measure voltage from VIC 1 pins S
and R.
Key ON, measure voltage from VIC 1 pins M
and L.
Intermittent
problem. Go
to Preliminary
Between 4.8
and 5.2
volts?
Go to Step
(5)
Go to Step (4)
Refer to the
vehicle wiring
diagram and
check ground
back to ECU,
repair as
necessary.
Refer to the
vehicle wiring
diagram and
repair the
power supply
and ECU.
Check for
possible ECU
codes 524260
and 524261
for diagnostic
aids.

Between 4.8
and 5.2
volts?
199
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
If there is a
glitch in the
sweep, replace the
pedal position
Step (3).
Step
Action
Value(s)
Yes
No
Reinstall the
pins to the
connector.
Go to step 6
Reinstall the
pins to the
connector.
Replace pedal
step 8.
<5?
Go to step 7
Repair the
open in the
harness. Go
to step 8
Repair or
replace the
harness. Go
to Step (8)
Replace the
ECU. Go to
Step (8).
System OK.
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
Check pedal sensor

pedal.

result.
F3.
connector?
from the ECM.
Observe the MIL.
codes.
codes?
200
201
Code
91-2
522712-3
522712-4
522713-3
5227132-4

Definition
Condition
Differ by more
Coherence
Then
Less then
Greater Then
Less then
Greater Then
Limit
12 to
25 %
0.09
4.97
0.09
2.49
Comment
Varies with Pedal
Position
volts
volts
volts
volts
Circuit Description
202

Step
Action
Value(s)
Yes

system check?
Go to Step
(2)

monitor

Disconnect VIC 1
Key ON, measure voltage from VIC pins S
and R.
Key ON, measure voltage from VIC pins M
and L.
Intermittent
problem. Go
to Preliminary
Between 4.8
and 5.2 volts
Go to Step
(5)
Go to Step (4)
Refer to the
vehicle wiring
diagram and
check ground
back to ECU,
repair as
necessary.
Refer to the
vehicle wiring
diagram and
repair the
power supply
and ECU.
Check for
possible ECU
codes 524260
and 524261
for diagnostic
aids.

Between 4.8
and 5.2 volts
203
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
If there is a
glitch in the
sweep, replace the
pedal position
Step (3).
Step
Action
Value(s)
Check pedal sensor

pedal.

result.
F3.
connector?
204
Yes
No
Reinstall the
pins to the
connector.
Go to Step
(6)
Reinstall the
pins to the
connector.
Replace pedal
Step (8).
Go to Step
(7)
Repair the
open in the
harness. Go
to Step (8)

harness. Go
to Step (8)
Replace the
ECU. Go to
Step (8).
Step
Action

from the ECM.
Observe the MIL.
codes.

codes?
205
Value(s)
Yes
System OK.
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
No
DTC 522735 Oxygen Sensor Short/Open
Heated Oxygen Sensor

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

Step
1
Action
Value(s)

Check?
Ignition OFF
Disconnect HEGO connector C018
Ignition ON
EGO connector pins C and D

Ignition ON
HEGO connector pin C and engine ground
3
Do you have voltage?

HEGO connector pin D and battery positive
Ignition ON
Do you have voltage?
Ignition OFF
Disconnect ECU-C Connector
ECU-C connector pin L2 and HEGO connector pin D

Ignition ON
HEGO connector pin D and battery positive
Replace ECM
7
207
Yes
No
Go to Step
(2)
Go to OBD
System
Check Section
System Battery Voltage
Go to Step
(8)
Go To Step
(3)
Repair open
HEGO heater
supply circuit
from power
relay. See
wire harness
repair.
Repair open
HEGO
ground circuit. See
wire harness
repair.
Go to Step
(4)
Go to Step
(5)
Go to Step
(6)
Repair the
open HEGO
heater
ground. See
wire harness
repair.
Repair the
HEGO heater
ground shorted to voltage.
See wire harness Repair.
Go to Step
(7)
Go to Step
(10)
Step
Action
Using a DVOM measure the resistance of the
HEGO heater (sensor side) between pins C and
D.
Does the DVOM show a resistance value greater
than 25 Ohms?
Replace the HEGO sensor
10

the ECM.
temperature
Observe the MIL
stored codes.
codes?
208
Value(s)
Yes
No
Greater than
25 Ohms
Go to Step
(9)
Go to Step
(5)
Go to Step
(10)
System OK
Go to OBD
System
Check
209

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

Step
Action
system check?
Value(s)
Go to Step
(2)
No
Go to OnBoard
Diagnostics
System
Check/
Malfunction
indicator
lamp.
Go to Step
(3)
Repair open in
Component
Power Relay
circuit. Go to
Step (8)
9.6,
1.5 @
21C?
Go to Step
(4)
Replace the
O2 Sensor.
Go to Step
(8)
>30M
Go to Step
(5)
Replace the
O2 Sensor.
Go to Step
(8)
Go to Step
(6)
Repair the
open in the
circuit. Go to
Step (8)
Go to Step
(7)
Repair the
short to
ground in the
harness. Go
to Step (8)
Yes
Key OFF, disconnect C018

Key ON, measure voltage from C018 pin D
to ground.
2

NOTE: Voltage is supplied from the Component
Power Relay circuit and will only be present for
1 to 2 seconds when the key is first turned on.
Measure resistance across the O2 sensor
heater circuit, pins C and D.
Is the resistance 9.6, 1.5 @ 21C?
Measure the resistance from the O2 sensor
heater circuit pins C and D to ground
result.
Key OFF, disconnect ECU-C
Measure resistance from C018 pin C to
ECU-C pin L2
<5M

Measure the resistance from C018 pin C to
ground.
6
>30M
Key ON, engine running, monitor the system

for faults
Flex the connectors at the ECU while watching for faults
Was a fault indicated by wiggling the wires?
211

ECU harness.
Go to Step (8)
Replace the
ECU. Go to
Step (8)
Step
Action
from the ECM.
Observe the MIL.
codes.
Does the engine operate normally with no
stored codes?
212
Value(s)
Yes
No
System OK.
Go to OnBoard
Diagnostics
System
Check/
Malfunction
Indicator
lamp.
213
DTC 522752 Start Failure Due to Cam Signal Error
Conditions for setting the DTC

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

Step
1
Action
Value(s)

(OBD) system check?
Check connections at C004, ECU-B pin M1,
M2, L1, and ECU-C pins A4 and F1.
Key OFF, disconnect C004 Connector.

Key ON, measure voltage across C004 pins
A and C.
Between 4.8
and 5.2 volts

Reconnect C004.
Using suitable probe, back probe C004 pins
B and C.
Connect a Multi-meter capable of measuring
Duty Cycle, + to pin B, - to pin C.
Crank the engine.
Does the duty cycle read 90% (or 10%)? Duty
cycle can show either 90% or 10% 5% depending on the meter.
Wiring check
Key OFF, disconnect ECU-C and C004
Measure resistance from :
C004 pin A to ECU-C pin A4
C004 pin B to ECU-C pin F1
C004 pin C to ECU-B pin M2
C004 pin A to ground.
C004 pin B to ground
C004 pin C to ground
<5
>30M
Is resistance greater than 30M?

C004 pin A to C004 pin B
C004 pin A to C004 pin C
C004 pin B to C004 pin C
>30M
Is resistance greater than 30M?

Replace ECU computer.
Yes
No
Go to step 2
Perform OBD
System check
Intermittent
problem. Go
to Preliminary
Go to Step
(3)
Go to Step
(4)
Go to Step
(5)
Go to Step
(5)
Replace Cam
Sensor, Go to
Step (9)
Go to Step
(6)
Repair the
circuit as
necessary.
Refer to Wire
Harness
Repair. Go to
Step (9)
Go to Step
(7)
Repair short
to ground as
necessary.
Refer to Wire
Harness
Repair. Go to
Step (9)
Go to Step
(8)
Repair short
in harness.
Refer to Wire
Harness repair. Go to
Step (9)
Go to Step
(9)
8
Is replacement completed?
215
Step
Action
Value(s)

from the ECM.
Observe the MIL.
codes.

codes?
216
Yes
No
System OK
System
Check/Malfun
ction Indicator
lamp.
217
DTC 523821 Oil Lamp Circuit Open
Engine Low Oil Pressure Signal

Check Condition-Engine running for greater than 10 seconds with engine speed greater than 500 rpm.
Fault Condition-No oil pressure signal for more than 5 seconds
Engine shut down
Circuit Description
The Oil Pressure Switch is used to communicate a low oil pressure condition to the ECM. Engine
damage can occur if the engine is operated with low oil pressure. This fault will set if the oil pressure
switch remains closed with the engine running. The switch is set to open above 6 PSI.
Circuit Description
Never assume the fault is due to an electrical malfunction. Low oil pressure can damage the engine. Verify
oil pressure before proceeding with this diagnostic.
218
DTC 523821 Oil Lamp Circuit Open

Step
1
Action
Check?
Verify that the engine has oil and oil pressure

using a mechanical oil pressure gauge before
proceeding with this chart. Oil pressure must
remain above 6 psi.
Does the engine have oil pressure above 6 psi?
Ignition ON, Engine Running DST connected
in stem Data Mode
Clear DTC 523821
Warm the engine by idling until the ECT
temperature is above 160 degrees F. and
has been running for at least one minute
Increase engine speed above 500 RPM
Does DTC 523821 reset?
Clear DTC 523821
Key OFF
Disconnect oil pressure switch connector
C012 and isolate the connector from engine
ground.
Start and run the engine
Does DTC 523821 reset?
Replace oil pressure switch

Ignition OFF
Disconnect ECM harness connector ECU-C
the oil pressure switch connector pin and engine ground
Inspect ECU-B connector pin C1 for damage
corrosion or contamination
Did you find a problem?
219
Value(s)
Yes
Go to Step
(2)
No
Go to OBD
System.
Check Section
Go to Step
(3)
Repair faulty
Oiling System
Go to Step
(4)
Intermittent
problem. Go
to Intermittent
section
Go to Step
(6)
Go to Step
(5)
Go to Step
(9)
Repair the
shorted to
ground oil
pressure circuit as
necessary.
Repair the
circuit as
necessary.
Engine Electrical.
Go to Step
(7)
Go to Step
(8)
Step
Action
Value(s)
Replace ECM
8

the ECM.
temperature
Observe the MIL
After operating the engine within the test parameters of DTC 523821check for any stored
codes.
codes?
220
Yes
No
Go to Step
(9)
System OK
Go to OBD
System
Check
221
DTC 524260 5 Volt Power Supply 1 Out of Spec

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

Supply 1

Supply 2
ECU-A pin G2
ECU-B pin G1
ECU-B pin G2
ECU-C pin B3
Pedal 1 5 volt supply VIC 1 pin M

Not Used
Throttle position sensor supply pin 2
Not Used
ECU-A pin F2
ECU-B pin J2
ECU-B pin H2
Pedal 2 5 volt supply VIC 1 pin S

FRP Pin B and Crank Sensor Pin 1
MAP Sensor supply pin 3
222

Step
Action
Value(s)
Disconnect all sensors for the 5 volt supply

showing the fault.
Refer to the wiring diagram and measure the
voltage from the 5 volt supply to the ground
of each sensor or component
Are all supplies between 4.8 and 5.2 volts?

One at a time, reconnect a sensor while
monitoring the voltage at another sensor.
3
Does the voltage go out of range when reconnecting a sensor?
Examine the connector of the sensor that
causes the voltage to go out of range.
4
Is there any damage to the connector?
No
Go to Step
(2)
System
Check/Malfun
ction indicator
lamp.
Go to Step
(3)
Go to Step
(5)

(OBD) system check?
Yes
Refer to the 5 volt supply table and check

each supply circuit for a short to power or
ground.
Are there any harness faults?

Reconnect all connectors.
Clear all codes.
With the Key ON, engine off, monitor the system for any faults.
Does the fault return? Are any faults detected?
Flex the connectors at the ECU while watching for faults.
7
Does the fault return?
223
Between 4.8
and 5.2 volts
Go to Step
(4)
Repair as
necessary.
Go to Step
(8).
Intermittent
problem. Go
to Preliminary
Replace the
sensor that
causes the
fault in the
voltage. Go to
step last
Step (8).
Go to Step
(6)
Replace the
ECU. Go to
Step (8)
Go to Step
(7)

harness. Go
to Step (8).
Intermittent
problem. Go
to Preliminary
Step
Action
Value(s)

from the ECM.
Observe the MIL.
codes.

codes?
224
Yes
No
System OK.
System
Check/Malfun
ction Indicator
lamp.
225

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

Supply 1

Supply 2
ECU-A pin G2
ECU-B pin G1
ECU-B pin G2
ECU-C pin B3
Pedal 1 5 volt supply VIC 1 pin M

Not Used
Throttle position sensor supply pin 2
Not Used
ECU-A pin F2
ECU-B pin J2
ECU-B pin H2
Pedal 2 5 volt supply VIC 1 pin S

FRP Pin B and Crank Sensor Pin 1
MAP Sensor supply pin 3
226

Step
Action
Value(s)
Yes
No
Go to Step
(2)
System
Check/Malfun
ction indicator
lamp.
Go to Step
(3)
Go to Step
(5)

system check?
1
Disconnect all sensors for the 5 volt supply

showing the fault.
Refer to the wiring diagram and measure the
voltage from the 5 volt supply to the ground
of each sensor or component.
Are all supplies between 4.8 and 5.2 volts?

One at a time, reconnect a sensor while
monitoring the voltage at another sensor.
3
Does the voltage go out of range when reconnecting a sensor?
Examine the connector of the sensor that
causes the voltage to go out of range.
4
Is there any damage to the connector?
Refer to the 5 volt supply table and check

each supply circuit for a short to power or
ground.
Are there any harness faults?

Reconnect all connectors.
Clear all codes.
With the Key ON, engine off, monitor the system for any faults.
Are any faults detected?
Flex the connectors at the ECU while watching for faults.
7
Does the fault return?
227
Between 4.8
and 5.2 volts
Go to Step
(4)
Repair as
necessary.
Go to Step
(8).
Intermittent
problem. Go
to Preliminary
Replace the
sensor that
causes the
fault in the
voltage. Go to
step last
Step (8).
Go to Step
(6)
Replace the
ECU. Go to
Step (8)
Go to Step
(7)

harness. Go
to Step (8).
Intermittent
problem. Go
to Preliminary
Step
Action
Value(s)

from the ECM.
Observe the MIL.
codes.

codes?
228
Yes
No
System OK.
System
Check/Malfun
ction Indicator
lamp.
229
DTC 524266 ETC Wire Shorted/Fail
Throttle Position Sensor

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

Step
1
Action
Value(s)

Check?
Ignition ON
data stream mode.
Clear DTC 524266
Ignition OFF
Ignition ON

fly assembly.
3
bore?
Ignition OFF
C017
ECU-B

connector pin G3.

connector pin G2.

connector pin M3.
231
Yes
No
Go to Step
(2)
Go to OBD
System Check
Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Remove the
foreign object
or replace the
throttle if
damage is
found. Go to
Step (17)
Go to Step (4)
Repair the
shorted to
ground TPS
circuit as
necessary.
Go to Step (5)
Go to Step
(6)
Go to Step
(7)
Go to Step
(8)
Repair the
open circuit as
necessary.
Repair the
open circuit as
necessary.
Repair the
open circuit as
necessary.
Step
Action
Value(s)

connector pin D3.
8

connector pin M4.
9

connector pin G4.
10

11
12

the ECM.
temperature.
Observe the MIL
stored codes.
codes?
Replace the ECM
13
232
Yes
Go to Step
(9)
Go to Step
(10)
Go to Step
(11)
No
Repair the
shorted TPS
circuit to
ground as
necessary.
Repair the
shorted TPS
circuit to
ground as
necessary.
Repair the
shorted TPS
circuit to
ground as
necessary.
Go to Step
(12)
System OK
Go to Step
(13)
Go to Step
(14)
Step
Action
14
Value(s)

the ECM.
temperature.
Observe the MIL
stored codes.

codes?
233
Yes
No
System OK
Go to OBD
System Check
Throttle Position Sensor

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

Step
1
Action
Value(s)

Check?
Ignition ON
data stream mode.
Clear DTC 524286
Ignition OFF
Ignition ON

fly assembly.
3
bore?
Ignition OFF
C017
ECU-B

connector pin G3.

connector pin G2.

connector pin M3.
connector pin D3.
8
235
Yes
No
Go to Step
(2)
Go to OBD
System Check
Section
Go to Step
(3)
Intermittent
problem. Go
to Intermittent
section
Remove the
foreign object
or replace the
throttle if
damage is
found. Go to
Step (17)
Go to Step (4)
Repair the
shorted to
ground TPS
circuit as
necessary.
Go to Step (5)
Go to Step
(6)
Go to Step
(7)
Go to Step
(8)
Go to Step
(9)
Repair the
open circuit as
necessary.
Repair the
open circuit as
necessary.
Repair the
open circuit as
necessary.
Repair the
shorted TPS
circuit to
ground as
necessary.
Step
Action
Value(s)

connector pin M4.
9

connector pin G4.
10

11
12

the ECM.
temperature.
Observe the MIL
stored codes.
codes?
Replace the ECM
13
14

the ECM.
temperature.
Observe the MIL
stored codes.
codes?
236
Yes
Go to Step
(10)
Go to Step
(11)
No
Repair the
shorted TPS
circuit to
ground as
necessary.
Repair the
shorted TPS
circuit to
ground as
necessary.
Go to Step
(12)
System OK
Go to Step
(13)
Go to Step
(14)
System OK
Go to OBD
System Check
Servicing the Fuel System
237
I.
II. FUSE BOX MOUNTING BRACKET
This procedure relates to removal and installation

of the ECM--see Diagnostic Scan Tool for accessing ECM software.
REMOVAL PROCEDURE
ECM
REMOVAL PROCEDURE
1. Disconnect the negative battery cable.

2. Disconnect the electrical connectors from the
ECM. Rotate the locking tabs on each connector to unlock the electrical connectors.
Disconnect the connector closest to the negative battery terminal first. Disconnect the
center connector second. Disconnect the connector closest to the positive battery terminal
last.
3. Remove the screws securing the ECM,
1. Disconnect the negative battery cable

2. Remove the four Screws, Washers and Spacers securing the ECM to the Bracket.
3. Remove the two Bolts securing the Fuse Box
bracket to the Coil Bracket.
INSTALLATION PROCEDURE
1. Secure the Coil Bracket and Fuse Box bracket
by placing with two Bolts to the engine.
Torque 29.5-36.8 ft.lbs. (40-50 Nm).
2. Attach the Fuse Box with four Screws (if removed). Torque to 2-3 ft. lbs. (2.7-4 Nm).
1. Place the ECM in position and secure with
2.
3.
4.
5.
screws. Tighten the nuts to 9 to 11 Nm

(79.66 to 97.36 in. lbs).
Connect the electrical connectors to the ECM.
Connect the electrical connector closest to the
positive battery terminal first. Connect the center connector second. Connect the connector
closest to the negative battery terminal last.
Rotate the locking tabs to lock the electrical
connectors in position.
Connect the negative battery cable.
Turn the ignition key to the ON position
Start the vehicle and check for proper operation of the electronic throttle body and the
ECM by exercising the accelerator pedal with
the vehicle in neutral.
III. ENGINE WIRE HARNESS REPLACEMENT

1. Disconnect negative battery cable.
2. Lay out the new Wire Harness, noting the location, type of connectors, and identifying
markings. Take special note of identical or
similar connectors (such as the coils or HEGO
Sensors) to avoid crossing connections during
installation. NOTE the routing of the existing
wire harness in and around the engine and the
vehicle. Refer to the Electrical Schematic.
238
3. Remove electrical connection from Oil Pressure Sender.

4. Using a wrench, hold the brass adapter (to
prevent from turning) and turn the Switch
counter-clockwise and remove. Do not remove the brass adapter from the engine block
(unless it is to be replaced).
Ensure that all connections are made to

the correct locations on the engine and its
components. Crossing connections may
cause poor engine performance, a MIL
warning and/or permanent damage to the
ECM.
3. Remove all Wire Harness connectors on the

vehicle.
4. Remove all clips and brackets holding the
Wire Harness and remove harness from vehicle.
5. Lay the new wire harness over the engine and
route each end to its connection. Verify that
all connectors match prior to installation.
6. Connect all connectors and Ring Terminals.
7. Install all clips and brackets to hold down the
harness.
8. Reconnect negative battery cable.
9. Start the vehicle.
10. Check for MIL illumination. If a DTC code is
found, refer to the Electrical Section for further
diagnosis.
1. Apply Loctite 567 (or equivalent high-temp

thread locker/sealer) to the threads on the Oil
Pressure Sender. If the Brass Adapter was
removed or is to be added to a new Sender,
add thread locker/sealer and thread on to the
engine block. Torque to 2-3 turns past tight.
2. Install Oil Pressure Sender. Torque to 2-3
turns past tight, ensuring the electric connector (screw) is accessible.
3. Attach electrical connector.
5. Start the engine and let run until it reaches
normal operating temperature. Check for oil
leaks around sensor. If leaks are found, repair
as necessary.
6. If a DTC code is found, refer to the Electrical
Section for further diagnosis.
IV. OIL PRESSURE SENDER
V. DISTRIBUTOR
The Oil Pressure Sender, shown installed on

the side of the engine below the ECM and
above the starter.
REMOVAL PROCEDURE
The Distributor
REMOVAL PROCEDURE
2. Mark each Spark Plug Wire with its corresponding cylinder or position on the Distributor

2. Locate the Oil Pressure Sender on the side of
the engine.
239
Cap.
3. Remove Spark Plug Wires from the Distributor
Cap by pulling and twisting each Spark Plug
Wire boot turn.
4. Remove Ignition Coil wire.
5. Remove the electrical connector from the
base of the Distributor.
6. Remove the two Screws that hold the Distributor Cap to the housing and remove Cap.
7. Using a grease pencil or similar marking tool,
mark the location of the Rotor on the distributor housing and engine.
8. Remove the Distributor hold down bolt.

VI. TEMPERATURE MANIFOLD PRESSURE
SENSOR (TMAP)
REMOVAL PROCEDURE
2. Locate the TMAP Sensor on the Intake Manifold plenum.
3. Disconnect electrical connector.
4. Remove the retaining screw.
5. Remove TMAP Sensor by pulling straight up
with a slight rocking motion.
IMPORTANT
Do not engage the starter, or change the positions
of the cam or crankshaft, timing gears or any other internal engine components while the
distributor is removed. Any change in the position
of these components will alter the timing.
1. Align the Rotor with the mark made on the
Distributor housing (the location of the rotor
when it was removed) and place into the engine ensuring the rotor, distributor housing
and the mark on the engine are all in alignment when the Distributor is fully seated.
2. Install the Distributor mounting clam Bolt and
tighten to 18 ft. lbs (25 Nm). Verify that the
rotor and Distributor housing remain in line
with the mark.
3. Install Distributor Cap.
TMAP Sensor
1. Install the TMAP and secure with Retaining
Screw. Torque to 7-9 ft.lbs. (9.5-12.2 Nm).
2. Reconnect electrical connector.
3. Reconnect the negative battery cable.
4. Start engine and run until it reaches normal
operating temperature.
5. Check for MIL illumination. If a DTC code is
found, refer to the Electrical Section for further
diagnosis.
IMPORTANT
Do not reuse old Distributor Cap Screws. Use
new Screws only.
4. Connect the electrical connection to the base
of the Distributor.
5. Connect Spark Plug wires to the Distributor
Cap, ensuring the wires are connected to the
correct cylinder. NOTE that the firing order is
1-3-4-2. Refer to the IGNITION SYSTEM
SPECIFICATIONS in the Appendix for additional information.
6. Connect Ignition Coil wire to Distributor Cap.
8. Start engine. Run engine through all throttle
ranges and under load to ensure normal operation.
9. Using the DST, clear DTC information from
the ECM.
240
VII. FUEL TEMPERATURE/PRESSURE

SENSOR
normal operating temperature.

VIII. ENGINE COOLANT TEMPERATURE
SENSOR (ECT)
REMOVAL PROCEDURE
2. Drain the coolant.
3. Locate the ECT just below the thermostat
housing .
4. Remove electrical connector from the ECT.
REMOVAL PROCEDURE
1. Relieve the LPG fuel system pressure. Refer
to XVIII. LPG FUEL SYSTEM PRESSURE
RELIEF.
3. Locate the Fuel Temperature Sensor on the
fuel rail.
Sensor.
5. Unscrew the sensor from the Fuel Rail.
The coolant may be hot. Use caution when

removing hose(s) to prevent contact.
1. Apply a light coat of Loctite 567 or equivalent
pipe thread sealant on the threads of the ECT.
1. Lubricate the O-ring on the Fuel Temperature
Sensor with a light coat of Vaseline or petroleum jelly. Do not contaminate the tip of the
sensor.
The HEGO is sensitive to silicone based

products and can become contaminated.
Avoid using silicone sealers/lubricants on
any fuel or exhaust related components.
2. Install the sensor into the Fuel Rail. Torque
to 6-7.5 ft. lbs. (8-10 Nm). DO NOT
EXCEED 7.5 ft. lbs. (10 Nm).
3. Reconnect the electrical connector to the Fuel
Temperature Sensor.
5. Open valve on the LPG tank.
6. Turn ignition key to ON and check for leaks at
the inlet and outlet fittings using a commercial
grade soapy solution or an electronic leak detector. If leaks are detected make repairs.
7. Start the vehicle and let run until it reaches
2. Install the ECT into the engine and torque

until tight.
3. Connect the ECT electrical connector.
4. Refill the cooling system.
8. Allow the engine to cool, check coolant level
and add coolant if necessary.
241
IX. HEATED EXHAUST GAS OXYGEN SENSOR

(HEGO)
1. Inspect Throttle Body Gasket. Replace if necessary.

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

Oxygen Sensor.
IMPORTANT
Before installing the Oxygen sensor lubricate
threads with anti-seize compound GM P/N
5613695 or equivalent. Avoid contaminating sensor tip with compound.
1. Install Oxygen Sensor.
2. Reconnect electrical connector to the Oxygen
Sensor.
normal operating temperature and is in closed
loop.
Regulator
REMOVAL PROCEDURE
RELIEF.
3. Remove the electrical connector on the
Shutoff Valve.
4. Remove the Fuel Hose from the regulator.
5. Remove the LPG Fuel Line at the flare fitting
attached to the Shutoff Valve.
X. THROTTLE BODY AND/OR GASKET

REMOVAL PROCEDURE
1.
2.
3.
4.
Disconnect the negative battery cable.

Remove the air intake.
Remove Throttle Body electrical connector.
Remove four Screws that secure the Throttle
Body.
5. Remove the Throttle Body and the Gasket.
242
XII. CHECKING/DRAINING OIL BUILD-UP IN

THE LOW PRESSURE REGULATOR
During the course of normal operation oil or
heavy ends may build inside the secondary
chamber of the Regulator. These oil and heavy
ends may be a result of poor fuel quality, contamination of the fuel, or regional variation of the fuel
make up. A significant build up of oil can affect
the performance of the secondary diaphragm response. The Recommended Maintenance
Schedule found in this section recommends that
the oil be drained periodically. This is the minimum requirement to maintain the emission
warranty. More frequent draining of the Regulator
is recommended for special situation where substandard fuel may be a problem. IMPCO
recommends the Regulator be drained at every
engine oil change if contaminated or substandard
fuel is suspected or known to be have been used
or in use with the emission complaint fuel system.
This is known as special maintenance, and failure
to follow this recommendation may be used to deny a warranty claim.
A small amount of fuel may still be present

in the fuel line. Use gloves and proper eye
protection to prevent burns. If liquid fuel
continues to flow from the connections
when removed, make sure the manual
valve is fully closed.
6. Clamp both Coolant Hoses as close to the
Regulator as possible.
7. Remove Coolant hoses.

8. Remove the Bolt securing the Regulator.
IMPORTANT:
Draining the Regulator when the engine is warm
will help the oils to flow freely and permit easier
removal from the Regulator.
1. Secure Regulator with Bolt. Torque to 12.5

ft.lbs. (17 Nm).
2. Attach the LPG Fuel Line at the flare fitting
attached to the Shutoff Valve.
3. Reconnect LPG Fuel Line (to Fuel Rail).
4. Connect Coolant Lines secure with hose
clamps. Remove clamps from hoses (if used
during removal).
5. Connect the fuel supply line (from tank).
6. Slowly open LPG Tank Valve.
To drain the Regulator, follow the steps below:

1. Move the equipment to a well ventilated area
and ensure no external ignition sources are
present.
2. Turn off LPG Valve and Relieve the LPG fuel
system pressure. Refer to XVIII. LPG FUEL
SYSTEM PRESSURE RELIEF.
IMPORTANT:
The fuel cylinder manual valve contains an Excess Flow Check Valve. Open the manual valve
slowly to prevent activating the Excess Flow
Check Valve.
7. Reconnect negative battery cable. Turn ignition key to ON and check for leaks at the inlet
and outlet fittings using a commercial grade
soapy solution or an electronic leak detector.
If leaks are detected make repairs.
8. Start engine and check for fuel and coolant
leaks. If leaks are detected make repairs.
9. Check for MIL illumination.
10. Run engine to normal operating temperature
and turn key to OFF.
11. Check coolant level and add coolant if necessary.
A small amount of fuel may still be present in

the fuel line. Use gloves and proper eye protection to prevent burns. If liquid fuel
continues to flow from the connections when
removed, make sure the manual valve is fully
closed.
4. Remove the plug on the Regulator under the
lower coolant port.
5. Place a small receptacle in the engine compartment to catch any liquid that may come
243
out of the Regulator.

6. Inspect the Regulator for any large dried particles and remove. Use a safety solvent to
remove any build up.
12. Dispose of any drained material in safe and

proper manner.
XIII. FUEL FILTER ELEMENT (HIGH PRESSURE)
REMOVAL PROCEDURE
RELIEF.
Use only Safety Solvents for the cleaning of

the regulator and its components. Solvents such as carburetor or brake cleaners
may damage gaskets, seals, O-rings, diaphragms or other non-metal components.

the fuel line. Use gloves and proper eye protection to prevent burns. Make sure the
manual valve is fully closed.
Regulator, showing filter related components.

7. Reinstall the Plug. Torque until tight.
8. Connect negative battery cable.
9. Open Valve on LPG tank.
3. Disconnect the fuel inlet and outlet lines from

the LPG Regulator.
4. Remove the fuel inlet fitting (7) and O-ring (6).
5. Remove the plastic body (5), foam filter (4),
paper filter element (3), and filter gasket (2).
6. Remove the screws (5), fuel outlet fitting (4)
O-ring (3), and filter (2). Discard O-ring and filter.
IMPORTANT:
The fuel cylinder manual valve contains an Excess Flow Check Valve open the manual valve
Check Valve.
10. Turn Key ON. Check for leaks at the inlet and
outlet fittings using a soapy solution or an
electronic leak detector. If leaks are detected
make repairs.
11. Start engine and check for leaks at all serviced fittings. If leaks are detected make
repairs.
1. Install new filter (2) in port for fuel outlet fitting.
Install new O-ring (3) and fuel outlet fitting (4).
2. Install retaining screws (5) for fuel outlet fitting
(4). Tighten screws to 2 to 3 Nm (17.7 to
26.55 in. lb.).
244
3. Install the filter gasket (6), new paper filter element (7), new foam filter (8), and plastic body
(9).
4. Install the fuel inlet fitting (11) and O-ring (10).
Tighten to 18 to 20 Nm (13.3 to 14.75 ft.lbs.).
5. Connect the fuel inlet line to the LPG Regulator.
6. Connect the negative battery cable.
7. Slowly open the fuel valve on tank.

Check Valve.
5. Slowly open the fuel valve on tank.
6. Turn the key to the ON position and back to
the OFF position to pressurize the fuel system. Check for leaks.
7. Check for leaks at connections by using soapy
solution or electron leak detector. If leaks are
detected, make proper repairs.
8. Start engine and ensure correct operation in
all throttle ranges.
IMPORTANT:
Check Valve.
XV. FUEL RAIL
8. Turn the key to the ON position and back to

the OFF position to pressurize the fuel system. Check for leaks.
10. Start engine and ensure correct operation in
all throttle ranges.
REMOVAL PROCEDURE
RELIEF.
3. Remove the pin securing the fuel inlet hose,
then remove fitting from the fuel rail.
4. Remove Fuel Pressure Sensor electrical connection.
5. Remove two bolts securing the Fuel Rail.
6. Carefully pull the rail flush along the Fuel Rail
and away from the Fuel Injectors.
7. If rail is to be replaced, remove the Fuel Pressure Sensor. Refer to VII. FUEL PRESSURE
SENSOR.
XIV. LOCK-OFF SOLENOID AND CARTRIDGE

RELIEF.
3. Disconnect the electrical connector from the
lock-off solenoid.
4. Remove the nut and solenoid from the cartridge
5. Remove the cartridge from the LPG Regulator.
1. Install Fuel Pressure Sensor, if removed Refer
to VII. FUEL PRESSURE SENSOR.
2. Lubricate Fuel Injector O-rings with petroleum
jelly or Vaseline.
1. Install new cartridge into LPG Regulator.
Tighten cartridge to 16 to 24 Nm (11.8 to 17.7
ft.lbs.).
2. Install solenoid and nut onto cartridge. Tighten nut to 7.85 Nm (69.5 in.lbs.).
3. Connect electrical connector to solenoid.
4. Connect the negative battery cable.
IMPORTANT:
245
REMOVAL PROCEDURE
RELIEF.
3. Remove the Fuel Rail. Refer to XV. FUEL
RAIL.
4. Remove Injector electrical connector.
5. Remove Clip Retaining Fuel Injector (connecting it to the Injector Adapter).
The Fuel Injectors are held in place with an

internal "C" ring. When removing the fuel injectors, pull the injectors straight out. Do not
pry the injectors with a screwdriver or prybar,
as this can damage the injectors or injector
adapters.
3. Carefully place the Fuel Rail over the injectors, sliding along the Fuel Rail Bracket.
Ensure the Fuel Injectors and O-rings are
properly seated.
4. Align holes on Fuel Rail with holes in the
bracket and insert screws. Torque to 7-9
ft.lbs. (9.5-12.2 Nm).
5. Connect Fuel Pressure Sensor electrical connection.
6. Insert fuel inlet port fitting and secure with pin.
8. Start engine and check leaks. If leaks are
detected make repairs.
6. Remove Injector.
1. Inspect the O-rings on the Injector and Injector
Adapter and replace if necessary. Lubricate
with Vaseline or petroleum jelly.
XVI. FUEL INJECTOR
2. Install the Fuel Injectors into the Fuel Injector
246
Adapters. Push the Injectors into the Adapters

using hand pressure only.
3. Install the Clip Retaining Fuel Injector (connecting it to the Injector Adapter).
4. Ensure all Injectors are properly aligned to
mate to the Fuel Rail.
5. Install Fuel Rail. Refer to X. FUEL RAIL
6. Connect the electrical connector(s) to the fuel
injector(s). Verify that the connectors
click/lock into place.
7. Connect the fuel line to the fuel rail.
take Manifold to prevent dirt or debris from entering the engine, possibly causing permanent
engine damage.
1. Lubricate the O-rings on the Fuel Injector
Adapter with Vaseline or petroleum jelly and
place back on the Intake Manifold, ensuring it
is properly seated.
XVII. FUEL INJECTOR ADAPTERS

REMOVAL PROCEDURE
2. Install Injector of top of Adapter. Refer to XI.

FUEL INJECTOR.
3. Install Fuel Rail. Refer to X. FUEL RAIL.
Fuel Injector Adapter

RELIEF.
3. Remove the Fuel Rail. Refer to X. FUEL
RAIL.
4. Remove the Injector(s). Refer to XI. FUEL
INJECTOR.
5. Remove the Fuel Injector Adaptor(s) from the
Intake Manifold.
6. Place tape or rag over the opening in the In-
247
XVIII. LPG FUEL SYSTEM PRESSURE RELIEF
Oil leaks
Oil in the air cleaner
Sludge in the engine
A leaking PCV orifice or hose may cause the following problems:
The LPG fuel system operates at pressure

up to 21.5 bar (312 psi). To minimize personal injury, relieve the LPG fuel system
pressure before servicing the LPG fuel system components.
Rough Idle
Stalling
High idle speed
FUNCTIONAL CHECK
1. Close the LPG fuel tank manual shut-off valve
(MSV).
2. Start and run the vehicle until the engine stalls
from lack of fuel.
3. Turn the ignition switch to OFF.
Any blow-by in excess of the system capacity, from

a badly worn engine, sustained heavy load, etc., is
exhausted into the air cleaner and is drawn back
into the engine.
Proper operation of the crankcase ventilation system depends on a sealed engine. If irregular oil
flow or dilution is noted and the crankcase ventilation system is functioning properly, check the
engine for another possible cause. Correct any of
these problems first.
Residual vapor pressure will be present in

the fuel system. Ensure the work area is
well ventilated before disconnecting any
fuel line.
If an engine is idling rough, inspect for a clogged

PCV orifice, a dirty vent filter, air cleaner element,
or plugged hose. Replace any faulty items found.
Use the following procedure:
1. Remove the PCV hose from the rocker arm
cover.
2. Operate the engine at idle.
3. Place your thumb over the end of the hose in
order to check for vacuum. If there is no vacuum at the hose end, inspect for plugged hoses
and/or clogged or damaged manifold vacuum
port.
4. Turn the engine OFF.
5. Inspect the PCV orifice in the valve cover for
debris or blockage. Clean with carburetor
cleaner as necessary.
Never use an open flame of any type to

check for LPG leaks.
IMPORTANT
Always inspect the LPG fuel system for leaks after
performing service. Check for leaks at the fittings
of the serviced or replaced component. Use a
commercially available liquid leak detector or an
electronic leak detector. When using both methods, use the electronic leak detector first to avoid
contamination by the liquid leak detector
XX. COOLANT HOSE
XIX. CRANKCASE VENTILATION SYSTEM

INSPECTION/DIAGNOSIS
REMOVAL PROCEDURE
RESULTS OF INCORRECT PCV OPERATION
1. Stop engine.
2. Drain coolant.
A plugged positive crankcase ventilation (PCV)

orifice or hose may cause the following conditions:
Rough or unstable idle

Stalling or low idle speed
248
IMPORTANT
Hoses are designed for specific applications. DO
NOT use Hose material or length other than
specified by the OEM. DO NOT mix the inlet or
outlet ends of the Hose when reinstalling.

3. Remove clamps from each end of the Hose
and remove Hose.
1. Slide Hose Clamps over each end of the Fuel

Hose.
2. Insert Port Fittings into each end of the Hose.
3. Slide each Hose Clamp to a position approximately from the end of the Hose and
tighten.
4. Lightly lubricate new O-ring with Vaseline or
petroleum jelly prior to installation.
IMPORTANT
Coolant hoses are specifically designed for their
application. DO NOT use hose material or length
other than the OEM specified parts. DO NOT mix
the inlet or outlet ends of the Hose when reinstalling.
1. Slide Clamps over each end of the Hose.
2. Insert Port Fittings into each end of the Hose.
3. Slide Hose Clamp to a position approximately
from the end of the Hose and tighten.
4. Refill with coolant.
5. Start engine and let run until it reaches operating temperature.
6. Check for leaks. If leaks are detected, make
repairs.
7. Stop engine and allow to cool. Check coolant
level and add coolant as necessary.
XXI. FUEL VAPOR HOSE

REMOVAL PROCEDURE
RELIEF.
3. Remove Retaining Clips securing Port Fittings
on both ends and remove with Hose attached.
4. Remove Hose Clamps.
5. Remove Port Fittings from Hose.
5. Reinstall Hose at both ends and secure using

Retaining Pins.
7. Open LPG tank valve.
8. Turn Key to the ON position for several seconds, then turn back to OFF. Check for
leaks at the inlet and outlet fittings using a
If leaks are detected, make repairs.
9. Start engine and check for leaks.

fuel line.
249
XXII. FUEL VAPOR PORT FITTING
IMPORTANT:
Check Valve.
REMOVAL
RELIEF.
3. Remove retaining clip securing the Port Fitting
in the port and remove.
4. Loosen Hose Clamp securing the Port Fitting
in the Hose and pull Port Fitting from hose.
8. Turn Key to the ON position for several seconds, then turn back to OFF. Using a liquid
or electronic leak detection tool, inspect the
REGULATOR, fuel hoses and all serviced fittings for leaks.
9. Start engine and check for leaks.
XXIII. REGULATOR PRESSURE CHECK
INSTALLATION
1. Refer to XXIV. LPG FUEL RAIL PRESSURE

CHECK to check the Regulator outlet pressure.
IMPORTANT
Port Fittings are designed for specific applications,
DO NOT any other adapter or fitting other than the
part specified by the OEM.
XXIV. LPG FUEL RAIL PRESSURE CHECK
1. Slide Hose Clamp over the Hose.

2. Insert Port Fitting into hose.
3. Slide Hose Clamp over the end of the Hose
and tighten.
4. Lightly lubricate O-rings on the Port Fitting
with Vaseline or petroleum jelly.

RELIEF.
3. Remove the Fuel Pressure Sensor. Refer to
VII. FUEL TEMPERATURE/PRESSURE
SENSOR.

fuel line.
4.
5.
6.
7.
8.
Connect the test fitting, Hose and Gauge.

Open LPG Tank Valve.
Connect negative battery cable.
Turn ignition to ON and note value on gauge.
Relieve the LPG fuel system pressure. Refer
RELIEF.
9. Remove Gauge. Install Fuel Temperature
Sensor. Refer to VII. FUEL
TEMPERATURE/PRESSURE SENSOR.
5. Reinstall Hose Port into port and secure using

a Retaining Pin.
7. Open LPG tank valve.
250
The HEGO is sensitive to silicone based

products and can become contaminated.
Avoid using silicone sealers/lubricants on
any fuel or exhaust related components.
11. Turn key to ON.
12. Check for leaks. If leaks are detected, make
repairs.
XXV. LPG FUEL SYSTEM LEAK TEST
1. Use a commercially available liquid leak detector or an electronic leak detector and follow the
manufacturers instructions.
IMPORTANT
When using both methods, use the electronic leak
detector first to avoid contamination by the liquid
leak detector.
1. Back Pressure Gauge

2. Heated Exhaust Gas Oxygen Sensor
(HEGO 1--Sensor between the engine and
catalytic converter).
3. Exhaust Pipe/Muffler
XXVI. RESTRICTED EXHAUST SYSTEM

DIAGNOSIS
Exhaust Back Pressure Test
PROCEDURE:
XXVII. CATALYTIC CONVERTER
1. Stop Engine. Carefully remove the HEGO.

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

Screws. Torque to 21 in.lbs. (2.4 Nm)
4. Connect the sensor harness connector.
5. Connect Spark Plug wires to the Distributor
Cap, ensuring the wires are connected to the
correct cylinder. NOTE that the firing order is
1-3-4-2. Refer to the IGNITION SYSTEM
SPECIFICATIONS in the Appendix for additional information.
6. Start engine. If a DTC code is found, refer to
the Electrical Section for further diagnosis.
REMOVAL PROCEDURE
1. Remove the Vacuum Line from each fitting.
IMPORTANT
DO NOT use a hose other than the OEM specified
part.
XXXI. FUEL FILTER REPLACEMENT
1. Reinstall the Fuel Vapor Hose to each fitting.

2. Start engine and check for leaks using a
NOTE: The following instructions only include the

low pressure LPG Vapor Fuel Filter and not the
high pressure liquid LPG fuel filter on the regulator. Refer to XIII. FUEL FILTER ELEMENT (HIGH
PRESSURE) for the high pressure filter on the
Regulator.
XXIX. LPG FUEL CONTROL SYSTEM CHECK

1. The fuel system can be thoroughly diagnosed
by use of the DST tool. See section
DIAGNOSTIC SCAN TOOL.
XXX. CAMSHAFT POSITION SENSOR
REMOVAL PROCEDURE
2. Label Spark Plug Wires with matching Distributor Cap numbers and remove by pulling and
twisting each spark plug wire boot turn.
3. Remove Ignition Coil wire.
base of the Distributor.
5. Remove the two Screws that hold the Distributor Cap to the housing and remove Cap.
6. Remove the Rotor Screws.
7. Turn the engine crankshaft to align the square
slot in the reluctor wheel with the Cam Sensor.
8. Remove the two screws securing the CMP
Sensor
9. Remove the Camshaft Sensor from the Distributor.
Low Pressure LPG Vapor Fuel Filter

1. Move the equipment to a well ventilated area
and verify that sparks, ignition and any heat
sources are not present.
RELIEF.
the fuel line. Use gloves and proper eye protection to prevent burns. Make sure the
manual valve is fully closed.
IMPORTANT
Do no not reuse the old Distributor Cap, Rotor or
Cam Sensor Screws.
1. Mount Camshaft Sensor on Distributor and
secure with new Screws. Torque to 19 in.lbs.
(2.2 Nm)
2. Install the Rotor on the reluctor wheel and secure with new Rotor Screws. Torque to 18
in.lbs. (2.0 Nm).
4. Remove the clamps securing the fuel hoses to

the fuel filter.
5. Remove the hoses connected to the fuel filter.
6. Loosen the Cushioned Clamp securing the
252
Fuel Filter and slide out.

7. Discard Fuel Filter.
1. Slide the Fuel Filter inside the cushioned
clamp and tighten.
2. Place clamps over hoses.
3. Connect hoses to the Fuel Filter.
4. Tighten hose clamps on Fuel Filter.
5. Retighten clamp securing Fuel Filter.
6. Connect negative battery cable.
7. Open LPG fuel valve on tank.
IMPORTANT:
Check Valve.
8. Turn Key to ON. Check for leaks at the inlet
and outlet fittings, and the filter housing end
connection using a soapy solution or an electronic leak detector. If leaks are detected
make repairs.
9. Start engine and check for leaks once more.
XXXIV. PCV
REMOVAL
1. Remove Hose Clamp on Hose connected to
PCV and remove Hose.
2. While gently rocking back and forth, pull PCV
from its mounting gasket and remove.
253
254
LPG Parts Diagram
255
THROTTLE BODY ASSEMBLY
2--@)
256
THROTTLE BODY ASSEMBLY

Item #
1
2
3
4
5
Description
Qty
Screw, Hex Sck Cap

Washers, Conical Spring 6mm
Throttle Body
Gasket, Throttle Body
Bracket, Fuel Rail Mount
4
4
1
2
1
257
IMPCO
Part Number
S1-30295-0655
W1-31039-006
A7-324
A7-245
B4-51980-001
FUEL RAIL & INJECTORS
258
FUEL RAIL & INJECTORS

Item #
Description
Qty
IMPCO
Part Number
1
2
3
Sensor, Fuel Rail Pressure

Screw, Hex Flange M6-1.0 x 35 mm
Fuel Rail, 3.0L
1
2
1
A7-473
P1-30559
R8-51549-001
4
5
6
7
Pin, Retaining
O-Ring, Inlet
Spacer, O-ring
Injector, LPG/CNG
1
4
4
4
P1-30559
A7-657
A7-656
A7-654
8
9
10
O-ring, Adapter
Adapter, Fuel Injector
O-ring, FKM-75 .362 ID
4
4
4
A7-655
A4-51981-001
GMN-033
259
REGULATOR ASSEMBLY
260
REGULATOR ASSEMBLY
Item #
Description
Qty
Regulator Assy (Fully Assembled with all parts)

Filter Kit (Includes 2, 6, 7, 8, 9)
Outlet Fitting Service Kit (Includes 3 & 4)
Screw Kit (Includes 3 screws)
Inlet Fitting w/O-Ring (Includes 10 & 11)
Drain Plug & O-ring Kit (Includes 12 & O-ring)
Lock-Off Assembly
1
1
1
1
1
1
1
5
12
13
261
IMPCO
Part Number
A7-434
A7-170
A7-172
A7-176
A7-171
A7-173
A7-175
HOSE ASSEMBLIES COOLANTNACUUM/FUEL
262
HOSE ASSEMBLIES COOLANT/VACUUM/FUEL

Item
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Description
Qty
Fitting, Port
Clamp, Oetiker
Hose, Vacuum
Hose 3/8 ID Fuel/Oil
Hose, 5/8 Fuel/Oil
Clamp, Ear Oetiker
Pin, Retaining
Clamp, Worm Drive
Clamp, Oetiker
Hose, 5/8 ID Fuel/Oil
Bracket, Vapor Filter
Filter, LPG Vapor
Hose, Formed Gate
Hose, Formed Gate
Clamp, Worm Drive
Bolt, M8 x 1.25 x 25
Nut, Hex
1
2
1
1
1
2
1
4
4
1
1
1
1
1
1
2
2
263
IMPCO
Part Number
AF4-50733-001
C1-51552-07-170
H1-19231-001
H1-19231-004
H1-19231-006
C2-51552-05-113
P1-30559
0130845
C1-51552-07-256
H1-19231-006
A10-167
A8-367
H1-50599-001
A10-169
1510113
97330010
THERMOSTAT & HOUSING
264
THERMOSTAT & HOUSING

Item #
Description
Qty
Part Number
GM Part Number
1
2
3
4
Bolt
Thermostat Housing
Gasket, Thermostat Housing
Thermostat
2
1
1
1
90328100
7142071
7140310
7140340
09424320
14096853
10105135
10220957
265
266

Item
#
1
Description
Qty
IMPCO Part Number
ECM, Liugong
A11-103
267
SENSORS
4
5
6
268
SENSORS
Item #
Description
1
2
3
4
5
6
7
HEGO
Crank Sensor
Sensor, TMAP
Oil Pressure Switch
Adapter, Oil Pressure Switch
Coolant Temp Switch
Adapter, Coolant Switch
Qty.
Used
1
1
1
1
1
1
1
269
IMPCO
Part Number
S8-50328-001
S8-51822-001
E1466001
S10-50352-001
7242360
7144790
7176570-06
GM Part
Number
12567712
DISTRIBUTOR
270
DISTRIBUTOR
Item #
Description
Qty.
Part Number
1
2
3
4
Distributor
Distributor Cap
Rotor
Module/Sensor
1
1
1
1
93442429
89060454
7241620
7245370
271
GM
Part Number
93442429
89060454
10467546
10485432
FUSE BOX & BRACKET
272
FUSE BOX & BRACKET

Item #
1
2
3
4
5
6
Description
Screw, Hex M4 x 16mm
Washer, Split Lock M4
Fuse Box Cover
Bracket, ECM
Screw, Hex Flange
Seal, Fuse Box
273
Qty.
Part Number
4
4
1
1
2
1
S1-30295-0416
W1-1988-003
C1-52520-001
B4-51789-001
90325088
S3-52522-001
IGNITION COIL
274
IGNITION COIL
Item #
1
Description
Coil, Ignition
275
Qty.
Part Number
10489421
MANIFOLDS
276
MANIFOLDS
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Description
Gasket, Int/Ext
Manifold, Exhaust GM 3.0L
Stud, 3/8-16 x 2
Bolt, Socket Head 3/8 x 16 Grade 8
Washer, Belleville 3/8
Screw, Hex Flange M5-0.8 8x8
Nut, Serrated
Washer, 3/8 Type A Hard
Screw, Hex Flange M6 x 12mm
Screw, Hex Flange M6-1.0x x 16mm
Screw Hex Flange M6-1.0 x 12mm
Shield, Heat-GM 3.0L 2 Piece
Heat Shield, RB Exhaust
Heat Shield, Alternator 3.0L
TMAP Sensor
Fitting, 1/8 NPT 3/8 Hose Brass
Fitting, 1/8 NPT .19 ID Hose
Bracket, Maxifuse Mount
Gasket, Exhaust Flange
Strap, Cnvlt Cdt 13mm
Sensor, O2
277
Qty.
Part Number
1
1
2
4
8
4
2
4
8
3
5
1
1
1
1
1
1
1
1
2
1
7152170
7152150
S3-50596-001
90368100
W1-50595-037
S1-50237-20-0508
N1-30876-037
92300101
S1-30871-02-0612
S1-30871-02-0616
S1-50237-02-0620
7152160
G4-50067-001
G4-50068-001
E1466001
2H-103B
F4-4
B4-51889-001
7152175
S17-51979-001
S8-50234-001
WIRE HARNESS/FUSES/FUSE BOX COVER
Fuse Box Layout
278
WIRE HARNESS/FUSES/FUSE BOX COVER

Part Number
Manufacturer Part
Number
1054112
Littelfuse 1520007Z
Littelfuse 299070
Littelfuse 1520004Z
Item #
Description
Qty
1
2
3
4
Auxiliary
Power Fuse
Starter Fuse
VSW
Starter Relay
Power Relay
Shut Off
Valve Relay
Cover
Fuse 70A
Fuse Holder
Wire Harness, 4 Cyl
10A Minifuse
20A Minifuse
20A Minifuse
10A Minifuse
Starter Relay
Power Relay
1
1
1
1
1
1
1
1
1
1
AW-50727-001
914584
7381270
7381270
914584
885014
885014
Littelfuse 297010
Littelfuse 297020
Littelfuse 297020
Littelfuse 297010
3011CCR1U0112VDC
3011CCR1U0112VDC
Lock Off
885014
3011CCR1U0112VDC
279
PCV VENT & VALVE
280
PCV VENT & VALVE

Item #
Description
Qty
Part Number
GM Part
Number
1
2
3
4
Vent, Elbow
Grommet oil filter cap
PCV
Grommet, PCV Valve
1
1
1
1
F4-51936-001
G3-51937-001
V3-51806-001
7120140
06487779
14050440
06487779
14001875
281
MISCELLANEOUS ENGINE
4
5
16
15
282
MISCELLANEOUS ENGINE
Item #
1
2
3
4
5
6
7
8
9
10
11
12
Description
Engine, MY 2011-2010GM 3.0L
Sensor, Crank
Plug, 3/8 NPT Socket Head Brass
Fitting, Pipe Thread Reducer
Oil Filter PF454
Plug -14 NPT
Switch, Oil Pressure
Spark Plug, R44LTS
Plug, 14mm Fuel Rail Port
Fitting, 1/2NPT 5/8 NIP Brass
Strap, Lifting Eye
Screw, Hex Flange 3/8-16 x 1
283
Qty
Part Number
1
1
1
1
1
1
1
4
4
1
1
1
7044670
S8-51822-001
P3-12
7176570-06
7110851
7242360
S10-50352-001
E10-50075
P3-50597-001
F4-17920
7010130
90325100
ALTERNATOR
284
ALTERNATOR
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Description
3/8-16x1-1/2 Bolt Hx GR5
Washer, Lock 3/8
Washer, Flat 3/8
3/8-16x1 bolt Hx Gr5
5/16-18x1 Bolt Sched Grd 8
Sapcer, Fan Mount 3.0L
5/16-18x1 Bit Hx Gr5
Washer, Lock, M8
Bracket, Alternator
Alternator, 7SI
Nut, Hex Flange Serrated M5 x 1.0
Nut, 3/8-16 Grade 5
Spacer, Alternator Brkt
Bracket, Alt Lower
Bolt, Hex 3/8-16 x 4 Grade 5
Bolt, M8-1.25 Hx Head Grd 10.9
Washer, Lock, Med, M8, Zn
Washer, Flat Heavy 5/6
Pulley, Water Pump
Pulley, Crankshaf
3/8-24x2 bolt Hx Gr5
5/16-18 x Grade 5
3/8-16x3-1/2 Blt Sched Gr5
ASM Fan Hub 3.0L
Pulley Twin Belt
Ring Retaining OD 0.669
Pully ASM P/B Boos Pump Idler
Bracket Tensioner
Pulley, Water Pump-Mod
Bracket Fan Tensioner MTG
285
Qty
Part Number
2
15
5
2
4
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
8
1
1
1
1
1
1
1
1
90305150
93300000
92300000
90305125
90268100
7143890
90205125
93200000
7144570
7144070
N1-30876-M06
95300000
7244570
7244560
90305400
98333025
93930000
92200020
7144040
7071620
90315200
90215075
7144160
7144220
7144130
7144030
7030110
7144000
7144040
7143881
STARTER
11
13
12
10
286
STARTER
Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
Description
Bolt
Nut Hex M5 x 0.8 Brass
Washer, Lock Bronze
Nut, Hex M8 x 1.25 Brass
Washer, lock med M8 Zn
Starter Motor
Bracket, Starter 2kW 3.0L
Nut Hex #10-24
Washer, Lock #10 Med
Washer Flat #10
5/16-18 Bolt Hex Gr5
Washer, Loc, Med 5/16
Washer, flat, SAE, 5/16
287
Qty
Part Number
2
1
1
1
1
1
1
1
1
1
1
1
1
7242530
97111000
93003000
97331000
93930000
7244520
B4-52110-001
95000000
93000000
92000000
9205075
93200000
92200000
TOOL KIT & ACCESSORIES
10
11
12
13
14
Standard Oetiker Pliers, IMPCO P/N 14100037 and Injector Test Lamp OTC-6023 (not included in any IMPCO ITK kit)
288
TOOL KIT & ACCESSORIES

Item
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Description
Test Kit Gauge 0-5 PSI (2-5205)
Test Kit-Gage 0-10" WC (2-5010)
Hose, 3/16" Id Vacuum, Bulk
Harness, Adapter Gen 2 DLC to Gen 1 DLC
Fitting Assembly, Test Cap (System II LPR
Secondary Pressure Test Adapter)
Fitting, 1/8 NPT 3/16Hs Nip Brass
Assembly, Fitting Test Cap 3/4
Pin, Retainer
Case, Metal, 14.25 x 9 x 4.25
Fitting, 1/8 NPT 1/4Hs El Nylon
Tool, 20IPR Torx-Plus Bit
Fitting, UNF, HS Vac Nip
Gauge, Test Fuel System
ASM, CAN Dongle (ECOM Cable)
289
Qty.
Used
1
1
1.5
1
IMPCO Part Number

TG-005
TG-010
H1-11
E1557400
AF4-31105
2
1
10
1
2
1
1
1
1
F4-4
AF4-50254-002
P1-30559
C9-50724-001
F4-8
T7-50172
F4-2
TG-31119-001
E2046002
The follow parts manual includes GM Service parts and their GM part numbers for the 3.0L 2011
engine. The IMPCO part number for the complete service block is:
3.0L (GM Engine Code BL3)
7044670
290
291
3.0L UPPER
6_,
7-,
8-e
9
10
11_J1 /
13 u fl 12
15
14
:--1"
22
----?11
16
23
292
3.0L UPPER
Item #
Description
Qty
Part Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Cap, Oil
Bolt, Vlv
Reinforcement, Vlv Rkr Arm Cvr
Cover, Vlv Rkr Arm
Gasket, Vlv Rkr Arm Cvr
Rotator, Vlv
Key, Vlv Stem
Nut, Vlv Rkr Arm
Ball, Vlv Rkr Arm
Arm Kit, Vlv Rkr w/Ball
Rod, Vlv Push
Shield, Vlv Stem Oil
Stud, Vlv
Cap, Vlv Sprg
Seal, Vlv Stem Oil
Spring, Vlv
Bolt, Cyl Hd
Plug, Cyl Hd Core Hole
Gasket, Eng Cool Therm Hsg
Housing, Eng Cool Therm
Bolt, Eng Cool Therm Hsg
Lifter, Vlv
Head, Cyl Cmpl w/Valves, Springs, Retainers & Seals
Insert, Vlv Push Rod
Plug, Inj Hole
Valve, Int
Valve, Exh
Gasket, Cyl HD
1
5
5
1
1
4
16
8
8
8
8
12
8
8
8
8
10
2
1
1
3
8
93802366
09439930
03877670
02770089
14096154
14042575
24503856
12557390
93427660
05723551
93414888
10007818
03814692
10038209
10214034
94666172
10166832
03826506
10140501
93442430
09424320
05232720
93442423
8
4
4
4
1
NSS
P3-50597-001*
14075641
94665131
14096660
23
24
25
26
27
28
AR=As Required; NSS=Not Sold Separately; NA=Not Available
*IMPCO Part Number
293
3.0L LOWER
88
294
3.0L LOWER
Item #
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Description
Qty
Ring Kit (STD)

Ring Kit (0.020 O.S.)
Ring Kit (0.030 O.S.)
Piston (w/Pin)(STD)
Piston (w/Pin)(0.020 O.S.)
Rod Connecting (Includes 4 & 6)
Bolt, Connecting Rod (Part of 3)
Bearing Kit, Connecting Rod (STD)
Bearing Kit, Connecting Rod (O.S. 0.001)
Nut, Conn Rod (Part of 3)
Bearing, Oil Pmp Drive
Gasket W/Pmp
Pump, Water
Bolt, W/Pmp
Hub, Fan W/Pmp (Part of 9)
Washer, 6.3mm ID
Bolt, Cm/Shaft
Bolt, W/Pmp 5/16
Key, Cm/Shft
Bolt, CM/Shaft
Washer, CM/Shf
Gear, CM/Shf
Plate Kit, CM/Shf
Ring, CM/Shf
Bearing, CM/Shf
Camshaft, Eng
Valve, Oil Filter
Pin, Cyl HD
Fitting, Oil Fltr
Bearing Kit, Cr/Shf (#1,2,3,4)(0.001 U.S.)
Bearing Kit, Cr/Shf (#1,2,3,4)(STD)
Bearing Kit, Cr/Shf (#5)(0.001 U.S.)
Bearing Kit, Cr/Shf (#5)(STD)
Key, Woodruff #9
Seal, Cr/Shft Frt Oil
Gear, Cr/Shf
Gasket, Front Engine Cvr
Cover, Eng Frt
Balancer, Cr/Shf
4
4
8
4
1
8
1
1
1
1
3
3
2
2
2
1
1
1
1
4
1
1
8
1
4
1
1
1
1
1
1
Part Number
88894219
12361570
14089026
93442974
93419821
10108688
00461372
12493123
12493124
00326312
03866766
10101256
88894247
09442184
NSS
11503663
09442895
09440366
00106751
09442008
10101744
02771369
12508079
00549631
14002525
02770015
25013759
00585927
03853870
12329955
12329954
10048778
12329774
00106751
12577710
02768986
14096156
03992251
03826280
295
Item #
Description
Qty
Part Number
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
Seal, Absorber, Cr/Shf

Washer, External Tooth
Bolt, Cr/Shf Balancer
Nut, Oil Pan
Washer
Bolt, Oil Pan (1/4-20 x 1/2, 1/8 THD)
Plug, Oil Pan Drn
Gasket, Oil Pan Drn Plug
Pan, Oil
Bolt, Oil Pan (1/4-20 x 1/2, 1/8 THD)
Screw, RD HD Slotted
Washer
Cover, O/Pmp
Gasket O/Pmp Cover
Spring, Oil Pressure Rlf Vlv
Plug, Oil Press Rlf Vlv
Valve, Oil Pressure Rlf
Bolt, O/Pmp
Reinforcement, Eng Frt Cvr (Incl w/31)
1
1
1
10
10
10
1
1
1
14
4
4
1
1
1
1
1
3
1
NSS
00136857
10126796
12338130
09439510
09442895
See IMPCO Catalog
See IMPCO Catalog
93419740
09440033
00133043
09439510
03792507
03789970
03814903
03930824
03829433
09424877
NSS
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
Gasket, Oil Pan

Bolt, Eng Frt Cvr
Pump, Oil
Nozzle, Cm/Shf Gr Lub
Bracket, O/Pmp
Crankshaft
Bolt, Hex 1/4-20 x 3/4
Washer, Flat
Nut, O/Pmp
Pin, Oil Press Flf Vlv
Screen, O/Pmp (Part of 54)
Bolt, Cr/Shf Brg Cap
Cap, Cr/Shf Brg
Pin, Cr/Shf RR Oil Seal
Housing, Cr/Shf RR Oil Seal (Incl 71 & 72)
1
12
1
1
1
1
1
1
1
1
1
8
4
1
1
14096637
09442895
14091485
03875950
03970417
93442002
09425113
11609328
09442946
12551790
02778192
03872781
03970194
09441003
14088556
67
68
69
Bolt, Cr/Shf Oil Seal

Bolt, Cr/Shf RR Oil Seal Hsg
Gasket, Cr/Shf RR Oil Seal Hsg
Stud, Cr/Shf Brg Cap
Stud, Cr/Shf RR Oil Seal (Part of 66)
Seal, Cr/Shf (Part of 66)
2
2
1
1
2
1
14096659
14096658
12555771
03852870
14080362
10088158
70
71
72
296
Item #
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
Description
Gear, Flywhl Ring (Part of 78)
Washer, Flywhl
Bolt, Flywhl (7/16-20 x 31/32)
Bolt, Vlv Push Rod Cvr
Bearing, Clu Pilot
Flywheel, Eng (Includes 73)
Cover
Pin, Trans Loc (5/8 x 1 3/16)
Gasket, Vlv Push Rod Cvr
Plug, Eng Blk Oil Gal
Engine Block
Plug, CM/Shf
Plug, Eng Blk Core Hole
Plug, Oil
Plug, Eng Blk Oil
Tube, Oil Lvl
Indicator, Oil Lvl
Sealer, Vlv Push Rod Cvr
Stud, Vlv Push Rod Cvr
Nut, Vlv Push Rod Cvr
Washer, Vlv Push Rod Cvr
Ring, Cr/Shf Psn Sen Reluctor
Seal, Cr/Shf Psn Sen Conn
Sensor, Cr/Shf Posn
Bolt, Cr/Shf Posn Sen
Gasket, F/Pmp
Cover, F/Pmp OPG
Washer, F/Pmp MT
Bolt, F/Pmp
Plug, Eng Blk Core Hole
Qty
Part Number
1
1
6
4
1
1
1
2
1
1
1
1
AR
1
1
1
1
AR
4
4
4
1
1
1
1
1
1
2
2
2
03991408
00136857
00839756
03814350
14061685
93419731
93423830
01453658
12378521
14090911
NSS
110241154
03826505
NSS
03835577
93434708
14025224
12346286
00352169
00451399
02436163
NSS
NSS
12567712
11588712
93802517
93439184
02436162
09424877
88891749
297
298
Labor Time Guide
299
INTRODUCTION
TIME ALLOWANCES
This Guide provides the labor times for repairs

and service operations covered under warranty
for IMPCO Technologies Engine Systems Division fuel systems. It applies to 2008 model year
3.0L GM Emission Certified Engines
The labor times include the removal, disassembly, cleaning, re-assembly, installation and/or
adjustment of the affected component or assembly. Any cleaning time is limited to the
installation or replacement of components (such
as mating surfaces) and does not include cleaning other areas of the vehicle contaminated by
failure of the component (e.g. coolant sprayed
inside the engine compartment). Labor operations that require more than one technician are
adjusted to represent the total time for all technicians.
The warranty reimbursement for the labor operations can be calculated when used in conjunction
with the IMPCO Policy & Procedures Manual.
The labor times published in this Guide identify
labor operations and labor times required to perform a repair, replacement and/or adjustment
operation. These times represent those of an average technician in a typical dealership using
standard hand tools, equipment and some Special Service Tools. They are not intended to be
used as retail labor rates.
LABOR TIME STUDY DEVELOPMENT

GENERAL
The labor times published in this Guide were developed by IMPCO using genuine IMPCO parts
and procedures listed in the IMPCO Service
Manual. They include the actual time required to
perform the operation and diagnose the system
or component failure. All operations also include
a standard allowance for access time to locate
the vehicle, move it to a safe and suitable work
area, access the engine, use of Special Service
Tools and time to open packaged parts. The
times also provide for operation variables but do
not include time to remove and/or replace nonIMPCO components and accessories.
GLOSSARY OF TERMS
OPERATION DESCRIPTION
The Operation Description identifies the repair to
be performed and may include sub-headings
such as: ADD conditions, NOTES, INCLUDES
and other information. This information is essential for both the technician and warranty claim
processing personnel to properly complete a
warranty claim for accurate cost recovery.
FAILED PART / CAUSAL PART

The Failed or Causal Part is the part that caused
the repair and/or replacement of other parts. The
technician must identify the part as defective
(i.e., one that exhibits a flaw or manufacturers
defect in material or workmanship). The Causal
Part must be tagged for warranty failure analysis identification prior to returning it to IMPCO
Technologies.
TROUBLE CODES / CONDITION CODING

TOOLS
The labor time studies were based on the use of
standard hand tools and Special Service Tools.
No power-operated tools were used. The labor
times were developed by general technicians following procedures described in the Service
Manual Supplement, Service Publications and
good shop practices. The times were calculated
using an engine mounted on a stand.
Each failed or causal part must be coded to identify the manufacturers defect of the part as
accurately as possible (see Trouble Code chart).
The code selected by the repairing technician
identifies the manufacturers defect and/or workmanship condition qualifying the repair for
warranty coverage.
ADD CONDITIONS
Add Conditions may be required to complete or
supplement a labor operation and are included in
the Add sections under the Labor Operation Description. If an ADD is performed, the allowed
300
labor time for the ADD must be recorded on the

shop repair order under the Operation Number.
complete when the cause of failure has been

identified.
REPLACE
REPAIR DIAGNOSIS
Replace is used when the part or assembly is

subject to replacement only. This includes the
transfer of attached components from the original
part to the new part, the installation of the new
part and any inspection, adjustment, or required
cleaning or lubrication operations.
These are the checks, tests and measurements

required to identify the cause of a failure and/or
failed part. Examples include:
R&R OR REPLACE
R&R refers to a part or assembly that is removed
and re-installed after the part has been aligned,
adjusted, repaired as a separate operation or
removed for a sublet repair. Replace means the
part or assembly can be replaced with a new (or
exchanged) part or assembly (see the Replace
paragraph above).
INCLUDES
The INCLUDES which follow some of the Labor
Descriptions are provided to assist in determining
whether or not certain items or functions are included within the operation (these are not all
encompassing to simplify the use of this Guide).
Examples include:
Fuel System Evacuation

Leak Check
Cooling system drain and refill
Refer to the IMPCO Service Manual Supplement

or use the Request for Review Form to question
and/or recommend changes.
Cleaning and inspection of all parts.

Use of test equipment.
Use of common instruments such as an
ohmmeter, volt-amp meter, a leak detector or
a cooling system pressure tester that may be
required by IMPCO Service Manual Supplement procedures.
Repair Diagnosis is the responsibility of the technician.
LABOR OPERATION NUMBER

A Labor Operation Number is assigned to the
labor performed and must be recorded on the
warranty claim. The Labor Operation Number
can be found in this Guide or IMPCO Technical
Service Bulletins.
OVERLAPPING LABOR
Overlapping labor is labor time is where two operations include the same repair steps.
Overlapping time is not compensated; therefore,
the repeated labor time must be deducted from
the second labor operation so that the total time
entered is less than the sum of the combined labor times.
CUSTOMER PROBLEM ANALYSIS
DUPLICATE LABOR
It is the duty of the service technician to translate

the customer's complaint into a specific symptom.
Examples include: stalling, hesitation,
surges, engine cranks but will not start, etc.
Symptoms also include readily apparent failures
to the senses of sight, touch, sound and smell,
such as leaking coolant line or cracked casting.
Duplicate Labor is the same labor charged twice,

either to two different cost recovery sources, or
overlapping labor charged to the same or different cost recovery sources. Duplicate Labor is
not eligible for compensation unless authorized
by IMPCO.
SYMPTOM DIAGNOSIS
Symptom Diagnosis is the process used to determine the source of the problem and is the
responsibility of both the technician and dealership management.
Symptom Diagnosis is
STRAIGHT TIME
Straight Time is applicable only when a labor operation is required and no labor operation
description or operation number exists in this
Guide. All Straight Time is governed by Policy
A and is subject to review and approval by
IMPCO before payment is reimbursed. Precise
301
labor step documentation indexed to time is required and must be recorded on the shop repair
order to identify and justify this expense. Prior
approval may be obtained by contacting IMPCO
Technical Assistance 1-866-473-2851.
time that is necessary to complete a satisfactory

diagnosis that beyond the normal time allowed.
This time must be identified as Additional Diagnostics and follow the same time recording and
labor step documentation as Straight Time.
ADDITIONAL OR OTHER LABOR
It is the responsibility of qualified dealership supervisory personnel to assist technicians in both

customer Problem Analysis and Symptom Diagnosis.
Additional or Other Labor may be required when

unusual or abnormal conditions are encountered.
This time must be identified as such and follow
the same time recording and labor step documentation as Straight Time.
Warranty
compensation for all additional time falls under
Policy A and is subject to review and approval
by IMPCO before payment is reimbursed. Prior
approval may be obtained by contacting IMPCO
Technical Assistance at 1-866-473-2851.
POLICY CODES
Certain IMPCO Policy Codes apply to the Generic Labor Operations listed on page 7. Policy
codes and descriptions are:
Policy A Is subject to review by IMPCO before reimbursement.
Policy B Will require approval from IMPCO
before expense is incurred
Policy S Sublet of work to a facility outside
the normal OEM dealer network, and requires
approval from IMPCO prior to incurring the expense
All prior approvals may be obtained by contacting
IMPCO Technical Assistance at 1-866-473-2851.
NORMAL & ADDITIONAL DIAGNOSTICS

Normal repair diagnosis time is included in all
labor time operations. Additional Diagnostics is
TECHNICAL ASSISTANCE
Service technicians must call the OEM Technical
Assistance whenever extensive diagnosis or repair advice is required, or to verify a vehicles
warranty.
OEM Technical Assistance personnel must contact IMPCO Technical Service personnel to
obtain authorization for those repairs or additional labor that require prior authorization for
warranty compensation. IMPCO Technical Assistance may be contacted at (1-866-473-2851)
between the hours of 8:00 a.m. and 5:00 p.m.
Pacific Time Monday through Friday except holidays.
COMPLETED WARRANTY CLAIMS

OEMs can choose to submit their electronic
forms via an FTP site using the OEM user ID and
Passwords (supplied by IMPCO Technical Assistance). The forms may be submitted individually
or batched. The claims will be reviewed and approved or declined and the OEM will be notified
via an electronic response from the IMPCO warranty administrator. The OEM may then submit
an invoice for payment of approved claims to
IMPCO for payment of those claims.
302
FUEL SYSTEM LABOR OPERATIONS

Engine-Electrical
OPERATION
NUMBER
TIME
ALLOWED
ENGINE CONTROL MODULE (ECM)REPLACEMENT
E0050
0.8
ENGINE CONTROL MODULE (ECM)REFLASH
E0057
0.3
ENGINE WIRE HARNESSREPAIR
E1015
0.9
ENGINE WIRE HARNESSREPLACEMENT
E2015
1.5
PLUGS, SPARKREPLACE ONE
J4226
0.4
PLUGS, SPARKREPLACE ALL
J4227
0.7
WIRES, SPARK PLUG-REPLACE ALL
J4207
0.3
COIL, IGNITIONREPLACEMENT
J4340
0.6
BRACKET, FUSE BOX-REPLACE
E3037
0.4
M1007
0.3
ELECTRONIC THROTTLE BODYREPLACEMENT
M0075
0.8
THROTTLE BODY/GASKETREPLACEMENT
E3012
0.8
CAP, DISTRIBUTOR - REPLACE
J4360
0.2
ROTOR, DISTRIBUTOR - REPLACE
J4380
0.2
DISTRIBUTOR ASSEMBLY - REPLACE
J4530
0.8
LABOR OPERATION DESCRIPTION
LPG FUEL CONTROL SYSTEM CHECK

INCLUDES: Connect scan tool or test equipment. Check for trouble codes
(DTCs), check HEGO operation, disconnect scan tool or test equipment.
303

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

Fuel Delivery
OPERATION
NUMBER
TIME
ALLOWED
M1001
0.8
PRESSURE REGULATOR-REPLACEMENT
INCLUDES: Transfer of all fittings
PRESSURE REGULATOR REPAIR (SEE M1001 FOR REPLACEMENT)
0.9
E3005
ADD: Allowance for the replacement of regulator port O-rings 0.3
0.3
FUEL FILTER, HIGH PRESSURE LIQUID-REPLACE
E3041
0.5
FUEL FILTER, LOW PRESSURE VAPOR-REPLACE
E3042
0.3
BRACKET, LOW PRESSURE VAPOR LPG FILTER-REPLACE
E3052
0.3
BRACKET, REGULATOR MOUNTINGREPLACEMENT
E3009
0.5
FUEL INJECTOR, ADAPTER AND/OR FUEL RAIL-REPLACE
1.0
ADD: Each Additional Fuel Injector

ADD: Fuel Injector Hose
ADD: Fuel Injector Adapter (each)
E3044
0.2
0.1
0.1
FUEL RAIL BRACKET-REPLACE
E3046
0.3
LEAK CHECK LPG SYSTEM
G0004
0.2
M1006
0.3
F1003
0.8
LPG FUEL SYSTEM PRESSURE CHECK

INCLUDES: Connect fuel pressure gauges. Check regulator primary and
secondary pressure. Disconnect gauges.
SHUT-OFF VALVEREPLACEMENT
305

Exhaust
OPERATION
NUMBER
TIME
ALLOWED
CATALYTIC CONVERTERREPLACEMENT
N1001
5.0
RESTRICTED EXHAUST SYSTEM DIAGNOSIS
E3017
0.3
OPERATION
NUMBER
TIME
ALLOWED
T1001
0.7
E3047
0.3
E3048
0.4
E3049
0.2
Hoses
COOLANT HOSESREPLACE ALL
INCLUDES: Drain & Fill Radiator
COOLANT HOSE PORT FITTING-REPLACE
FUEL VAPOR HOSEREPLACE ALL
INCLUDES: Replacement of Vapor Hose Port Fittings
FUEL VAPOR HOSE PORT-FITTING-REPLACE
VACUUM LINE-REPLACE ONE
0.4
T1002
ADD: Additional Line Replace Allowances. Diagnosis Time: 0.1

PCV-INSPECT OR REPLACE
0.1
E3050
306
0.3

Engine-Exterior Components
OPERATION
NUMBER
TIME
ALLOWED
WATER PUMP AND/OR GASKET-REPLACE
J3480
0.7
STARTERREPLACEMENT
J4560
0.6
ALTERNATORREPLACEMENT
J4570
0.5
DRIVE BELTREPLACEMENT
J4571
0.5
THERMOSTAT, AND/OR GASKETREPLACEMENT
J4580
0.4
FLYWHEEL/HARMONIC BALANCERREPLACEMENT
J0720
0.5
307

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

Includes: R&R intake manifold.
J0308
0.3
ROCKER ARMREPLACEMENT
Includes: R&R intake manifold and rocker cover(s).
ADD: Replace all rocker arms:
J0358
STUD, VALVE ROCKER ARM BALL-REPLACEMENT

ADD: To replace an additional stud
J0388
0.5
0.3
CYLINDER HEAD GASKET-REPLACEMENT

Includes: R&R intake manifold, rocker covers(s) and compression test.
J0508
2.3
CYLINDER HEAD-REPLACEMENT
Includes: R&R intake manifold, rocker cover(s) and compression test.
J0518
3.0
J0528
2.9
0.4
0.9
0.2
0.4
0.3
VALVERECONDITION OR REPLACEMENT
ADD: Each additional cylinder
ADD: To recondition all valves
ADD: To ream and fit guides for oversize stems
2.5
VALVE SPRING, CAP AND/OR SEALSREPLACEMENT

Includes: R&R rocker cover(s)
ADD: Each additional cylinder
ADD: All springs, caps and/or seals
J0548
PUSH RODREPLACEMENT, ONE CYLINDER

ADD: To replace all push rods:
J0588
LIFTER, VALVEREPLACEMENT, ONE CYLINDER

ADD: To replace all lifters:
J0628
0.3
0.9
0.8
0.2
308
0.9
0.3

EngineInternal Components
OPERATION
NUMBER
TIME
ALLOWED
TIMING COVER OIL SEALREPLACEMENT

Includes: R&R balancer
J0750
0.7
TIMING COVER AND/OR GASKETREPLACEMENT

Includes: R&R balancer
J0780
2.0
TIMING CHAINREPLACEMENT
1.6
J0820
ADD: Replace crankshaft gear
0.2
CAMSHAFT TIMING GEARREPLACEMENT
3.9
J0840
ADD: Replace crankshaft gear
0.2
CAMSHAFTREPLACEMENT
J0850
6.0
OIL PAN AND/OR GASKETREPLACEMENT

Includes: Fluid replacement
J1000
2.2
PUMP, ENGINE OILREPLACEMENT

Includes: R&R engine oil pan and fluid replacement
J1020
2.5
J1120
2.8
SEAL, REAR MAIN BEARINGREPLACEMENT

Includes: R&R engine oil pan and fluid, replace lower seal and repack
upper seal
BEARING, CRANKSHAFT MAINREPLACE ONE
Includes: R&R engine oil pan and fluid, and use of plastic type gauge
ADD: Replace main bearings
Each additional (NOT to equal or exceed ALL)
All main bearings
4.1
J1200
ADD: Replace connecting rod bearings

All rod bearings
309
0.5
1.2
0.3
1.2

EngineInternal Components
OPERATION
NUMBER
BEARING, CONNECTING RODREPLACE ONE

Includes: R&R engine oil pan and fluid, and use of plastic type gauge
ADD: Replace connecting rod bearings
All rod bearings
PISTON, ROD AND/OR RINGSREPLACEMENT
Includes: R&R all necessary components and use of plastic type gauge
TIME
ALLOWED
2.9
J1180
0.4
2.0
3.3
ADD: Replace rings only

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

Each rod (NOT to exceed ALL)
All rods
0.3
1.2
ADD: To replace pistons only

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

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

EngineReplacement
OPERATION
NUMBER
TIME
ALLOWED
9.0
BLOCK, ENGINE FITTEDREPLACEMENT

Includes: R& R all components, fluids and accessories
ADD: To recondition all valves and guides
J1800
ENGINE, PARTIALREPLACEMENT
Includes: R& R all components, fluids and accessories
ADD: To recondition all valves and guides
J1820
ENGINE, ASSEMBLYREPLACEMENT
Includes: R&R all components, fluids and accessories
J1880
3.5
ENGINE, MOUNTS, FRONTREPLACEMENT
J1506
0.3
311
2.6
7.2
2.6
MISCELLANEOUS
OPERATION
NUMBER
TIME
ALLOWED
G0001
Policy B
0.5
FASTENER OR FITTING TIGHTENING
G0003
0.1
DRIVE TESTS
G0006
0.2
G0007
Policy S
0.0

ADDITIONAL DIAGNOSTIC TIME Policy B
Subject to review by IMPCO Technical Support
SUBLET TIME Policy S*

*Requires Prior Approval By IMPCO Technical Support;
312
REQUEST FOR REVIEW OF LABOR TIMES

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

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

Please insure this Request for Review is filled out completely so that it can be investigated
and processed without delay.
SERVICE FACILITY INFORMATION
Service Facility Name:
Service Facility Address:
City:
State:
Telephone Number (
Zip Code
OPERATION NUMBER
Fax Number: (
CURRENT PUBLISHED
TIME
SUGGESTED TIME
VEHICLE INFORMATION:
Model Year
Mileage
Model Line
SERIAL#
Engine
TECHNICIAN INFORMATION:
Technicians Name
Are you certified in this area of repair?
Yes
No
How many times have you performed this repair?
Once
Is the IMPCO Service Manual Supplement accurate?
Yes
Twice
No
How many?
Describe the inaccuracy:
(Please include any additional inaccuracies and/or suggestions on a separate sheet. We

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

Date: (required)
A detailed, step by step labor description is required on the back of this form before a labor
time study will be considered for review.
315
LABOR TIME STUDY FORM

Step
Labor Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
(Attach additional sheets if necessary)

Total Repair Time (minutes/seconds)
316
Watch Time
(Min/Sec)
Definitions
317
Air Valve Vacuum (AVV): The vacuum signal taken from below the air valve assembly and above
the throttle butterfly valve.
ADP: Adaptive Digital Processor.
Air/Fuel Ratio: The amount or balance of air and
fuel in the air fuel mixture that enters the engine.
Analog Voltmeter: A meter that uses a mechanical needle to point to a value on a scale of
numbers. It is usually of the low impedance type
and used to measure voltage and resistance.
Aromatics: Pertaining to or containing the sixcarbon ring characteristic of the benzene series.
Found in many petroleum distillates.
Backfire: Combustion of the air/fuel mixture in the
intake or exhaust manifolds. A backfire can occur
if the intake or exhaust valves are open when
there is a mis-timed ignition spark.
Benzene: An aromatic (C6H6). Sometimes blended
with gasoline to improve anti-knock value. Benzene is toxic and suspected of causing cancer.
Bi-Fueled: A vehicle equipped to run on two fuels.
Blow-By: Gases formed by the combustion of fuel
and air, which ordinarily should exert pressure
only against the piston crown and first compression ring. When rings do not seal, these gases
escape or blow by the side of the piston into the
crankcase.
BTU: British Thermal Unit. A measurement of the
amount of heat required to raise the temperature
of 1lb. of water 1 degree F.
Butane: An odorless, colorless gas, C4H10 found in
natural gas and petroleum. One of the five LP
gases.
CAFE: Corporate Average Fuel Economy.
CARB: California Air Resources Board.
Carbon Monoxide (CO): A chemical compound of
a highly toxic gas that is both odorless and colorless.
Carburetor: An apparatus for supplying an internal-combustion engine a mixture of vaporized fuel
and air.
Cathode Ray Tube: A vacuum tube in which cathode rays usually in the form of a slender beam
are projected on a fluorescent screen and produce a luminous spot.
Circuit: A path of conductors through which electricity flows.
Closed Loop Operation: Applies to systems utilizing an oxygen sensor. In this mode of operation,
the system uses oxygen sensor information to determine air/fuel ratio. Adjustments are made
accordingly and checked by comparing the new
oxygen sensor to previous signals. No stored information is used.
CNG: Compressed Natural Gas.

CKP: Crankshaft Position Sensor
CMP: Camshaft Position Sensor
Conductor: A material, normally metallic, that
permits easy passage of electricity.
Contaminants: Impurities or foreign material present in fuel.
Control Module: One of several informal names
for a solid state microcomputer which monitors
engine conditions and controls certain engine
functions; i.e. air/fuel ratio, injection and ignition
time, etc. The formal name and the one used
throughout this manual is ECM, or Engine Control
Module.
Converter: A LPG fuel system component containing varying stages of fuel pressure regulation
combined with a vaporizer.
Cryogen: A refrigerant used to obtain very low
temperatures.
Current: The volume or flow of electrons through a
conductor. Measured in amperes or amps.
DBW: Drive By Wire
Dedicated Fuel System: A motor fuel system designed to operate on only one fuel type.
Diaphragm: A thin, flexible membrane that separates two chambers. When the pressure in one
chamber is lower than in the other chamber, the
diaphragm will move toward the side with the low
pressure.
Diaphragm Port: The external port located at the
fuel inlet assembly and connected to the vacuum
chamber above the air valve diaphragm.
DLC: Data Link Connector.
DTC: Diagnostic Trouble Code
DST: Diagnostic Scan Tool.
DVOM: Digital Volt/ohm Meter. A meter that uses a
numerical display in place of a gauge and is usually of the high impedance type.
ECT: Engine Coolant Temperature.
ECM: Electronic Control Module
ECOM: A DLC cable supporting CAN and serial
communication with a Spectrum II or III ECM.
EFI: Electronic Fuel Injection. A fuel injection system, which uses a microcomputer (ECM) to
determine and control the amount of fuel, required by, and injected into, a particular engine.
EGO: Exhaust Gas Oxygen, used to describe a
sensor. Also known as HEGO (Heat Exhaust
Gas Oxygen) sensor, O2 or Oxygen sensor.
EGR: Exhaust Gas Recirculation.
EPA: Environmental Protection Agency: A regulating agency of the Federal government which,
among other duties, establishes and enforces automotive emissions standards.
318
Ethanol: Grain alcohol (C2H5OH), generally produced by fermenting starch or sugar.

Evaporative Emissions Controls: An automotive
emission control system designed to reduce hydrocarbon emissions by trapping evaporated fuel
vapors from the fuel system.
Excess Flow Valve: A check valve that is caused
to close by the fuel when the flow exceeds a predetermined rate.
FTV: Fuel Trim Valve.
FFV: Flexible Fuel Vehicle.
Firing Line: The portion of an oscilloscope pattern
that represents the total amount of voltage being
expended through the secondary circuit.
FMVSS: Federal Motor Vehicle Safety Standards.
FPP: Foot Pedal Position Sensor
Fuel Injector: a spring loaded, electromagnetic
valve which delivers fuel into the intake manifold,
in response to an electrical input from the control
module.
Fuel Lock: A solenoid-controlled valve located in
the fuel line to stop the flow when the engine
stops or the ignition switch is off.
Gasohol: 10 percent ethanol, 90 percent gasoline.
Often referred to as E-10.
Gasoline: A motor vehicle fuel that is a complex
blend of hydrocarbons and additives. Typical octane level is 89.
GCP: Spectrum III (90-pin) ECM.
Greenhouse Effect: A scientific theory suggesting
that carbon dioxide from the burning of fossil fuels
is causing the atmosphere to trap heat and cause
global warming.
HC: Hydrocarbon. An organic chemical compound.
HD 10: A fuel of not less than 80% liquid volume
propane and not more than 10% liquid volume
propylene.
HD 5: A fuel of not less than 90% liquid volume
propane and not more than 5% liquid volume
propylene.
HDV: Heavy Duty Vehicle.
Heavy Ends: A term used to describe the buildup
of wax-like impurities that fall out of LPG when
vaporized.
HEGO: Heated Exhaust Gas Oxygen, used to describe a sensor. Also known as EGO (Exhaust
Gas Oxygen sensor), O2 or Oxygen sensor.
Hg: Chemical symbol for the element mercury.
Used in reference to a measure of vacuum (inches of Hg).
Histogram: The graphical version of a table which
shows what proportion of values fall into specific
categories over a specific period of time.
Hydrocarbon: A chemical compound made up of

hydrogen and carbon (HC). Gasoline and almost
all other fuels are hydrocarbons.
Hydrostatic Relief Valve: A pressure relief device
installed in the liquid LPG hose on a LPG fuel
system.
IAT: Intake Air Temperature
Ideal Mixture: The air/fuel ratio at which the best
compromise of engine performance to exhaust
emissions is obtained. Typically 14.7:1.
Ignition Reserve: The difference between available voltage and the required voltage.
ILEV: Inherently Low Emission Vehicle. IMPCO:
Imperial Machine Products Company. IMPCO
Technologies, Inc. A manufacturer of both
LPG and Gasoline fuel systems.
Impedance: A form of opposition of AC electrical
current flow (resistance) measured in ohms.
Insulation: A nonconductive material used to cover
wires in electrical circuits to prevent the leakage
of electricity and to protect the wire from corrosion.
Intercept: An electrical term for a type of splice
where the original circuit is interrupted and redirected through another circuit.
ITK: IMPCO Test Kit
Knock: Sound produced when an engines air/fuel
mixture is ignited by something other than the
spark plug, such as a hot spot in the combustion
chamber. Also caused by a fuel with an octane
rating that is too low and/or incorrect ignition timing. Also called detonation or ping.
Lambda Sensor: A feedback device, usually located in the exhaust manifold, which detects the
amount of oxygen present in exhaust gases in relation to the surrounding atmosphere. (See
HEGO).
LDV: Light Duty Vehicle.
Lean Mixture: An air to fuel ratio above the stoichiometric ratio; too much air.
LEV: Low Emission Vehicle.
Limp-in or Limp Home: A mode where the ECM
or a component has failed, but the vehicle remains operational although the engine may
operate minimally. This term may also describe
the drivability characteristics of a failed computer
system.
Liquid Petroleum Gas (LPG): A fuel commonly
known as propane consisting mostly of propane
(C3H8), derived from the liquid components of
natural gas stripped out before the gas enters the
pipeline, and the lightest hydrocarbons produced
during petroleum refining. Octane level of LPG is
107.
319
LPG: Liquified Petroleum Gas.

M85: A blend of gasoline and methanol consisting
of 85% methanol and 15% gasoline.
Measurements of Pressure: 1 PSI=2.06 Hg
(mercury) = 27.72 H2O (water column). At sea
level atmospheric pressure is 29.92 Hg.
Methanol: Known as wood alcohol (CH3OH), a
light, volatile, flammable alcohol commonly made
from natural gas.
MIL: Malfunction Indicator Lamp.
Misfire: Failure of the air/fuel mixture to ignite during the power stroke.
Mixer: Fuel introduction device that does not include a throttle plate.
MFI: Multiport Fuel Injection. A fuel injection system
that uses one injector per cylinder mounted on
the engine to spray fuel near the intake valve area of combustion chamber.
MSV: Manual Shut-Off Valve. Refers to the manually operated valve on the LPG tank.
MTBE: Methyl Tertiary Butyl Ether. Oxygenate add
to gasoline to reduce harmful emissions and to
improve the octane rating.
Multi-fuel System: A motor fuel system designed
to operate on two different fuels, such as LPG
and gasoline.
Natural Gas: A gas formed naturally from buried
organic material, composed of a mixture of hydrocarbons, with methane (CH4) being the
dominant component.
NGV: Natural Gas Vehicle.
NOX: See Oxides of Nitrogen.
OBD: On Board Diagnostic
Octane Rating: The measurement of the antiknock
value of a motor fuel.
OEM: Original Equipment Manufacturer, the vehicle
manufacturer.
Open-Loop: An operational mode during which
control module memory information is used to determine air/fuel ratio, injection timing, etc., as
opposed to actual oxygen sensor input.
Orifice: A port or passage with a calibrated opening designed to control or limit the amount of flow
through it.
Oscilloscope: An instrument that converts voltage
and frequency readings into traces on a cathode
ray tube (also see Cathode Ray Tube).
Oxides of Nitrogen: Chemical compounds of nitrogen bonded to various amounts of oxygen
(NOX). A chief smog forming-agent.
Oxygen Sensor: An automotive fuel system that
produces a signal in accordance with the oxygen
content of the exhaust gas. (See Lambda Sensor).
Oxygenate: Oxygenates (such as MTBE, ethanol

and methanol) added to gasoline to increase the
oxygen content and therefore reduce exhaust
emissions.
Ozone: A radical oxygen module (O3) that is found
in the upper atmosphere and filters out ultraviolet
radiation from the sun. Ground level ozone is
formed by NOX, during the formation of photochemical smog.
Particulates: Microscopic pieces of solid or liquid
substances such as lead and carbon that are discharged into the atmosphere by internal
combustion engines.
Positive Crankcase Ventilation (PCV): An automotive emission control system designed to
reduce hydrocarbon emissions by routing crankcase fumes into the intake manifold rather than to
the atmosphere.
Power Derate: A mode of reduced engine power
output for the purposes of protecting engine components during a failure or malfunction.
Pressure Differential: The differential between
atmospheric pressure and intake manifold (referred to as vacuum) pressure.
Pressure Regulator: A device to control the pressure of fuel delivered to the fuel injector(s).
Primary Circuit: The low-voltage or input side of
the ignition coil.
Propane: An odorless and colorless gas, C3H8,
found in natural gas and petroleum.
Psia: pounds per square inch absolute
PTV: Pressure Trim Valve
Reactivity: Refers to the tendency of an HC in the
presence of NOX and sunlight to cause a smogforming reaction. The lighter the HC, the lower
reactivity tends to be.
Regulator: An assembly used to reduce and control the pressure of a liquid or vapor.
Resistance: The opposition to the flow of current in
an electrical circuit. Measured in ohms.
Rest Pressure: Fuel pressure maintained within
the system after engine shutdown.
Rich Mixture: An air to fuel ratio below the stoichiometric ratio; too much fuel.
SAE: Society of Automotive Engineers.
Secondary Circuit: The high-voltage output side of
the ignition coil.
SEFI or SFI: Sequential Electronic Fuel Injection or
Sequential Fuel Injection.
Sensors: Devices that provide the control module
with engine information as needed to properly
control engine function.
320
Spark Line: The portion of an oscilloscope pattern

that represents the time during which the air/fuel
mixture is being burned in the combustion chamber.
Splice: An electrical term for the joining of two or
more conductors at a single point.
Stoichiometric Ratio: An ideal fuel/air ratio for
combustion in which all of the fuel and most of
the oxygen will be burned.
Sulfur Oxides: Chemical compounds where sulfur
is bonded to oxygen produced by the combustion
of gasoline or any other fuel that contains sulfur.
As sulfur oxides combine with water in the atmosphere to form sulfuric acid.
System Pressure: The fuel pressure maintained in
the system during normal engine operation.
Tap: An electrical term for a type of splice where
the original circuit is not interrupted.
TBI: Throttle Body Injection. Any of several injection systems that have the fuel injector(s)
mounted in a centrally located throttle body.
Throttle Body: Controls engine RPM by adjusting
the engine manifold vacuum to the mixer. Consists of a housing shaft, throttle liner and butterfly
valve.
TLEV: Transitional Low Emission Vehicle.
TMAP: Combined Air Inlet and Manifold Pressure
Sensor.
Toluene: A liquid aromatic hydrocarbon C7H8.
TPS: Throttle Position Sensor.
TSB: Technical Service Bulletin.

ULEV: Ultra Low Emission Vehicle.
USB: Universal Serial Bus. A plug or interface supplied on most personal computers.
Vaporization: A process in which liquid changes
states into gas.
Venturi Air Valve Vacuum (VAVV): An amplified
air valve vacuum signal coming from the venturi
area of the mixer, directly exposed to airflow before the addition of vaporized LPG.
Volt/ohmmeter (VOM): A combination meter used
to measure voltage and resistance in an electrical
circuit. Available in both analog and digital types.
May also referred to as AVOM and DVOM.
Voltage: The electrical pressure that causes current to flow in a circuit. Measured in volts.
Voltage Drop: A lowering of the voltage in a circuit
when resistance or electrical load is added.
Voltmeter: A meter that uses a needle to point to a
value on a scale of numbers usually of the low
impedance type; used to measure voltage and
resistance.
VSS: Vehicle Speed Sensor
Xylene: C6H4 (CH3)2. Any of three toxic, flammable,
and oily isomeric aromatic hydrocarbons that are
dimethyl homologues of benzene and usually obtained from petroleum or natural gas distillates.
ZEV: Zero Emission Vehicle.
321
322
Appendix
323
Altitude vs. Barometric Pressure

Altitude Measured
In Feet (ft)
14,000
Kilopascals
(kpa)
56-64
Pounds Per Square

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

Firing Order
1-6-5-4-3-2
Spark Plug Type
R44LTS (AC Plug)
Spark Plug Gap
.035 in (0.889 mm)
Spark Plug Torque
11 lb ft (15 Nm)
Spark Plug Wire Resistance
1000 Ohms per ft.
325
Extended ECT Temperature vs. Resistance

Degrees F.
Degrees C.
Ohms10%
302
150
47
284
140
60
266
130
77
248
120
100
230
110
132
212
100
177
194
90
241
176
80
332
158
70
467
140
60
667
122
50
973
113
45
1188
104
40
1459
95
35
1802
86
30
2238
77
25
2796
68
20
3520
59
15
4450
50
10
5670
41
7280
32
9420
23
-5
12300
14
-10
16180
-15
21450
-4
-20
28680
-22
-30
52700
-40
-40
100700
326
DTC (SPN & FMI Chart)
327

2011 LPG30 LLiu Gong Impco

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2011 Emission Certified

LPG Fuel System

Parts & Service Manual

2011 Emission Certified

Fuel other than HD-5 or HD-10 may cause harm

*Not Applicable in the state of California.

HOW TO IDENTIFY THE ENGINE YEAR

The emission label on the engine will identify the

Any maintenance and repair should be performed

AIR FILTRATION REQUIREMENTS

For parts or labor to be reimbursed under the

For parts or labor not reimbursed under warranty, a

FUEL SYSTEM CAUTIONS

Unlike gasoline or propane vapors that

Do not use Teflon tape to seal any fuel

WARNINGS, CAUTIONS AND NOTES

Do not smoke, carry lighted tobacco or

A WARNING is an advisement that by performing a process or procedure listed in this manual

Do not allow LPG to contact the skin.

A WARNING is an advisement that

Do not allow LPG to accumulate in areas below ground level such as in a

Less severe than WARNING but has the

Do not make repairs to the fuel system

This caution label may also appear in area of this

dures. In addition it may also be used to indicate

A NOTE statement applies to a specific item or

Serpentine belts utilize a spring-loaded tensioner

When performing maintenance on the engine,

Alcohol or Methanol based anti-freeze or

If any of these conditions exist the belt should be

Alcohol or Methanol based anti-freeze or

The regular removal of dust, dirt and debris

If any of these conditions exist the hose

Verify that any additional electrical services

ILSAC GF-4 oils are highly recommended. Oils

Reduced Phosphorous levels (20%) for reduced catalyst poisoning

Improved hi temp deposit control (1.5X detergents = 25% improvement)

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

5. If the oil level is below the ADD mark reinstall

An overfilled crankcase (oil level being too

Engine oil will be hot. Use protective

When refueling or exchanging the fuel cylinder,

Check for leaks at the inlet and outlet fittings,

AIR FUEL MIXER/THROTTLE CONTROL

Leaks at the inlet fitting.

Inspect Air cleaner element according to the

The measurement of oxygen in the exhaust

PRESSURE REGULATOR MAINTENANCE AND

Check for any fuel leaks at the inlet and outlet

EXHAUST SYSTEM AND CATALYTIC

When inspecting the Exhaust system check the

Exhaust manifold at the cylinder head for

LPG CERTIFIED ENGINE MAINTENANCE REQUIREMENTS

General Maintenance Section

LPG Fuel System

LPG FUEL SYSTEM OPERATION

DESCRIPTION AND OPERATION OF THE FUEL

Typical LPG Cylinder

LPG FUEL TANK

The bulkhead assembly should never be

of the tank. A replaceable, high pressure, inline

connection with the throttle and there is no direct

A throttle related failure will cause a LIMP