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Hyster F004 Service Manual – PDF DOWNLOAD
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Description
Hyster F004 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster F004 Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR:
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster F004 Service Manual – PDF DOWNLOAD
1510481-8000SRM0989-(09-2004)-US-EN............................................. 1 toc......................................................................... 1 Diagrams................................................................ 1 Safety Precautions Maintenance and Repair............................... 2 General................................................................. 5 1510481-8000SRM0989-(10-2005)-US-EN............................................. 53 toc......................................................................... 53 Diagrams................................................................ 53 Safety Precautions Maintenance and Repair............................... 54 General................................................................. 57 1559540-0900SRM1088-(11-2004)-US-EN.............................................125 toc.........................................................................125 Electronic Controlled LPG/Gasoline Fuel System..........................125 Safety Precautions Maintenance and Repair...............................126 General.................................................................131 Fuel System Warnings and Cautions...................................131 Glossary................................................................132 Description and Operation of LPG Fuel System............................136 Propane Fuel System.................................................136 LPG Fuel Tank.......................................................136 Service Line........................................................136 Fuel Filter.........................................................138 Low Pressure Lock-Off (LPL).........................................138 Low Pressure Regulator (LPR)........................................139 Air Fuel Mixer......................................................139 Throttle Control Device.............................................140 Drive By Cable..................................................140 Three-Way Catalytic (TWC) Muffler...................................141 Electronic Control Module (ECM).....................................141 Heated Exhaust Gas Oxygen (HEGO) Sensor.............................142 Description and Operation of Gasoline Fuel System.......................144 Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine ....144 Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only........144 Gasoline Fuel Storage Tank..........................................144 Gasoline Fuel Pump..................................................144 Fuel Filter.........................................................144 Fuel Pressure Regulator, 3.0L Only..................................147 Fuel Rail and Pressure Regulator, 4.3L Only.........................148 Fuel Injector.......................................................148 Throttle Control Device.............................................148 Drive By Cable..................................................148 Three-Way Catalytic Muffler.........................................149 Electronic Control Module (ECM).....................................149 Heated Exhaust Gas Oxygen (HEGO) Sensor.............................151 LPG Fuel System Repair..................................................151 Propane Fuel System Pressure Relief.................................151 Propane Fuel System Leak Test.......................................151 Propane Fuel Filter Replacement.....................................152 Remove..........................................................152 Install.........................................................152 Low Pressure Lock-Off (LPL) Replacement.............................152 Remove..........................................................152 Install.........................................................152 Pressure Trim Valve (PTV) Replacement...............................154 Remove..........................................................154 Install.........................................................154 Low Pressure Regulator..............................................154 Remove..........................................................154 Install.........................................................155 Fuel Trim Valve (FTV) Solenoid Replacement..........................155 Remove..........................................................155 Install.........................................................155 Temperature Manifold Absolute Pressure (TMAP).......................157 Remove..........................................................157 Install.........................................................157 Throttle Body Replacement...........................................157 Remove..........................................................157 Install.........................................................159 Mixer Replacement...................................................159 Remove..........................................................159 Install.........................................................160 Coolant Hose Replacement............................................160 Remove..........................................................160 Install.........................................................160 Vapor Hose Replacement..............................................160 Remove..........................................................160 Install.........................................................160 Balance Line Hose Replacement.......................................160 Remove..........................................................160 Install.........................................................161 PTV Hose Replacement................................................161 Remove..........................................................161 Install.........................................................161 FTV Hose Replacement................................................161 Remove..........................................................161 Install.........................................................161 Throttle Position Sensor (TPS) Replacement..........................161 Foot Pedal Position (FPP) Sensor Replacement........................164 Electronic Control Module (ECM) Replacement.........................167 Remove..........................................................167 Install.........................................................167 Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement.................168 Remove..........................................................168 Install.........................................................168 Three-Way Catalytic Muffler (TWC) Replacement.......................168 Remove..........................................................168 Install.........................................................168 Restricted Exhaust System Diagnosis.................................168 Exhaust System Description......................................168 Tools Required..............................................168 Diagnostic Tool.............................................168 Check at Heated Exhaust Gas Oxygen Sensor (HEGO)................168 Gasoline Fuel System Repair.............................................169 Gasoline MPFI and TBI Fuel System Pressure Relief...................169 Gasoline Fuel System Leak Test......................................170 Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only........170 Remove..........................................................170 Install.........................................................170 Throttle Body Assembly Replacement, 3.0L Only.......................172 Remove..........................................................172 Install.........................................................172 Throttle Body Assembly Replacement, 4.3L Only.......................172 Remove..........................................................172 Install.........................................................173 Fuel Rail Replacement, Gasoline 4.3L Only...........................173 Remove..........................................................173 Install.........................................................175 Injector Replacement, Gasoline 4.3L Only............................175 Remove..........................................................175 Install.........................................................175 Injector Replacement, Gasoline 3.0L Only............................175 Remove..........................................................175 Install.........................................................176 Temperature Manifold Absolute Pressure (TMAP) Replacement...........176 Remove..........................................................176 Install.........................................................176 Throttle Position Sensor (TPS) Replacement..........................176 Foot Pedal Position (FPP) Sensor Replacement........................180 Electronic Control Module (ECM) Replacement.........................182 Remove..........................................................182 Install.........................................................182 Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement.................182 Remove..........................................................182 Install.........................................................183 Three-Way Catalytic Muffler (TWC) Replacement.......................183 Remove..........................................................183 Install.........................................................183 Restricted Exhaust System Diagnosis.................................183 Exhaust System Description......................................183 Tools Required..............................................183 Diagnostic Tool.............................................183 Check at Heated Exhaust Gas Oxygen Sensor (HEGO)................183 LPG System Diagnosis....................................................184 Fuel System Description.............................................184 Diagnostic Aids.....................................................185 Tools Required..................................................185 Duty Cycle Monitoring Tool......................................185 Diagnostic Tool.................................................185 Pressure Gauges.................................................185 Test Description................................................185 Gasoline System Diagnosis...............................................193 Fuel System Description, 3.0L Only..................................193 Fuel System Description, 4.3L Only..................................193 Diagnostic Aids.....................................................194 Tools Required..................................................194 Diagnostic Tool.................................................194 Test Description................................................194 LPG Symptom Diagnosis...................................................201 Gasoline Symptom Diagnosis..............................................214 Wire Harness Repair.....................................................224 On Vehicle Service Wiring Harness Repair............................224 Connectors and Terminals............................................225 Twisted/Shielded Cable Repair...................................225 Twisted Leads Repair............................................226 Micro-Pack......................................................227 Metri-Pack......................................................227 Remove......................................................227 Weather-Pack....................................................229 Weather-Pack Terminal Repair................................230 tables......................................................................125 Table 1. TPS Replacement Procedure......................................162 Table 2. FPP Replacement Procedure......................................165 Table 3. TPS Replacement Procedure......................................177 Table 4. FPP Replacement Procedure......................................180 Table 5. LPG Fuel System Diagnosis......................................185 Table 6. Fuel Control Diagnosis.........................................189 Table 7. Gasoline Fuel System Diagnosis, 3.0L Only......................195 Table 8. Gasoline Fuel System Diagnosis, 4.3L Only......................198 Table 9. Preliminary Checks.............................................201 Table 10. Intermittent .................................................202 Table 11. No Start......................................................203 Table 12. Hard Start....................................................205 Table 13. Cuts Out or Misses............................................206 Table 14. Hesitation, Sag, or Stumble...................................207 Table 15. Backfire......................................................208 Table 16. Lack of Power, Sluggishness, or Sponginess....................209 Table 17. Poor Fuel Economy.............................................210 Table 18. Rough, Unstable, Incorrect Idle, or Stalling..................211 Table 19. Surges or Chuggles............................................213 Table 20. Preliminary Checks............................................214 Table 21. Intermittent..................................................215 Table 22. No Start......................................................216 Table 23. Hard Start....................................................217 Table 24. Cuts Out or Misses............................................218 Table 25. Hesitation, Sag, or Stumble...................................219 Table 26. Backfire......................................................220 Table 27. Lack of Power, Sluggishness, or Sponginess....................221 Table 28. Poor Fuel Economy.............................................222 Table 29. Rough, Unstable, Incorrect Idle, or Stalling..................223 Table 30. Surges or Chuggles............................................224 1559545-2200SRM1090-(11-2004)-US-EN.............................................235 toc.........................................................................235 Electronic Control Module (ECM) Diagnostic Troubleshooting..............235 Safety Precautions Maintenance and Repair...............................236 General.................................................................245 Description of ECM Based Diagnostics....................................245 Definition of Terms.................................................245 Diagnostics Overview of the Spectrum Fuel System....................245 Malfunction Indicator Lamp (MIL)....................................246 Spectrum Diagnostic Trouble Codes (DTC).............................246 Using a Laptop Computer to Diagnose the Spectrum System.............246 Installing the Spectrum Diagnostic Software.....................247 Connecting a Laptop Computer to the Spectrum System.............247 Diagnostic Communication Error..................................247 Diagnostic Trouble Codes............................................248 Checking Diagnostic Trouble Codes...............................248 Clearing Diagnostic Trouble Codes...............................248 DATA Stream.........................................................249 Reading Sensor and Actuator Values..............................249 Graphing and Data Logging.......................................250 Ignition System Test................................................251 Disabling Ignition Outputs......................................251 Injector Test.......................................................252 Disabling Injectors.............................................252 Throttle Test.......................................................252 Using a Diagnostic Jumper to Diagnose the ECI System............253 On-Board Diagnostics System Check/Malfunction Indicator Lamp............254 Circuit Description.................................................254 Preliminary and Intermittent Checks.....................................257 GM 3.0L Wiring Schematics and Connectors................................259 GM 3.0L Diagnostic Trouble Codes........................................273 DTC 111 - IAT High Voltage Motorola® TMAP...........................273 Circuit Description.............................................273 Conditions for Setting the DTC..................................273 DTC 112 - IAT Low Voltage Motorola® TMAP............................276 Circuit Description.............................................276 Conditions for Setting the DTC..................................276 DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP.................278 Circuit Description.............................................278 Conditions for Setting the DTC..................................278 Diagnostic Aids.................................................279 DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP.................280 Circuit Description.............................................280 Conditions for Setting the DTC..................................280 Diagnostic Aids.................................................280 DTC 115 - Oil Pressure Low..........................................281 Circuit Description.............................................281 Conditions for Setting the DTC..................................281 DTC 121 - ECT Voltage High..........................................284 Circuit Description.............................................284 Conditions for Setting the DTC..................................285 DTC 122 - ECT Voltage Low...........................................288 Circuit Description.............................................288 Conditions for Setting the DTC..................................288 DTC 123 - ECT Higher Than Expected 1................................290 Circuit Description.............................................290 Conditions for Setting the DTC..................................290 DTC 124 - ECT Higher Than Expected 2................................292 Circuit Description.............................................292 Conditions for Setting the DTC..................................292 DTC 131 - MAP High Pressure Motorola® TMAP..........................294 Circuit Description.............................................294 Conditions for Setting the DTC..................................294 Diagnostic Aids.................................................294 DTC 132 - MAP Low Voltage Motorola® TMAP............................297 Circuit Description.............................................297 Conditions for Setting the DTC..................................297 DTC 134 - BP High Pressure Motorola® TMAP...........................301 Circuit Description.............................................301 Conditions for Setting the DTC..................................301 DTC 135 - BP Low Pressure Motorola® TMAP............................302 Circuit Description.............................................302 Conditions for Setting the DTC..................................302 DTC 142 - Crank Sync Noise..........................................306 Circuit Description.............................................306 Conditions for setting the DTC..................................306 DTC 143 - Never Crank Synced At Start...............................310 Circuit Description.............................................310 Conditions for Setting the DTC..................................310 DTC 144 - Camshaft Sensor Loss......................................313 Circuit Description.............................................313 Conditions for Setting the DTC..................................313 DTC 145 - Camshaft Sensor Noise.....................................316 Circuit Description.............................................316 Conditions for Setting the DTC..................................316 DTC 211 - Closed Loop Multiplier High (LPG).........................319 Circuit Description.............................................319 Conditions for Setting the DTC..................................319 Diagnostic Aids.................................................319 DTC 212 - HO 2 S Open/Inactive......................................322 Circuit Description.............................................322 Conditions for Setting the DTC..................................322 DTC 221 - Closed Loop Multiplier High (Gasoline)....................324 Circuit Description.............................................324 Conditions for Setting the DTC..................................324 Diagnostic Aids.................................................325 DTC 222 - Closed Loop Multiplier Low (Gasoline).....................328 Circuit Description.............................................328 Conditions for Setting the DTC..................................328 Diagnostic Aids.................................................328 DTC 224 - Closed Loop Multiplier Low (LPG)..........................330 Circuit Description.............................................330 Conditions for Setting the DTC..................................330 Diagnostic Aids.................................................330 DTC 241 - Adaptive Lean Fault (High Limit-Gasoline).................332 Circuit Description.............................................332 Conditions for Setting the DTC..................................332 Diagnostic Aids.................................................332 DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)..................335 Circuit Description.............................................335 Conditions for Setting the DTC..................................335 Diagnostic Aids.................................................335 DTC 243 - Adaptive Learn High (LPG).................................338 Circuit Description.............................................338 Conditions for Setting the DTC..................................338 Diagnostic Aids.................................................338 DTC 244 - Adaptive Learn Low (LPG)..................................341 Circuit Description.............................................341 Conditions for Setting the DTC..................................341 Diagnostic Aids.................................................341 DTC 261 - System Voltage High.......................................344 Circuit Description.............................................344 Conditions for Setting the DTC..................................344 DTC 262 - System Voltage Low........................................346 Circuit Description.............................................346 Conditions for Setting the DTC..................................346 DTC 411 - Injector Driver 1 Open....................................348 Circuit Description.............................................348 Conditions for Setting the DTC..................................348 DTC 412 - Injector Driver 1 Shorted.................................351 Circuit Description.............................................351 Conditions for Setting the DTC..................................351 DTC 511 - COP Failure...............................................354 Circuit Description.............................................354 Conditions for Setting the DTC..................................354 DTC 512 - Invalid Interrupt.........................................356 Circuit Description.............................................356 Conditions for Setting the DTC..................................356 DTC 513 - A/D Loss..................................................358 Circuit Description.............................................358 Conditions for Setting the DTC..................................358 DTC 514 - RTI 1 Loss................................................360 Circuit Description.............................................360 Conditions for Setting the DTC..................................360 DTC 515 - Flash Checksum Invalid....................................362 Circuit Description.............................................362 Conditions for Setting the DTC..................................362 DTC 516 - Ram Failure...............................................364 Circuit Description.............................................364 Conditions for Setting the DTC..................................364 DTC 531 - External 5V Ref Lower Than Expected.......................366 Circuit Description.............................................366 Conditions for Setting the DTC..................................366 DTC 532 - External 5V Ref Higher Than Expected......................368 Circuit Description.............................................368 Conditions for Setting the DTC..................................368 DTC 555 - RTI 2 Loss................................................370 Circuit Description.............................................370 Conditions for Setting the DTC..................................370 DTC 556 - RTI 3 Loss................................................372 Circuit Description.............................................372 Conditions for Setting the DTC..................................372 DTC 611 - FPP High Voltage..........................................374 Circuit Description.............................................374 Conditions for Setting the DTC..................................374 DTC 612 - FPP Low Voltage...........................................378 Circuit Description.............................................378 Conditions for Setting the DTC..................................378 DTC 631 - TPS1 Signal Voltage High..................................382 Circuit Description.............................................382 Conditions for Setting the DTC..................................382 DTC 632 - TPS1 Signal Voltage Low...................................385 Circuit Description.............................................385 Conditions for Setting the DTC..................................385 DTC 638 - Throttle Unable To Close..................................388 Circuit Description.............................................388 Conditions for Setting the DTC..................................388 Diagnostic Aids.................................................389 DTC 651 - Maximum Govern Speed Override.............................391 Circuit Description.............................................391 Conditions for Setting the DTC..................................391 Diagnostic Aids.................................................391 DTC 652 - Fuel Rev Limit............................................394 Circuit Description.............................................394 Conditions for Setting the DTC..................................394 Diagnostic Aids.................................................394 DTC 653 - Spark Rev Limit...........................................396 Circuit Description.............................................396 Conditions for Setting the DTC..................................396 Diagnostic Aids.................................................396 GM 4.3L Wiring Schematics and Connectors................................400 GM 4.3L Diagnostic Trouble Codes........................................417 DTC 111 - IAT High Voltage Bosch® TMAP..............................417 Circuit Description.............................................417 Conditions for Setting the DTC..................................417 DTC 111 - IAT High Voltage Motorola® TMAP...........................420 Circuit Description.............................................420 Conditions for Setting the DTC..................................420 DTC 112 - IAT Low Voltage Bosch® TMap...............................422 Circuit Description.............................................422 Conditions for Setting the DTC..................................423 DTC 112 - IAT Low Voltage Motorola® TMAP............................425 Circuit Description.............................................425 Conditions for Setting the DTC..................................425 DTC 113 - IAT Higher Than Expected 1 Bosch® TMAP....................428 Circuit Description.............................................428 Conditions for Setting the DTC..................................428 Diagnostic Aids.................................................428 DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP.................429 Circuit Description.............................................429 Conditions for Setting the DTC..................................429 Diagnostic Aids.................................................429 DTC 114 - IAT Higher Than Expected 2 Bosch® TMAP€...................430 Circuit Description.............................................430 Conditions for Setting the DTC..................................430 Diagnostic Aids.................................................430 DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP.................431 Circuit Description.............................................431 Conditions for Setting the DTC..................................431 Diagnostic Aids.................................................431 DTC 115 - Oil Pressure Low..........................................432 Circuit Description.............................................432 Conditions for Setting the DTC..................................432 DTC 121 - ECT Voltage High..........................................434 Circuit Description.............................................434 Conditions for Setting the DTC..................................435 DTC 122 - ECT Voltage Low...........................................438 Circuit Description.............................................438 Conditions for Setting the DTC..................................438 DTC 123 - ECT Higher Than Expected 1................................441 Circuit Description.............................................441 Conditions for Setting the DTC..................................441 DTC 124 - ECT Higher Than Expected 2................................443 Circuit Description.............................................443 Conditions for Setting the DTC..................................443 DTC 131 - MAP High Pressure Bosch® TMAP.............................444 Circuit Description.............................................444 Conditions for Setting the DTC..................................444 Diagnostic Aids.................................................444 DTC 131 - MAP High Pressure Motorola® TMAP..........................448 Circuit Description.............................................448 Conditions for Setting the DTC..................................448 Diagnostic Aids.................................................448 DTC 132 - MAP Low Voltage Bosch® TMAP...............................451 Circuit Description.............................................451 Conditions for Setting the DTC..................................451 DTC 132 - MAP Low Voltage Motorola® TMAP............................454 Circuit Description.............................................454 Conditions for Setting the DTC..................................454 DTC 134 - BP High Pressure Bosch® TMAP..............................459 Circuit Description.............................................459 Conditions for Setting the DTC..................................459 DTC 134 - BP High Pressure Motorola® TMAP...........................461 Circuit Description.............................................461 Conditions for Setting the DTC..................................461 DTC 135 - BP Low Pressure Bosch® TMAP...............................463 Circuit Description.............................................463 Conditions for Setting the DTC..................................463 DTC 135 - BP Low Pressure Motorola® TMAP............................467 Circuit Description.............................................467 Conditions for Setting the DTC..................................467 DTC 142 - Crank Sync Noise..........................................470 Circuit Description.............................................470 Conditions for setting the DTC..................................470 DTC 143 - Never Crank Synced At Start...............................474 Circuit Description.............................................474 Conditions for Setting the DTC..................................474 DTC 144 - Camshaft Sensor Loss......................................477 Circuit Description.............................................477 Conditions for Setting the DTC..................................477 DTC 145 - Camshaft Sensor Noise.....................................480 Circuit Description.............................................480 Conditions for Setting the DTC..................................480 DTC 211 - Closed Loop Multiplier High (LPG).........................483 Circuit Description.............................................483 Conditions for Setting the DTC..................................483 Diagnostic Aids.................................................484 DTC 212 - HO 2 S Open/Inactive......................................486 Circuit Description.............................................486 Conditions for Setting the DTC..................................486 DTC 221 - Closed Loop Multiplier High (Gasoline)....................489 Circuit Description.............................................489 Conditions for Setting the DTC..................................489 Diagnostic Aids.................................................489 DTC 222 - Closed Loop Multiplier Low (Gasoline).....................492 Circuit Description.............................................492 Conditions for Setting the DTC..................................492 Diagnostic Aids.................................................492 DTC 224 - Closed Loop Multiplier Low (LPG)..........................494 Circuit Description.............................................494 Conditions for Setting the DTC..................................494 Diagnostic Aids.................................................495 DTC 241 - Adaptive Lean Fault (High Limit-Gasoline).................496 Circuit Description.............................................496 Conditions for Setting the DTC..................................496 Diagnostic Aids.................................................496 DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)..................499 Circuit Description.............................................499 Conditions for Setting the DTC..................................499 Diagnostic Aids.................................................499 DTC 243 - Adaptive Learn High (LPG).................................502 Circuit Description.............................................502 Conditions for Setting the DTC..................................502 Diagnostic Aids.................................................502 DTC 244 - Adaptive Learn Low (LPG)..................................505 Circuit Description.............................................505 Conditions for Setting the DTC..................................505 Diagnostic Aids.................................................505 DTC 261 - System Voltage High.......................................508 Circuit Description.............................................508 Conditions for Setting the DTC..................................508 DTC 262 - System Voltage Low........................................510 Circuit Description.............................................510 Conditions for Setting the DTC..................................510 DTC 511 - COP Failure...............................................512 Circuit Description.............................................512 Conditions for Setting the DTC..................................512 DTC 512 - Invalid Interrupt.........................................514 Circuit Description.............................................514 Conditions for Setting the DTC..................................514 DTC 513 - A/D Loss..................................................516 Circuit Description.............................................516 Conditions for Setting the DTC..................................516 DTC 514 - RTI 1 Loss................................................518 Circuit Description.............................................518 Conditions for Setting the DTC..................................518 DTC 515 - Flash Checksum Invalid....................................520 Circuit Description.............................................520 Conditions for Setting the DTC..................................520 DTC 516 - Ram Failure...............................................522 Circuit Description.............................................522 Conditions for Setting the DTC..................................522 DTC 531 - External 5V Ref Lower Than Expected.......................524 Circuit Description.............................................524 Conditions for Setting the DTC..................................524 DTC 532 - External 5V Ref Higher Than Expected......................526 Circuit Description.............................................526 Conditions for Setting the DTC..................................526 DTC 555 - RTI 2 Loss................................................528 Circuit Description.............................................528 Conditions for Setting the DTC..................................528 DTC 556 - RTI 3 Loss................................................530 Circuit Description.............................................530 Conditions for Setting the DTC..................................530 DTC 611 - FPP High Voltage..........................................532 Circuit Description.............................................532 Conditions for Setting the DTC..................................532 DTC 612 - FPP Low Voltage...........................................536 Circuit Description.............................................536 Conditions for Setting the DTC..................................536 DTC 631 - TPS1 Signal Voltage High..................................540 Circuit Description.............................................540 Conditions for Setting the DTC..................................540 DTC 632 - TPS1 Signal Voltage Low...................................543 Circuit Description.............................................543 Conditions for Setting the DTC..................................543 DTC 638 - Throttle Unable To Close..................................546 Circuit Description.............................................546 Conditions for Setting the DTC..................................546 Diagnostic Aids.................................................547 DTC 651 - Maximum Govern Speed Override.............................549 Circuit Description.............................................549 Conditions for Setting the DTC..................................549 Diagnostic Aids.................................................549 DTC 652 - Fuel Rev Limit............................................552 Circuit Description.............................................552 Conditions for Setting the DTC..................................552 Diagnostic Aids.................................................552 DTC 653 - Spark Rev Limit...........................................554 Circuit Description.............................................554 Conditions for Setting the DTC..................................554 Diagnostic Aids.................................................554 Wire Harness Repair.....................................................557 On Vehicle Service Wiring Harness Repair............................557 Connectors and Terminals............................................558 Twisted/Shielded Cable Repair...................................558 Twisted Leads Repair............................................559 Micro-Pack......................................................560 Metri-Pack......................................................560 Remove......................................................560 Weather-Pack....................................................562 Weather-Pack Terminal Repair................................563 tables......................................................................235 Table 1. OBD System Check...............................................255 Table 2. Preliminary Checks.............................................257 Table 3. Intermittent Checks............................................258 Table 4. Communication Port C002........................................259 Table 5. Coil Connector C003............................................259 Table 6. Fuel System Interface C004.....................................259 Table 7. Oil Pressure Connector C005....................................260 Table 8. Distributor Connector C006.....................................260 Table 9. Magnetic Pickup Connector C007.................................260 Table 10. Heated Oxygen Sensor C008.....................................260 Table 11. Throttle Position Sensor Connector C009.......................261 Table 12. Foot Pedal Position Connector C010............................261 Table 13. Governor Motor Connector C011.................................261 Table 14. TMAP Connector C012...........................................261 Table 15. Starter Solenoid C013.........................................262 Table 16. Engine Coolant Temperature C014...............................262 Table 17. Battery Connector C015........................................262 Table 18. Alternator Connection C016....................................262 Table 19. Battery Connector C017........................................262 Table 20. Alternator Connector C018.....................................263 Table 21. Instrument Panel Connector C019...............................263 Table 22. Instrument Panel Connector C020...............................263 Table 23. Instrument Panel Connector C021...............................264 Table 24. Fuel Trim Valve Connector C022................................264 Table 25. Fuel Lockoff Connector C023...................................264 Table 26. Pressure Trim Valve Connector C024............................265 Table 27. Throttle Body Injector Connector C025.........................265 Table 28. Relay and Fuse Center.........................................265 Table 29. DTC 111 - IAT Voltage High (Motorola® TMAP)...................274 Table 30. DTC 112 - IAT Low Voltage (Motorola® TMAP)....................277 Table 31. DTC 115 - Oil Pressure Low....................................282 Table 32. Temperature Resistance........................................284 Table 33. DTC 121 - ECT VOLTAGE HIGH....................................285 Table 34. DTC 122 - ECT Voltage Low.....................................289 Table 35. DTC 123 - ECT Higher Than Expected 1..........................291 Table 36. DTC 124 - ECT Higher Than Expected 2..........................293 Table 37. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP)..................295 Table 38. DTC 132 - MAP Low Voltage (Motorola® TMAP)....................298 Table 39. DTC 134 - BP High Pressure (Motorola® TMAP)...................301 Table 40. DTC 135 - BP Low Pressure (Motorola® TMAP)....................303 Table 41. DTC 142 - Crank Sync Noise....................................307 Table 42. DTC 143 - Never Crank Synced At Start.........................310 Table 43. DTC 144 - Camshaft Sensor Loss................................313 Table 44. DTC 145 - Camshaft Sensor Noise...............................316 Table 45. DTC 211 - Closed Loop Multiplier High (LPG)...................320 Table 46. DTC 212 - HO 2 S Open/Inactive................................323 Table 47. DTC 221 - Closed Loop Multiplier High (Gasoline)..............326 Table 48. DTC 222 - Closed Loop Multiplier Low (Gasoline)...............329 Table 49. DTC 224 - Closed Loop Multiplier Low (LPG)....................331 Table 50. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)...........333 Table 51. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)............336 Table 52. DTC 243 - Adaptive Learn High (LPG)...........................339 Table 53. DTC 244 - Adaptive Learn Low (LPG)............................342 Table 54. DTC 261 - System Voltage High.................................345 Table 55. DTC 262 - System Voltage Low..................................346 Table 56. DTC 411 - Injector Driver 1 Open..............................349 Table 57. DTC 412 - Injector Driver 1 Shorted...........................352 Table 58. DTC 511 - COP Failure.........................................355 Table 59. DTC 512 - Invalid Interrupt...................................357 Table 60. DTC 513 - A/D Loss............................................359 Table 61. DTC 514 - RTI 1 Loss..........................................361 Table 62. DTC 515 - Flash Checksum Invalid..............................363 Table 63. DTC 516 - Ram Failure.........................................365 Table 64. DTC 531 - External 5V Ref Lower Than Expected.................367 Table 65. DTC 532 - External 5 V Ref Higher Than Expected...............369 Table 66. DTC 555 - RTI 2 Loss..........................................371 Table 67. DTC 556 - RTI 3 Loss..........................................373 Table 68. DTC 611 - FPP High Voltage....................................375 Table 69. DTC 612 - FPP Low Voltage.....................................379 Table 70. DTC 631 - TPS1 Signal Voltage High............................383 Table 71. DTC 632 - TPS1 Signal Voltage Low.............................386 Table 72. DTC 638 - Throttle Unable To Close............................389 Table 73. DTC 651 - Maximum Govern Speed Override.......................392 Table 74. DTC 652 - Fuel Rev Limit......................................395 Table 75. DTC 653 - Spark Rev Limit.....................................397 Table 76. Communication Port C002.......................................400 Table 77. Injector Connector C003.......................................400 Table 78. Injector Connector C004.......................................400 Table 79. Oil Pressure Connector C005...................................401 Table 80. Throttle Position Sensor 1 Connector C006.....................401 Table 81. Foot Pedal Position Connector C006A...........................401 Table 82. Coil Connector C007...........................................401 Table 83. Module Connector C008.........................................402 Table 84. Crank Sensor Connector C009...................................402 Table 85. EGO Sensor Connector C010.....................................402 Table 86. Cam Connector C011............................................403 Table 87. Throttle Connector C012.......................................403 Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only).........403 Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)...........404 Table 90. Starter Solenoid Connector C014...............................404 Table 91. ECT Connector C015............................................404 Table 92. Starter Relay C016............................................404 Table 93. Power Relay C017..............................................404 Table 94. Fuel Pump Relay C018..........................................404 Table 95. Battery Connector C019........................................405 Table 96. Alternator Connector C020.....................................405 Table 97. Alternator Connector C021.....................................405 Table 98. Instrument Panel Connector C022...............................405 Table 99. Instrument Panel Connector C023...............................406 Table 100. Instrument Panel Connector C024..............................406 Table 101. Fuel Trim Valve Connector C025...............................406 Table 102. Fuel Lockoff Connector C026..................................407 Table 103. Pressure Trim Valve Connector C027...........................407 Table 104. Injector 1 Connector C028....................................407 Table 105. Injector 2 Connector C029....................................408 Table 106. Injector 3 Connector C030....................................408 Table 107. Injector 4 Connector C031....................................408 Table 108. Injector 5 Connector C032....................................409 Table 109. Injector 6 Connector C033....................................409 Table 110. Relay and Fuse Center........................................409 Table 111. DTC 111 - IAT Voltage High (Bosch® TMAP).....................418 Table 112. DTC 111 - IAT Voltage High (Motorola® TMAP)..................421 Table 113. DTC 112 - IAT Low Voltage (Bosch® TMAP)......................423 Table 114. DTC 112 - IAT Low Voltage (Motorola® TMAP)...................426 Table 115. DTC 115 - Oil Pressure Low...................................432 Table 116. Temperature Resistance.......................................435 Table 117. DTC 121 - ECT VOLTAGE HIGH...................................436 Table 118. DTC 122 - ECT Voltage Low....................................439 Table 119. DTC 123 - ECT Higher Than Expected 1.........................442 Table 120. DTC 124 - ECT Higher Than Expected 2.........................444 Table 121. DTC 131 - MAP High Pressure (Bosch® TMAP)....................445 Table 122. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP).................449 Table 123. DTC 132 - MAP Low Voltage (Bosch® TMAP)......................452 Table 124. DTC 132 - MAP Low Voltage (Motorola® TMAP)...................455 Table 125. DTC 134 - BP High Pressure (Bosch® TMAP).....................460 Table 126. DTC 134 - BP High Pressure (Motorola® TMAP)..................462 Table 127. DTC 135 - BP Low Pressure (Bosch® TMAP)......................463 Table 128. DTC 135 - BP Low Pressure (Motorola® TMAP)...................467 Table 129. DTC 142 - Crank Sync Noise...................................471 Table 130. DTC 143 - Never Crank Synced At Start........................474 Table 131. DTC 144 - Camshaft Sensor Loss...............................477 Table 132. DTC 145 - Camshaft Sensor Noise..............................480 Table 133. DTC 211 - Closed Loop Multiplier High (LPG)..................484 Table 134. DTC 212 - HO 2 S Open/Inactive...............................487 Table 135. DTC 221 - Closed Loop Multiplier High (Gasoline).............490 Table 136. DTC 222 - Closed Loop Multiplier Low (Gasoline)..............493 Table 137. DTC 224 - Closed Loop Multiplier Low (LPG)...................495 Table 138. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)..........497 Table 139. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)...........500 Table 140. DTC 243 - Adaptive Learn High (LPG)..........................503 Table 141. DTC 244 - Adaptive Learn Low (LPG)...........................506 Table 142. DTC 261 - System Voltage High................................509 Table 143. DTC 262 - System Voltage Low.................................510 Table 144. DTC 511 - COP Failure........................................513 Table 145. DTC 512 - Invalid Interrupt..................................515 Table 146. DTC 513 - A/D Loss...........................................517 Table 147. DTC 514 - RTI 1 Loss.........................................519 Table 148. DTC 515 - Flash Checksum Invalid.............................521 Table 149. DTC 516 - Ram Failure........................................523 Table 150. DTC 531 - External 5V Ref Lower Than Expected................525 Table 151. DTC 532 - External 5 V Ref Higher Than Expected..............527 Table 152. DTC 555 - RTI 2 Loss.........................................529 Table 153. DTC 556 - RTI 3 Loss.........................................531 Table 154. DTC 611 - FPP High Voltage...................................533 Table 155. DTC 612 - FPP Low Voltage....................................536 Table 156. DTC 631 - TPS1 Signal Voltage High...........................541 Table 157. DTC 632 - TPS1 Signal Voltage Low............................544 Table 158. DTC 638 - Throttle Unable To Close...........................547 Table 159. DTC 651 - Maximum Govern Speed Override......................550 Table 160. DTC 652 - Fuel Rev Limit.....................................553 Table 161. DTC 653 - Spark Rev Limit....................................556 1559550-2200SRM1097-(10-2004)-US-EN.............................................567 toc.........................................................................567 High Voltage Switch (HVS) Ignition......................................567 Safety Precautions Maintenance and Repair...............................568 Description.............................................................571 Distributor Ignition (DI) System....................................571 Crankshaft Position (CKP) Sensor....................................571 Camshaft Position (CMP) Sensor......................................571 Ignition Coil and Ignition Control Module (ICM).....................571 Secondary Ignition Components.......................................571 Spark Plugs and Wires...................................................571 Spark Plug Wire Inspection..........................................571 Spark Plug Wire Replacement.........................................571 Remove..........................................................571 Install.........................................................572 Spark Plug Inspection...............................................572 Usage...........................................................572 Inspection......................................................572 Visual Inspection...............................................574 Spark Plug Replacement..............................................574 Remove..........................................................574 Install.........................................................574 Distributor Repair......................................................575 Inspect.............................................................575 Overhaul............................................................575 Disassemble.....................................................575 Assemble........................................................578 Replace.............................................................578 Remove..........................................................578 Install Procedure 1.............................................580 Install Procedure 2.............................................581 Ignition Coil Replacement...............................................583 Remove..............................................................583 Install.............................................................583 Ignition Control Module Replacement.....................................584 Remove..............................................................584 Install.............................................................584 Camshaft Position (CMP) Sensor Replacement..............................584 Remove..............................................................584 Install.............................................................586 Crankshaft Position (CKP) Sensor Replacement............................586 Remove..............................................................586 Install.............................................................586 Wire Harness Repair.....................................................588 On Vehicle Service Wiring Harness Repair............................588 Connectors and Terminals............................................588 Twisted/Shielded Cable Repair...................................589 Twisted Leads Repair............................................590 Micro-Pack......................................................590 Metri-Pack......................................................590 Remove......................................................591 Weather-Pack....................................................592 Weather-Pack Terminal Repair................................593 Specifications and Special Tools........................................594 System Diagnosis........................................................596 tables......................................................................567 Table 1. Ignition System Specifications.................................594 Table 2. Fastener Tightening Specifications.............................594 Table 3. Special Tools..................................................595 Table 4. Distributor Ignition (DI)......................................596
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