Yale Forklift B879 (GC_GDC_GLC135-155CA) Service Manual – PDF DOWNLOAD

Description

Yale Forklift B879 (GC_GDC_GLC135-155CA) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift B879 (GC_GDC_GLC135-155CA) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1328
Downloadable : Yes
File Type : PDF

PART NO. 524150775 

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift B879 (GC_GDC_GLC135-155CA) Service Manual – PDF DOWNLOAD

524150775-0700YRM0626-(03-2003)-US-EN 1
toc 1
Cooling System 1
Safety Precautions Maintenance and Repair 2
General 5
Description 6
Radiator 6
Radiator Cap 6
Thermostat 6
Water Pump 7
Fan and Fan Shroud 7
Cooling System Checks 7
Radiator 7
Thermostat 7
Water Pump 8
Exhaust Leaks 8
Fan and Fan Shroud 8
Radiator Cleaning 8
Drain 8
Clean 8
Fill 9
Troubleshooting 10
524150779-1400YRM0046-(08-2012)-US-EN 13
toc 13
Differential 13
Safety Precautions Maintenance and Repair 14
General 17
Description 17
Differential Repair 17
Remove 17
Differential Carrier From Axle Housing, Remove 17
Differential and Ring Gear From Differential Carrier, Remove 21
Drive Pinion and Pinion Carrier From Differential Carrier, Remov 23
Disassemble 24
Differential and Ring Gear Assembly, Disassemble 24
Drive Pinion and Pinion Carrier, Disassemble 25
Clean and Inspect 28
Assemble 29
Pinion, Bearings, and Pinion Carrier, Assemble 29
Pinion Bearings, Adjust Preload 29
Press Method 29
Yoke or Flange Method 30
Triple-Lip Seal, Install 31
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion) 32
Differential and Ring Gear, Assemble 34
Differential Gears Rotating Torque, Check 36
Differential and Ring Gear Assembly, Install 37
Differential Bearings, Preload Adjust 38
Ring Gear, Runout Check 39
Ring Gear Backlash, Adjust 40
Gear Set, Tooth Contact Pattern Check 42
Thrust Screw, Install and Adjust 45
Install 45
Differential Assembly Into Axle Housing, Install 45
Specifications 46
Troubleshooting 50
tables 13
Table 1 Ring Gear Backlash Adjustment Specifications 41
Table 2 Ring and Pinion Tooth Contact Adjustment 42
Table 3 General Specifications 46
Table 4 Rivet Installation Pressure 46
Table 5 Pinion Adjustment 46
Table 6 Pinion Preload Pressure 47
Table 7 Torque Specifications 48
Table 8 Torque Specifications for Metric Hardware 49
Table 9 Torque Specifications for Metric (Fine) Hardware 49
524150790-2100YRM0103-(03-2007)-US-EN 53
toc 53
Tilt Cylinders 53
Safety Precautions Maintenance and Repair 54
General 57
Description 57
Tilt Cylinder Repair 57
Remove 57
Disassemble 57
Clean 57
Assemble 58
Tilt Cylinders With O-Ring or Single-Lip Seals 58
Tilt Cylinders 59
Install 60
Tilt Cylinder Leak Check 62
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 63
Torque Specifications 63
Piston Rod Nut 63
Retainer 63
Troubleshooting 64
tables 53
Table 1 Movement Rates (Maximum) for Tilt Cylinders 62
524150791-2200YRM0002-(01-2016)-US-EN 69
General 73
Description 74
Alternator Repair 76
Alternator Type A 76
Remove and Disassemble 76
Clean 78
Assemble 78
Install 79
Alternator Type B 82
Remove and Disassemble 82
Clean 82
Assemble 83
Install 84
General Check and Adjustment 84
Low Output Check (Type A or Type B) 85
High Output Check (Type A or Type B) 88
Brushes Circuit Check 89
Delco Alternators 89
Motorola Alternators 89
Diodes Check 90
Diode Bridge Check 90
Delco and Leece-Neville Alternators 90
Motorola Alternators 90
Rotor Field Winding Check 91
Stator Windings Check 92
Voltage Regulator Check 92
Troubleshooting 92
524150792-2200YRM0106-(01-2016)-US-EN 97
General 101
Description and Operation 102
Starter Repair 106
Remove 106
Disassemble 106
Clean 107
Assemble 107
Install 108
General Checks and Adjustments 108
Troubleshooting 110
524150794-4000YRM0135-(03-2011)-US-EN 117
toc 117
Lift Cylinders 117
Safety Precautions Maintenance and Repair 118
Safety Procedures When Working Near Mast 121
General 125
Description 125
Lowering Control Valve 125
Cylinders (General) 128
Lift Cylinder Repair 128
Lift Cylinder Removal Without Removing Mast 128
Standard Masts With Main Lift Cylinder Fastened to Crossmember o 128
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to 129
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift 130
Disassemble 130
Assemble 130
Lift Cylinder Installation in Mast 132
Standard Masts With Main Lift Cylinder Fastened to Crossmember o 132
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to 132
Chevron-Style Packing 133
Chevron-Style Packing Installation on Piston 133
Chevron-Style Packing Installation in Packing Gland 135
Lift Cylinders for HI VIS® Masts 137
Description 137
Lowering Control Valve 137
Remove 139
Disassemble 140
Assemble 140
Install 142
Main Lift Cylinders 142
Free-Lift Cylinder 142
Lift System Leak Check 142
Specifications 143
Troubleshooting 144
tables 117
Table 1 Cylinder Retainer Torque Specifications and Weight Guid 143
524150797-8000YRM0231-(02-2023)-US-EN 149
General 155
Threaded Fasteners 155
Nomenclature, Threads 155
Strength Identification 156
Cotter (Split) Pins 157
Fastener Torque Tables 162
Conversion Table 164
524150797-8000YRM0231-(03-2020)-US-EN 171
General 175
Threaded Fasteners 175
Nomenclature, Threads 175
Strength Identification 176
Cotter (Split) Pins 177
Fastener Torque Tables 182
Conversion Table 184
524153897-0600YRM0590-(04-2014)-US-EN 191
524153907-1900YRM0097-(05-2012)-US-EN 243
toc 243
Hydraulic Gear Pumps 243
Safety Precautions Maintenance and Repair 244
Description 247
Operation 248
Flow Control Valve 248
Relief Valve 248
Hydraulic Gear Pump Repair 249
Remove 249
Disassemble 250
Clean 250
Inspect 251
Assemble 254
Install 256
Pump Output Check 256
Method No 1 256
Method No 2 257
Hydraulic System Air Check 258
Troubleshooting 259
524153908-1900YRM0339-(10-2003)-US-EN 265
toc 265
Hydraulic Pump Drive Assembly 265
Safety Precautions Maintenance and Repair 266
General 269
Description 269
Hydraulic Pump Drive Assembly Repair 270
Remove and Disassemble 270
Clean 271
Inspect 271
Assemble and Install 271
Troubleshooting 272
524185156-1300YRM0324-(10-2003)-US-EN 275
toc 275
Two-Speed Powershift Transmission 275
Safety Precautions Maintenance and Repair 276
General 279
Mechanical Description 279
Torque Converter 279
Transmission Pump 280
Shaft Assemblies 280
Input Shaft 281
Forward Clutch Shaft 281
Clutch Assemblies 281
Countershaft 288
Output Shaft 288
Hydraulic Operation 289
Torque Converter 289
Seal Rings 290
Control Valve 290
System Pressure Regulator 293
Clutch Pressure Regulator 293
Torque Converter Regulator 294
Inching Spool 294
Direction Spool, Direction Control Lever 294
Direction Spool, Foot Directional Control Pedal 295
Range Spool 296
Drain Spool 296
Accumulator 296
Modulator Spool 296
Operation 297
Lubrication Circuit 297
Foot Directional Control Pedal 298
Oil Flow Diagrams 299
Neutral 299
Forward-Low 299
Forward-Low-Inching 299
Reverse-Low 300
524185157-1300YRM0325-(10-2003)-US-EN 307
toc 307
Two-Speed Powershift Transmission 307
Safety Precautions Maintenance and Repair 308
General 311
Transmission Repair 311
Transmission and Torque Converter, Remove 311
Transmission, Disassemble 313
Reverse-Low Clutch, Disassemble 316
Reverse-High Clutch, Disassemble 319
Forward-Low Clutch, Disassemble 322
Forward-High Clutch, Disassemble 325
Clean and Inspect 327
Forward Low and High Clutches Assembly 328
Forward Clutches, Assemble 330
Reverse-Low Clutch, Assemble 336
Reverse Clutches, Assemble 338
Transmission, Assemble 345
Torque Converter, Install 351
Control Valve Repair 352
Remove 352
Disassemble 353
Assemble 354
Install 356
Foot Directional Control Pedal 356
Remove and Disassemble 356
Assemble and Install 356
Stall Test 359
Linkage Adjustments 360
Linkage for Inching Pedal GDP60-70CA (GP/GLP/GDP135-155CA) (A878 360
Linkage for Inching Pedal GC/GLC/GDC135-155CA (A879, B879) 363
Linkage for Range Lever – Early Model GDP60-70CA (GP/GLP/GDP135- 365
Linkage for Direction Control Lever – Early Model GDP60-70CA (GP 367
Linkage for Range Lever – Later Model GDP60-70CA (GP\GLP\GDP135- 367
Linkage for Direction Control Lever – Later Model GDP60-70CA (GP 369
Linkage for Range Lever GC/GLC/GDC135-155CA (A879, B879) 371
Linkage for Direction Control Lever GC/GLC/GDC135-155CA (A879, B 371
Oil Pressure Check 373
System Pressure Check Port 374
Torque Converter Check Port 374
Clutch Pressure Check Port 374
Inching Pressure 374
Solenoid Check Ports ( Foot Directional Control Only) 374
Lubrication Pressure Check Ports 374
Specifications 374
Troubleshooting 375
Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi) 377
Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi) 378
Correct Solenoid Pressure (Foot Directional Control Only): 965 ± 379
Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi) 379
Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi) 380
tables 307
Table 1 Stall Speed Specifications 359
524185160-1600YRM0054-(10-2003)-US-EN 383
toc 383
Steering Control Unit 383
Safety Precautions Maintenance and Repair 384
General 387
Description 387
Operation 387
Steering Wheel and Column Assembly Repair 389
Steering Column Assembly Repair 389
Type A Steering Column Assembly 389
Remove and Disassemble 389
Assemble and Install 391
Type B Steering Column Assembly 393
Remove and Disassemble 393
Assemble and Install 393
Steering Control Unit 396
Disassemble 396
Clean 399
Assemble 400
System Air Removal 405
Troubleshooting 405
524185164-2000YRM0090-(10-2003)-US-EN 409
toc 409
Main Control Valve 409
Safety Precautions Maintenance and Repair 410
General 413
Description 413
Operation 413
Lift Spool 413
Tilt Spool 413
Tilt Backward 413
Tilt Forward 417
Two-Stage Relief Valve 418
Main Control Valve Repair 419
Remove and Disassemble 419
Clean and Inspect 419
Assemble 419
Install 420
Two-Stage Relief Valve 420
Troubleshooting 421
tables 409
Table 1 Relief Pressures (Oil temperature at 55 to 66 C ( 131 t 420
524185165-2200YRM0143-(02-2007)-US-EN 425
toc 425
Instrument Panel Indicators and Senders 425
Safety Precautions Maintenance and Repair 426
General 429
Description 430
Internal Combustion Engine Trucks 430
Instrument Cluster Panels at Base of Steering Column, Descriptio 435
Trucks With Instrument Cluster Display Panels, Description 436
Electric Lift Trucks 439
Battery Gauge With Lift Interrupt (Curtis 933/1 and 933/4 Models 440
Battery Gauge With Lift Interrupt and Brush Wear Indicator (GE), 440
EV-100LX Motor Controller Display Panel (ITW), Description 441
Adjustments – General 442
Replacement – General Information 442
Internal Combustion Engine Display Panel Replacement 442
Display Panels Mounted at Base of Steering Column 442
Remove 442
Install 444
Instrument Cluster Display Panels Mounted on Cowl 444
Remove and Install 444
Inner Components, Replace 444
Electric Truck Display Panel Replacement 446
GE and Curtis 933/1 and 933/4 Battery Gauges 446
Controller for Battery Indicator, Replace 446
ITW Display Panel, Replace 446
Remove 446
Sender Replacement 450
Fuel Level Sender 450
Pressure and Temperature Sender 450
Seat Sensor, Operator Presence System (OPS) 451
Remove 451
Install 451
Operator Presence System Module Replacement 451
Remove 451
Install 453
Specifications 454
Meter Specifications 454
Sender Specifications 455
Troubleshooting 456
Meter 456
Troubleshooting for Operator Presence System 457
tables 425
Table 1 Troubleshooting Procedure for Operator Presence Module 457
524185167-4000YRM0329-(09-2010)-US-EN 463
toc 463
Masts 463
Safety Precautions Maintenance and Repair 464
General 467
Description and Operation 467
General 467
Safety Procedures When Working Near Mast 468
Two-Stage Mast 470
Three-Stage Mast 471
Carriage Repair 472
Remove 472
Sideshift Carriage, Disassemble 474
Sideshift Carriage, Assemble 476
Install 476
Two-Stage Mast Repair 477
Remove 477
Disassemble 479
Clean and Inspect 479
Assemble 480
Install 481
Three-Stage Mast Repair 482
Remove 482
Disassemble 482
Clean and Inspect 483
Assemble 483
Install 484
Mast Operation Check 485
Lift and Tilt System Leaks Check 485
Lift System 485
Tilt System 486
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment 486
Lift Chain Adjustments 487
Mast Adjustments 489
Carriage Adjustment 491
Troubleshooting 492
tables 463
Table 1 Mast Parts Weight 477
Table 2 Hook-Type Carriage Chain Adjustment 488
Table 3 Pin-Type Carriage Chain Adjustment 488
524185171-8000YRM0519-(06-2007)-US-EN 497
toc 497
Diagrams 497
Safety Precautions Maintenance and Repair 498
524192611-0100YRM0449-(02-2007)-US-EN 575
toc 575
Frame 575
Safety Precautions Maintenance and Repair 576
General 579
Description 579
Counterweight Repair 580
Remove 580
Install 581
Hood Repair 581
Remove 581
Install 581
Overhead Guard Repair 582
Remove 582
Install 582
Operator Restraint System Repair 583
Automatic Locking Retractor (ALR) 583
Emergency Locking Retractor (ELR) 583
Fuel and Hydraulic Tanks Repair 584
Inspect 584
Small Leaks, Repair 584
Large Leaks, Repair 584
Clean 584
Steam Method of Cleaning 585
Chemical Solution Method of Cleaning 585
Additional Preparations for Repair 585
Radiator Repair 585
Remove 585
Install 586
Exhaust System Repair 586
Muffler 586
Remove 586
Install 586
Engine Repair 590
Remove 590
Install 590
Throttle Pedal Adjustment 592
Perkins 1104C-44(RE) Diesel Engine 592
Safety Labels 594
524192612-1400YRM0450-(09-2003)-US-EN 599
toc 599
Drive Axle 599
Safety Precautions Maintenance and Repair 600
General 603
Description 603
Drive Axle Repair 604
Remove 604
Units With Manual Transmission 604
Units With Powershift Transmission 604
Disassemble 604
Clean 605
Inspect 605
Assemble 606
Install 606
Units With Manual Transmission 606
Units With Powershift Transmission 607
Torque Specifications 607
Troubleshooting 608
524192613-1600YRM0451-(09-2003)-US-EN 611
toc 611
Steering Axle 611
Safety Precautions Maintenance and Repair 612
General 615
Description 615
Steering Axle Assembly Repair 616
Remove 616
Install 616
Wheels and Hubs Repair 617
Remove and Disassemble 617
Clean 617
Assemble and Install 617
Spindles, Bearings, and Tie Rods Repair 617
Remove 617
Clean 618
Assemble and Install 618
Steering Cylinder Repair 619
Remove and Disassemble 619
Clean and Inspect 619
Assemble and Install 620
Troubleshooting 620
524192614-1800YRM0452-(02-2004)-US-EN 625
toc 625
Brake System 625
Safety Precautions Maintenance and Repair 626
General 629
Description and Operation 629
Brake Booster and Master Cylinder 629
Service Brake Assembly 631
Parking Brake 631
Brake Shoe Assemblies Repair 632
Remove and Disassemble 632
Clean 633
Inspect 633
Assemble and Install 633
Master Cylinder Repair 634
Remove 634
Disassemble 634
Clean and Inspect 635
Assemble 635
Install 635
Brake Booster Repair 636
Remove 636
Disassemble 636
Clean and Inspect 636
Assemble 636
Install 637
Brake System Air Removal 638
Brake Pedal Adjustment 638
Brake Shoes Adjustment 639
Parking Brake Adjustment 639
Brake Booster Relief Valve Check 639
Troubleshooting 640
524192615-1900YRM0453-(09-2003)-US-EN 645
toc 645
Hydraulic System 645
Safety Precautions Maintenance and Repair 646
General 649
Description and Operation 649
Main Hydraulic Pump 649
Steering Pump 649
Main Control Valve 649
Control Valve Lever 653
Filter 653
Steering Control Unit 653
Brake Booster 653
Main Hydraulic Pump Repair 654
Remove 654
Disassemble 654
Clean and Inspect 654
Assemble 655
Install 655
Specifications 655
Hydraulic System 655
Hydraulic Tank 655
Hydraulic Oil 655
Relief Pressures* 655
Hydraulic Pump 655
Steering Pump 655
Troubleshooting 656
Lift, Lower, and Tilt Circuit 657
Steering and Brake System 658
524192616-8000YRM0454-(10-2003)-US-EN 663
toc 663
Capacities and Specifications 663
Safety Precautions Maintenance and Repair 664
Lift Truck Weights 667
Hydraulic System 667
Tire Sizes 667
Electrical System 668
Engine Specifications 668
Transmission Oil Pressures 669
Upright Speeds 669
Torque Specifications 670
Frame 670
Engine – GM V-6 670
Engine – Perkins 670
Powershift Transmission 670
Manual Transmission 670
Oil Clutch Assembly 671
Steering System 671
Brake System 671
Hydraulic System 671
Main Control Valve 671
Tilt Cylinders 671
Upright 671
Drive Axle 671
524192617-8000YRM0393-(06-2009)-US-EN 675
toc 675
Periodic Maintenance 675
Safety Precautions Maintenance and Repair 676
General 681
Serial Number Data 681
How to Move Disabled Lift Truck 681
How to Tow Lift Truck 681
How to Put Lift Truck on Blocks 682
How to Raise Drive Tires 682
How to Raise Steering Tires 682
Maintenance Schedule 683
Safety Procedures When Working Near Mast 691
Maintenance Procedures Every 8 Hours or Daily 693
How to Make Checks With Engine Stopped 693
Hydraulic System 693
Engine Oil 693
Drive Belts 693
Intake Manifold Rubber Cap 693
Cooling System 693
Air Filter 695
Fuel System 695
Primary Fuel Filter, Diesel Engine 695
Battery 696
Tires and Wheels 696
Forks 696
Adjust 697
Remove 698
Install 698
Forks, Mast, and Lift Chains, Inspect 698
Operator Restraint System 699
Automatic Locking Retractor (ALR) 699
Emergency Locking Retractor (ELR) 699
Safety Labels 701
How to Make Checks With Engine Running 701
Gauges, Lights, Horn, and Fuses 701
Oil Level, Powershift Transmission 702
Oil Level, Oil Clutch System, GLC60-70CA (GC/GLC/GDC135-155CA) 702
Control Levers and Pedals 702
Lift System Operation 703
Inching/Brake Pedal 703
Service Brakes 704
Parking Brake 704
Steering System 704
Maintenance Procedures Every 250 Hours or 6 Weeks 705
Engine Oil and Filter, GM V-6 705
Mast, Lubrication 705
Lift Chains, Lubrication 705
Crankcase Breather, GM V-6 Engine 705
Drive Shafts, GLC60-70CA (GC/GLC/GDC135-155CA) 705
Air Filter GM V-6 EPA Compliant Engine 706
Maintenance Procedures Every 350 Hours or 2 Months 707
Drive Belts 707
Perkins Diesel Engine 707
GM V-6 Engine, Early Models 707
GM V-6 Engine, Late Models 707
Forks, Wear and Damage Check 709
Lift Chains, Wear Check 709
Hydraulic Tank Breather, Clean and Check 710
Brake Fluid 710
Fuel System, Checks and Adjustments 710
Diesel Fuel System 710
LPG Carburetor 711
Gasoline Carburetor (Early Models) 711
Steering Axle, Lubrication 711
Cooling System, Clean Debris from Radiator Core 712
Air Filter 712
Maintenance Procedures Every 500 Hours or 3 Months 712
Engine Oil and Filter, Perkins Diesel Engine 712
Crankcase Breather, Perkins Diesel Engine 712
PCV Valve, GM V-6 713
Maintenance Procedures Every 1000 Hours or 6 Months 713
Manifold Heat Valve, GM V-6 713
Crankcase Breather, GM V-6 713
Ignition System, GM V-6 713
Valve Clearance, Check and Adjust 713
Fuel Filter, Diesel Engine, Replace 713
Fuel System Air Removal, Perkins (1004 42 Diesel Engine) 714
Fuel Injection Pump With Vent Tube 714
Fuel Injection Pump With Vent Screw 714
Differential and Drive Axle, Oil Level Check 716
Differential GC/GLC070-120LG/MG 716
Differential and Drive Axle for Powershift Transmission GLC60-70 716
Differential, Speed Reducer, and Drive Axle for Manual Transmiss 716
Control Levers and Pedals, Lubrication 716
Cooling System GM V-6 EPA Compliant Engine 716
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace 717
Inspect Engine Electrical System, Connectors, and FCVS Connectio 717
Spark Plug Replacement 718
Remove 718
Install 718
Maintenance Procedures Every 2000 Hours or Yearly 719
Hydraulic System 719
Hydraulic Oil and Filter GC/GLC070-120LG/MG, Replace 719
Hydraulic Oil and Filter GLC60-70CA (GC/GLC/GDC135-155CA), Repla 719
Powershift Transmission (All Units), Oil Change and Oil Filter, 719
Manual Transmission and Differential GLC60-70CA (GC/GLC/GDC135-1 720
Oil Clutch System GLC60-70CA (GC/GLC/GDC135-155CA), Oil and Filt 720
Differential and Drive Axle for Powershift Transmission (All Uni 720
Cooling System 720
PCV Valve, GM V-6 721
Service Brakes 721
LPG Filter, Replace (Pre-2004) 721
Oxygen Sensor GM V-6 EPA Compliant Engine 722
Gasoline Fuel Filter, Replace 722
Air Filter Element, GM V-6 EPA Compliant Engine 722
Test LPG/GAS Regulator Pressure 722
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks 722
Check Throttle Shaft for Sticking 723
Inspect Exhaust Manifold and Piping for Leaks 723
Hood Latch Check 724
Lift Chain Adjustments 724
Fuel Injectors Repair 726
Lift and Tilt System Leak Check 726
Lift Cylinders, Leak Check 726
Tilt Cylinders, Leak Check 726
Welding Repairs 727
Overhead Guard Changes 727
Wheel and Tire Replacement 728
Solid Rubber Tire, Change 728
Wheels, Install 729
Adhesives and Sealants 729
Hydraulic Oil, Lubricant, and Coolant Specifications 729
tables 675
Table 1 Maintenance Schedule 683
Table 2 Hook-Type Carriage Chain Adjustment 725
Table 3 Pin-Type Carriage Chain Adjustment 725
524201517-0600YRM1070-(06-2007)-US-EN 733
toc 733
Perkins Diesel Engines 733
Safety Precautions Maintenance and Repair 734
General 741
General Safety Rules 741
Description 742
Engine Serial Number Codes 744
Engine Data 744
Engine Removal and Installation 745
Cylinder Head Assembly Repair 746
Engine Breather 746
Remove 746
Install 746
Valve Cover 747
Remove 747
Install 747
Rocker Arm Assembly 748
Remove 748
Disassemble 748
Inspect 749
Assemble 749
Install 749
Valve Clearance Adjustments 750
Valve Springs 750
Cylinder Head Assembly 751
Remove 751
Inspect 752
Install 753
Valves and Valve Springs 755
Remove 755
Inspect 756
Install 756
Valve Guides 756
Inspect 756
Remove 757
Install 757
Valve Seats 758
Inspect 758
Repair 758
New Valve Seats, Install 759
Piston and Connecting Rod Assemblies Repair 760
General 760
Rod Bearings 760
Remove 760
Install 761
Piston and Connecting Rod Assembly 762
Service Note 762
Remove 762
Disassemble 762
Inspect 762
How to Select Correct Replacements 764
Assemble 764
Install 765
Piston Cooling Jets 767
Remove 767
Install 767
Crankshaft Assembly Repair 768
General 768
Crankshaft Pulley 768
Remove 768
Inspect 768
Install 768
Rear Oil Seal 769
Remove 769
Install 769
Crankshaft Flange Wear Sleeve 771
Remove 771
Install 771
Main Bearings 772
Remove 772
Inspect 772
Install 772
Thrust Washers 773
Crankshaft Axle Movement, Check 773
Remove 774
Install 774
Crankshaft 775
Remove 775
Inspect 775
Install 775
Crankshaft Timing Ring 777
Remove 777
Install 777
Flywheel 778
Remove 778
Ring Gear, Replace 778
Install 778
Flywheel Housing 779
Remove 779
Install 779
Timing Case and Timing Gears Repair 780
General 780
Timing Case Cover 780
Remove 780
Install 780
Front Oil Seal 781
Remove, With Timing Case Installed 781
Install, With Timing Case Installed 781
Remove, With Timing Case Removed 782
Install, With Timing Case Removed 782
Crankshaft Pulley Wear Sleeve, Install 783
Fuel Pump Gear 783
Remove 783
Install 785
Idler Gear and Hub 786
Remove 786
Disassemble 786
Standard Idler Gear and Hub Assembly 786
Heavy Duty Idler Gear and Hub Assembly 787
Assemble 787
Standard Idler Gear and Hub Assembly 787
Heavy Duty Idler Gear and Hub Assembly 787
Install 788
Camshaft Gear 789
Remove 789
Install 789
Crankshaft Gear 789
Remove 789
Install 789
Timing Case 790
Remove 790
Install 791
Power Take-Off (PTO) Adaptor 792
Remove 792
Disassemble 792
Assemble 793
Install 793
Camshaft and Tappets 793
Remove 793
Install 794
Cylinder Block Assembly Repair 794
General 794
Cylinder Block 794
Disassemble 794
Inspect 795
Assemble 795
Cylinder Bore 795
Inspect 795
Cylinder Liner Condition Check 795
Engine Timing 796
General 796
How to Set Number One Piston to TDC on Compression Stroke 796
Fuel Injection Pump Timing, Check 797
Fuel Injection Pump Timing, Adjust 798
Lubrication System Repair 800
General 800
Oil Filter, Replace 800
Oil Filter Head 801
Remove 801
Install 801
Oil Sump 801
Remove 801
Install 802
Oil Pump 803
Remove 803
Inspect 803
Install 804
Oil Strainer and Suction Pipe 804
Remove 804
Install 804
Relief Valve 805
Remove 805
Install 805
Dipstick Tube 805
Remove and Install 805
Fuel System Repair 806
General 806
Cold Start Advance Unit (KSB) 806
Typical Fuel System 808
Fuel Filter 809
Remove 809
Install 809
Fuel Injectors 810
Remove 810
Install 811
Fuel System Air Removal 812
Bosch EVPE Fuel Injection Pump 812
General 812
Remove 813
Install 814
Cooling System Repair 814
General 814
Thermostat 816
Remove 816
Install 816
Test 816
Coolant Pump 816
Remove 816
Disassemble 817
Assemble 818
Install 819
Fan 820
Remove and Install 820
Fan Drive 820
Remove 820
Install 820
Oil Cooler 820
Remove 820
Disassemble and Assemble 821
Install 821
Coolant Bypass Hose 821
Removal 821
Install 821
Electrical Equipment Repair 822
Drive Belt 822
Check 822
Adjust 822
Remove 822
Install 822
Alternator 823
Remove 823
Install 823
Fault Diagnosis 823
Normal Operation: 823
If the Warning Lamp is Not Illuminated When the Ignition Switch 824
If the Warning Light Continues to be Illuminated When the Altern 824
Starter Motor 825
Remove 825
Install 825
Test 825
Starting Aid 825
Remove 825
Install 826
Check 826
Power Supply Continuity 826
Operation 826
Pressure Sensor 827
Remove 827
Install 828
Temperature Sensor 828
Remove 828
Install 829
Engine Specifications 829
Cylinder Head Assembly 829
Piston and Connecting Rods 832
Crankshaft Assembly 834
Crankshaft Overhaul 834
Timing Case and Drive Assembly 836
Engine Block Assembly 837
Lubrication System 838
Fuel System 838
Cooling System 839
Flywheel and Housing 840
Electrical Equipment 840
Torque Specifications 840
Special Torque Specifications 841
Cylinder Head Assembly 841
Piston and Connecting Rod Assemblies 841
Crankshaft Assembly 841
Timing Case and Drive Assembly 841
Cylinder block 841
Fuel System 841
Lubrication System 841
Cooling System 842
Flywheel and Housing 842
Electrical Equipment 842
Special Tools 842
Troubleshooting 846
tables 733
Table 1 Cylinder Head 829
Table 2 Valve Guides 830
Table 3 Inlet Valves 830
Table 4 Exhaust Valves 831
Table 5 Valve Springs 832
Table 6 Tappets 832
Table 7 Rocker Arm Shaft 832
Table 8 Rocker Arms and Bushings 832
Table 9 Pistons 832
Table 10 Piston Rings 832
Table 11 Piston Pins 833
Table 12 Connecting Rods 833
Table 13 Small End Bushings 833
Table 14 Connecting Rod Bearings 834
Table 15 Piston Cooling Jets 834
Table 16 Crankshaft Overhaul Specifications 835
Table 17 Maximum Variation (Run-out) 836
Table 18 Camshaft 836
Table 19 Camshaft Thrust Washer 836
Table 20 Camshaft Gear 836
Table 21 Gear for Fuel Pump 836
Table 22 Crankshaft Gear 836
Table 23 Idler Gear and Hub 837
Table 24 Timing Gear Backlash Values 837
Table 25 Cylinder Block 837
Table 26 Oil Pump 838
Table 27 Idler Gear for Oil Pump 838
Table 28 Relief Valve 838
Table 29 Oil Filter 838
Table 30 Bosch Fuel Injection Pump 838
Table 31 Fuel Injector Settings 838
Table 32 Fuel Pump 839
Table 33 Fuel Filter 839
Table 34 Coolant Pump 839
Table 35 Thermostat 839
Table 36 Fan Drive Housing 839
Table 37 Limits for Flywheel Run Out and Alignment (Total Indic 840
Table 38 Alternator 840
Table 39 Starter Motor 840
Table 40 Starting Aids 840
Table 41 List of Possible Causes 847
524208004-0900YRM1088-(05-2006)-US-EN 851
toc 851
Electronic Controlled LPG/Gasoline Fuel System 851
Safety Precautions Maintenance and Repair 852
General 857
Fuel System Warnings and Cautions 857
Glossary 858
Description and Operation of LPG Fuel System 862
Propane Fuel System 862
LPG Fuel Tank 864
Service Line 864
Fuel Filter 864
Low Pressure Lock-Off (LPL) 864
Low Pressure Regulator (LPR) 865
Air Fuel Mixer 865
Throttle Control Device 866
Drive By Cable 866
Three-Way Catalytic (TWC) Muffler 867
Electronic Control Module (ECM) 867
Heated Exhaust Gas Oxygen (HEGO) Sensor 868
Description and Operation of Gasoline Fuel System 870
Gasoline Fuel System Throttle Body Injection (TBI), 3 0L Engine 870
Gasoline Multi-Point Fuel Injection (MPFI) System, 4 3L Only 870
Gasoline Fuel Storage Tank 870
Gasoline Fuel Pump 870
Fuel Filter 870
Fuel Pressure Regulator, 3 0L Only 873
Fuel Rail and Pressure Regulator, 4 3L Only 874
Fuel Injector 874
Throttle Control Device 874
Drive By Cable 874
Three-Way Catalytic Muffler 875
Electronic Control Module (ECM) 875
Heated Exhaust Gas Oxygen (HEGO) Sensor 877
LPG Fuel System Repair 877
Propane Fuel System Pressure Relief 877
Propane Fuel System Leak Test 877
Propane Fuel Filter Replacement 878
Remove 878
Install 878
Low Pressure Lock-Off (LPL) Replacement 878
Remove 878
Install 878
Pressure Trim Valve (PTV) Replacement 880
Remove 880
Install 880
Low Pressure Regulator 880
Remove 880
Install 880
Fuel Trim Valve (FTV) Solenoid Replacement 881
Remove 881
Install 881
Temperature Manifold Absolute Pressure (TMAP) 881
Remove 881
Install 881
Throttle Body Replacement 883
Remove 883
Install 883
Mixer Replacement 885
Remove 885
Install 885
Coolant Hose Replacement 885
Remove 885
Install 886
Vapor Hose Replacement 886
Remove 886
Install 886
Balance Line Hose Replacement 886
Remove 886
Install 886
PTV Hose Replacement 886
Remove 886
Install 886
FTV Hose Replacement 887
Remove 887
Install 887
Throttle Position Sensor (TPS) Replacement 887
Foot Pedal Position (FPP) Sensor Replacement 889
Electronic Control Module (ECM) Replacement 892
Remove 892
Install 892
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement 892
Remove 892
Install 893
Three-Way Catalytic Muffler (TWC) Replacement 893
Remove 893
Install 893
Restricted Exhaust System Diagnosis 893
Exhaust System Description 893
Tools Required 893
Diagnostic Tool 893
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) 893
Gasoline Fuel System Repair 894
Gasoline MPFI and TBI Fuel System Pressure Relief 894
Gasoline Fuel System Leak Test 895
Throttle Body Injector (TBI) Assembly Replacement, 3 0L Only 895
Remove 895
Install 895
Throttle Body Assembly Replacement, 3 0L Only 897
Remove 897
Install 897
Throttle Body Assembly Replacement, 4 3L Only 898
Remove 898
Install 898
Fuel Rail Replacement, Gasoline 4 3L Only 899
Remove 899
Install 899
Injector Replacement, Gasoline 4 3L Only 899
Remove 899
Install 899
Injector Replacement, Gasoline 3 0L Only 901
Remove 901
Install 901
Temperature Manifold Absolute Pressure (TMAP) Replacement 901
Remove 901
Install 901
Throttle Position Sensor (TPS) Replacement 901
Foot Pedal Position (FPP) Sensor Replacement 904
Electronic Control Module (ECM) Replacement 907
Remove 907
Install 907
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement 908
Remove 908
Install 908
Three-Way Catalytic Muffler (TWC) Replacement 908
Remove 908
Install 908
Restricted Exhaust System Diagnosis 908
Exhaust System Description 908
Tools Required 908
Diagnostic Tool 908
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) 909
LPG System Diagnosis 909
Fuel System Description 909
Diagnostic Aids 910
Tools Required 910
Duty Cycle Monitoring Tool 910
Diagnostic Tool 910
Pressure Gauges 910
Test Description 910
Gasoline System Diagnosis 918
Fuel System Description, 3 0L Only 918
Fuel System Description, 4 3L Only 918
Diagnostic Aids 919
Tools Required 919
Diagnostic Tool 919
Test Description 919
LPG Symptom Diagnosis 926
Gasoline Symptom Diagnosis 940
Wire Harness Repair 951
On Vehicle Service Wiring Harness Repair 951
Connectors and Terminals 951
Twisted/Shielded Cable Repair 952
Twisted Leads Repair 953
Micro-Pack 954
Metri-Pack 954
Remove 954
Weather-Pack 956
Weather-Pack Terminal Repair 957
tables 851
Table 1 TPS Replacement Procedure 887
Table 2 FPP Replacement Procedure 890
Table 3 TPS Replacement Procedure 902
Table 4 FPP Replacement Procedure 905
Table 5 LPG Fuel System Diagnosis 910
Table 6 Fuel Control Diagnosis 914
Table 7 Gasoline Fuel System Diagnosis, 3 0L Only 920
Table 8 Gasoline Fuel System Diagnosis, 4 3L Only 923
Table 9 Preliminary Checks 926
Table 10 Intermittent 927
Table 11 No Start 928
Table 12 Hard Start 930
Table 13 Cuts Out or Misses 931
Table 14 Hesitation, Sag, or Stumble 932
Table 15 Backfire 933
Table 16 Lack of Power, Sluggishness, or Sponginess 934
Table 17 Poor Fuel Economy 935
Table 18 Rough, Unstable, Incorrect Idle, or Stalling 937
Table 19 Surges or Chuggles 939
Table 20 Preliminary Checks 940
Table 21 Intermittent 941
Table 22 No Start 942
Table 23 Hard Start 943
Table 24 Cuts Out or Misses 944
Table 25 Hesitation, Sag, or Stumble 945
Table 26 Backfire 946
Table 27 Lack of Power, Sluggishness, or Sponginess 947
Table 28 Poor Fuel Economy 948
Table 29 Rough, Unstable, Incorrect Idle, or Stalling 949
Table 30 Surges or Chuggles 950
524208009-2200YRM1090-(04-2005)-US-EN 961
toc 961
Electronic Control Module (ECM) Diagnostic Troubleshooting 961
Safety Precautions Maintenance and Repair 962
General 971
Description of ECM Based Diagnostics 971
Definition of Terms 971
Diagnostics Overview of the Spectrum Fuel System 971
Malfunction Indicator Lamp (MIL) 971
Spectrum Diagnostic Trouble Codes (DTC) 972
Using a Laptop Computer to Diagnose the Spectrum System 972
Installing the Spectrum Diagnostic Software 972
Connecting a Laptop Computer to the Spectrum System 972
Diagnostic Communication Error 973
Diagnostic Trouble Codes 973
Checking Diagnostic Trouble Codes 974
Clearing Diagnostic Trouble Codes 974
DATA Stream 974
Reading Sensor and Actuator Values 974
Graphing and Data Logging 975
Ignition System Test 976
Disabling Ignition Outputs 976
Injector Test 977
Disabling Injectors 977
Throttle Test 978
Using a Diagnostic Jumper to Diagnose the ECI System 979
On-Board Diagnostics System Check/Malfunction Indicator Lamp 980
Circuit Description 980
Preliminary and Intermittent Checks 983
GM 3 0L Wiring Schematics and Connectors 985
GM 3 0L Diagnostic Trouble Codes 999
DTC 111 – IAT High Voltage Motorola® TMAP 999
Circuit Description 999
Conditions for Setting the DTC 999
DTC 112 – IAT Low Voltage Motorola® TMAP 1002
Circuit Description 1002
Conditions for Setting the DTC 1002
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP 1005
Circuit Description 1005
Conditions for Setting the DTC 1005
Diagnostic Aids 1005
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP 1006
Circuit Description 1006
Conditions for Setting the DTC 1006
Diagnostic Aids 1006
DTC 115 – Oil Pressure Low 1007
Circuit Description 1007
Conditions for Setting the DTC 1007
DTC 121 – ECT Voltage High 1010
Circuit Description 1010
Conditions for Setting the DTC 1011
DTC 122 – ECT Voltage Low 1014
Circuit Description 1014
Conditions for Setting the DTC 1014
DTC 123 – ECT Higher Than Expected 1 1016
Circuit Description 1016
Conditions for Setting the DTC 1016
DTC 124 – ECT Higher Than Expected 2 1018
Circuit Description 1018
Conditions for Setting the DTC 1018
DTC 131 – MAP High Pressure Motorola® TMAP 1020
Circuit Description 1020
Conditions for Setting the DTC 1020
Diagnostic Aids 1020
DTC 132 – MAP Low Voltage Motorola® TMAP 1022
Circuit Description 1022
Conditions for Setting the DTC 1022
DTC 134 – BP High Pressure Motorola® TMAP 1026
Circuit Description 1026
Conditions for Setting the DTC 1026
DTC 135 – BP Low Pressure Motorola® TMAP 1028
Circuit Description 1028
Conditions for Setting the DTC 1028
DTC 142 – Crank Sync Noise 1032
Circuit Description 1032
Conditions for setting the DTC 1032
DTC 143 – Never Crank Synced At Start 1035
Circuit Description 1035
Conditions for Setting the DTC 1035
DTC 144 – Camshaft Sensor Loss 1038
Circuit Description 1038
Conditions for Setting the DTC 1038
DTC 145 – Camshaft Sensor Noise 1041
Circuit Description 1041
Conditions for Setting the DTC 1041
DTC 211 – Closed Loop Multiplier High (LPG) 1044
Circuit Description 1044
Conditions for Setting the DTC 1044
Diagnostic Aids 1044
DTC 212 – HO 2 S Open/Inactive 1046
Circuit Description 1046
Conditions for Setting the DTC 1046
DTC 221 – Closed Loop Multiplier High (Gasoline) 1050
Circuit Description 1050
Conditions for Setting the DTC 1050
Diagnostic Aids 1051
DTC 222 – Closed Loop Multiplier Low (Gasoline) 1052
Circuit Description 1052
Conditions for Setting the DTC 1052
Diagnostic Aids 1052
DTC 224 – Closed Loop Multiplier Low (LPG) 1054
Circuit Description 1054
Conditions for Setting the DTC 1054
Diagnostic Aids 1055
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1056
Circuit Description 1056
Conditions for Setting the DTC 1056
Diagnostic Aids 1057
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1060
Circuit Description 1060
Conditions for Setting the DTC 1060
Diagnostic Aids 1060
DTC 243 – Adaptive Learn High (LPG) 1062
Circuit Description 1062
Conditions for Setting the DTC 1062
Diagnostic Aids 1062
DTC 244 – Adaptive Learn Low (LPG) 1066
Circuit Description 1066
Conditions for Setting the DTC 1066
Diagnostic Aids 1066
DTC 261 – System Voltage High 1068
Circuit Description 1068
Conditions for Setting the DTC 1068
DTC 262 – System Voltage Low 1070
Circuit Description 1070
Conditions for Setting the DTC 1070
DTC 411 – Injector Driver 1 Open 1073
Circuit Description 1073
Conditions for Setting the DTC 1073
DTC 412 – Injector Driver 1 Shorted 1076
Circuit Description 1076
Conditions for Setting the DTC 1076
DTC 511 – COP Failure 1079
Circuit Description 1079
Conditions for Setting the DTC 1079
DTC 512 – Invalid Interrupt 1081
Circuit Description 1081
Conditions for Setting the DTC 1081
DTC 513 – A/D Loss 1083
Circuit Description 1083
Conditions for Setting the DTC 1083
DTC 514 – RTI 1 Loss 1085
Circuit Description 1085
Conditions for Setting the DTC 1085
DTC 515 – Flash Checksum Invalid 1087
Circuit Description 1087
Conditions for Setting the DTC 1087
DTC 516 – Ram Failure 1089
Circuit Description 1089
Conditions for Setting the DTC 1089
DTC 531 – External 5V Ref Lower Than Expected 1091
Circuit Description 1091
Conditions for Setting the DTC 1091
DTC 532 – External 5V Ref Higher Than Expected 1094
Circuit Description 1094
Conditions for Setting the DTC 1094
DTC 555 – RTI 2 Loss 1096
Circuit Description 1096
Conditions for Setting the DTC 1096
DTC 556 – RTI 3 Loss 1098
Circuit Description 1098
Conditions for Setting the DTC 1098
DTC 611 – FPP High Voltage 1100
Circuit Description 1100
Conditions for Setting the DTC 1100
DTC 612 – FPP Low Voltage 1103
Circuit Description 1103
Conditions for Setting the DTC 1103
DTC 631 – TPS1 Signal Voltage High 1107
Circuit Description 1107
Conditions for Setting the DTC 1107
DTC 632 – TPS1 Signal Voltage Low 1110
Circuit Description 1110
Conditions for Setting the DTC 1110
DTC 638 – Throttle Unable To Close 1112
Circuit Description 1112
Conditions for Setting the DTC 1112
Diagnostic Aids 1112
DTC 651 – Maximum Govern Speed Override 1116
Circuit Description 1116
Conditions for Setting the DTC 1116
Diagnostic Aids 1116
DTC 652 – Fuel Rev Limit 1118
Circuit Description 1118
Conditions for Setting the DTC 1118
Diagnostic Aids 1118
DTC 653 – Spark Rev Limit 1121
Circuit Description 1121
Conditions for Setting the DTC 1121
Diagnostic Aids 1121
GM 4 3L Wiring Schematics and Connectors 1124
GM 4 3L Diagnostic Trouble Codes 1141
DTC 111 – IAT High Voltage Bosch® TMAP 1141
Circuit Description 1141
Conditions for Setting the DTC 1141
DTC 111 – IAT High Voltage Motorola® TMAP 1144
Circuit Description 1144
Conditions for Setting the DTC 1144
DTC 112 – IAT Low Voltage Bosch® TMap 1146
Circuit Description 1146
Conditions for Setting the DTC 1146
DTC 112 – IAT Low Voltage Motorola® TMAP 1149
Circuit Description 1149
Conditions for Setting the DTC 1149
DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP 1152
Circuit Description 1152
Conditions for Setting the DTC 1152
Diagnostic Aids 1152
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP 1153
Circuit Description 1153
Conditions for Setting the DTC 1153
Diagnostic Aids 1153
DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP€ 1154
Circuit Description 1154
Conditions for Setting the DTC 1154
Diagnostic Aids 1154
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP 1155
Circuit Description 1155
Conditions for Setting the DTC 1155
Diagnostic Aids 1155
DTC 115 – Oil Pressure Low 1156
Circuit Description 1156
Conditions for Setting the DTC 1156
DTC 121 – ECT Voltage High 1159
Circuit Description 1159
Conditions for Setting the DTC 1160
DTC 122 – ECT Voltage Low 1162
Circuit Description 1162
Conditions for Setting the DTC 1162
DTC 123 – ECT Higher Than Expected 1 1165
Circuit Description 1165
Conditions for Setting the DTC 1165
DTC 124 – ECT Higher Than Expected 2 1167
Circuit Description 1167
Conditions for Setting the DTC 1167
DTC 131 – MAP High Pressure Bosch® TMAP 1168
Circuit Description 1168
Conditions for Setting the DTC 1168
Diagnostic Aids 1168
DTC 131 – MAP High Pressure Motorola® TMAP 1172
Circuit Description 1172
Conditions for Setting the DTC 1172
Diagnostic Aids 1172
DTC 132 – MAP Low Voltage Bosch® TMAP 1175
Circuit Description 1175
Conditions for Setting the DTC 1175
DTC 132 – MAP Low Voltage Motorola® TMAP 1178
Circuit Description 1178
Conditions for Setting the DTC 1178
DTC 134 – BP High Pressure Bosch® TMAP 1182
Circuit Description 1182
Conditions for Setting the DTC 1182
DTC 134 – BP High Pressure Motorola® TMAP 1184
Circuit Description 1184
Conditions for Setting the DTC 1184
DTC 135 – BP Low Pressure Bosch® TMAP 1186
Circuit Description 1186
Conditions for Setting the DTC 1186
DTC 135 – BP Low Pressure Motorola® TMAP 1190
Circuit Description 1190
Conditions for Setting the DTC 1190
DTC 142 – Crank Sync Noise 1194
Circuit Description 1194
Conditions for setting the DTC 1194
DTC 143 – Never Crank Synced At Start 1197
Circuit Description 1197
Conditions for Setting the DTC 1197
DTC 144 – Camshaft Sensor Loss 1200
Circuit Description 1200
Conditions for Setting the DTC 1200
DTC 145 – Camshaft Sensor Noise 1203
Circuit Description 1203
Conditions for Setting the DTC 1203
DTC 211 – Closed Loop Multiplier High (LPG) 1206
Circuit Description 1206
Conditions for Setting the DTC 1206
Diagnostic Aids 1206
DTC 212 – HO 2 S Open/Inactive 1208
Circuit Description 1208
Conditions for Setting the DTC 1208
DTC 221 – Closed Loop Multiplier High (Gasoline) 1212
Circuit Description 1212
Conditions for Setting the DTC 1212
Diagnostic Aids 1212
DTC 222 – Closed Loop Multiplier Low (Gasoline) 1214
Circuit Description 1214
Conditions for Setting the DTC 1214
Diagnostic Aids 1215
DTC 224 – Closed Loop Multiplier Low (LPG) 1216
Circuit Description 1216
Conditions for Setting the DTC 1216
Diagnostic Aids 1217
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1218
Circuit Description 1218
Conditions for Setting the DTC 1218
Diagnostic Aids 1219
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1222
Circuit Description 1222
Conditions for Setting the DTC 1222
Diagnostic Aids 1223
DTC 243 – Adaptive Learn High (LPG) 1225
Circuit Description 1225
Conditions for Setting the DTC 1225
Diagnostic Aids 1226
DTC 244 – Adaptive Learn Low (LPG) 1228
Circuit Description 1228
Conditions for Setting the DTC 1228
Diagnostic Aids 1229
DTC 261 – System Voltage High 1230
Circuit Description 1230
Conditions for Setting the DTC 1230
DTC 262 – System Voltage Low 1232
Circuit Description 1232
Conditions for Setting the DTC 1232
DTC 511 – COP Failure 1235
Circuit Description 1235
Conditions for Setting the DTC 1235
DTC 512 – Invalid Interrupt 1237
Circuit Description 1237
Conditions for Setting the DTC 1237
DTC 513 – A/D Loss 1239
Circuit Description 1239
Conditions for Setting the DTC 1239
DTC 514 – RTI 1 Loss 1241
Circuit Description 1241
Conditions for Setting the DTC 1241
DTC 515 – Flash Checksum Invalid 1243
Circuit Description 1243
Conditions for Setting the DTC 1243
DTC 516 – Ram Failure 1245
Circuit Description 1245
Conditions for Setting the DTC 1245
DTC 531 – External 5V Ref Lower Than Expected 1247
Circuit Description 1247
Conditions for Setting the DTC 1247
DTC 532 – External 5V Ref Higher Than Expected 1250
Circuit Description 1250
Conditions for Setting the DTC 1250
DTC 555 – RTI 2 Loss 1252
Circuit Description 1252
Conditions for Setting the DTC 1252
DTC 556 – RTI 3 Loss 1254
Circuit Description 1254
Conditions for Setting the DTC 1254
DTC 611 – FPP High Voltage 1256
Circuit Description 1256
Conditions for Setting the DTC 1256
DTC 612 – FPP Low Voltage 1260
Circuit Description 1260
Conditions for Setting the DTC 1260
DTC 631 – TPS1 Signal Voltage High 1264
Circuit Description 1264
Conditions for Setting the DTC 1264
DTC 632 – TPS1 Signal Voltage Low 1267
Circuit Description 1267
Conditions for Setting the DTC 1267
DTC 638 – Throttle Unable To Close 1270
Circuit Description 1270
Conditions for Setting the DTC 1270
Diagnostic Aids 1271
DTC 651 – Maximum Govern Speed Override 1273
Circuit Description 1273
Conditions for Setting the DTC 1273
Diagnostic Aids 1273
DTC 652 – Fuel Rev Limit 1276
Circuit Description 1276
Conditions for Setting the DTC 1276
Diagnostic Aids 1276
DTC 653 – Spark Rev Limit 1278
Circuit Description 1278
Conditions for Setting the DTC 1278
Diagnostic Aids 1278
Wire Harness Repair 1281
On Vehicle Service Wiring Harness Repair 1281
Connectors and Terminals 1281
Twisted/Shielded Cable Repair 1282
Twisted Leads Repair 1283
Micro-Pack 1284
Metri-Pack 1284
Remove 1284
Weather-Pack 1286
Weather-Pack Terminal Repair 1286
tables 961
Table 1 OBD System Check 981
Table 2 Preliminary Checks 983
Table 3 Intermittent Checks 984
Table 4 Communication Port C002 985
Table 5 Coil Connector C003 985
Table 6 Fuel System Interface C004 985
Table 7 Oil Pressure Connector C005 986
Table 8 Distributor Connector C006 986
Table 9 Magnetic Pickup Connector C007 986
Table 10 Heated Oxygen Sensor C008 986
Table 11 Throttle Position Sensor Connector C009 987
Table 12 Foot Pedal Position Connector C010 987
Table 13 Governor Motor Connector C011 987
Table 14 TMAP Connector C012 987
Table 15 Starter Solenoid C013 988
Table 16 Engine Coolant Temperature C014 988
Table 17 Battery Connector C015 988
Table 18 Alternator Connection C016 988
Table 19 Battery Connector C017 988
Table 20 Alternator Connector C018 989
Table 21 Instrument Panel Connector C019 989
Table 22 Instrument Panel Connector C020 989
Table 23 Instrument Panel Connector C021 990
Table 24 Fuel Trim Valve Connector C022 990
Table 25 Fuel Lockoff Connector C023 990
Table 26 Pressure Trim Valve Connector C024 991
Table 27 Throttle Body Injector Connector C025 991
Table 28 Relay and Fuse Center 991
Table 29 DTC 111 – IAT Voltage High (Motorola® TMAP) 1000
Table 30 DTC 112 – IAT Low Voltage (Motorola® TMAP) 1003
Table 31 DTC 115 – Oil Pressure Low 1008
Table 32 Temperature Resistance 1010
Table 33 DTC 121 – ECT VOLTAGE HIGH 1011
Table 34 DTC 122 – ECT Voltage Low 1015
Table 35 DTC 123 – ECT Higher Than Expected 1 1017
Table 36 DTC 124 – ECT Higher Than Expected 2 1019
Table 37 DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP) 1021
Table 38 DTC 132 – MAP Low Voltage (Motorola® TMAP) 1023
Table 39 DTC 134 – BP High Pressure (Motorola® TMAP) 1027
Table 40 DTC 135 – BP Low Pressure (Motorola® TMAP) 1028
Table 41 DTC 142 – Crank Sync Noise 1032
Table 42 DTC 143 – Never Crank Synced At Start 1035
Table 43 DTC 144 – Camshaft Sensor Loss 1038
Table 44 DTC 145 – Camshaft Sensor Noise 1041
Table 45 DTC 211 – Closed Loop Multiplier High (LPG) 1045
Table 46 DTC 212 – HO 2 S Open/Inactive 1047
Table 47 DTC 221 – Closed Loop Multiplier High (Gasoline) 1051
Table 48 DTC 222 – Closed Loop Multiplier Low (Gasoline) 1054
Table 49 DTC 224 – Closed Loop Multiplier Low (LPG) 1056
Table 50 DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1058
Table 51 DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1061
Table 52 DTC 243 – Adaptive Learn High (LPG) 1064
Table 53 DTC 244 – Adaptive Learn Low (LPG) 1067
Table 54 DTC 261 – System Voltage High 1069
Table 55 DTC 262 – System Voltage Low 1071
Table 56 DTC 411 – Injector Driver 1 Open 1074
Table 57 DTC 412 – Injector Driver 1 Shorted 1077
Table 58 DTC 511 – COP Failure 1080
Table 59 DTC 512 – Invalid Interrupt 1082
Table 60 DTC 513 – A/D Loss 1084
Table 61 DTC 514 – RTI 1 Loss 1086
Table 62 DTC 515 – Flash Checksum Invalid 1088
Table 63 DTC 516 – Ram Failure 1090
Table 64 DTC 531 – External 5V Ref Lower Than Expected 1092
Table 65 DTC 532 – External 5 V Ref Higher Than Expected 1094
Table 66 DTC 555 – RTI 2 Loss 1097
Table 67 DTC 556 – RTI 3 Loss 1099
Table 68 DTC 611 – FPP High Voltage 1100
Table 69 DTC 612 – FPP Low Voltage 1104
Table 70 DTC 631 – TPS1 Signal Voltage High 1108
Table 71 DTC 632 – TPS1 Signal Voltage Low 1111
Table 72 DTC 638 – Throttle Unable To Close 1113
Table 73 DTC 651 – Maximum Govern Speed Override 1117
Table 74 DTC 652 – Fuel Rev Limit 1119
Table 75 DTC 653 – Spark Rev Limit 1122
Table 76 Communication Port C002 1124
Table 77 Injector Connector C003 1124
Table 78 Injector Connector C004 1124
Table 79 Oil Pressure Connector C005 1125
Table 80 Throttle Position Sensor 1 Connector C006 1125
Table 81 Foot Pedal Position Connector C006A 1125
Table 82 Coil Connector C007 1125
Table 83 Module Connector C008 1126
Table 84 Crank Sensor Connector C009 1126
Table 85 EGO Sensor Connector C010 1126
Table 86 Cam Connector C011 1126
Table 87 Throttle Connector C012 1127
Table 88 Bosch TMAP Connector C013 (Gasoline Fuel System Only) 1127
Table 89 Motorola TMAP Connector C013 (LPG Fuel System Only) 1127
Table 90 Starter Solenoid Connector C014 1127
Table 91 ECT Connector C015 1128
Table 92 Starter Relay C016 1128
Table 93 Power Relay C017 1128
Table 94 Fuel Pump Relay C018 1128
Table 95 Battery Connector C019 1128
Table 96 Alternator Connector C020 1128
Table 97 Alternator Connector C021 1129
Table 98 Instrument Panel Connector C022 1129
Table 99 Instrument Panel Connector C023 1129
Table 100 Instrument Panel Connector C024 1130
Table 101 Fuel Trim Valve Connector C025 1130
Table 102 Fuel Lockoff Connector C026 1130
Table 103 Pressure Trim Valve Connector C027 1131
Table 104 Injector 1 Connector C028 1131
Table 105 Injector 2 Connector C029 1131
Table 106 Injector 3 Connector C030 1131
Table 107 Injector 4 Connector C031 1132
Table 108 Injector 5 Connector C032 1132
Table 109 Injector 6 Connector C033 1132
Table 110 Relay and Fuse Center 1133
Table 111 DTC 111 – IAT Voltage High (Bosch® TMAP) 1142
Table 112 DTC 111 – IAT Voltage High (Motorola® TMAP) 1145
Table 113 DTC 112 – IAT Low Voltage (Bosch® TMAP) 1147
Table 114 DTC 112 – IAT Low Voltage (Motorola® TMAP) 1150
Table 115 DTC 115 – Oil Pressure Low 1157
Table 116 Temperature Resistance 1159
Table 117 DTC 121 – ECT VOLTAGE HIGH 1160
Table 118 DTC 122 – ECT Voltage Low 1163
Table 119 DTC 123 – ECT Higher Than Expected 1 1166
Table 120 DTC 124 – ECT Higher Than Expected 2 1168
Table 121 DTC 131 – MAP High Pressure (Bosch® TMAP) 1169
Table 122 DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP) 1173
Table 123 DTC 132 – MAP Low Voltage (Bosch® TMAP) 1176
Table 124 DTC 132 – MAP Low Voltage (Motorola® TMAP) 1179
Table 125 DTC 134 – BP High Pressure (Bosch® TMAP) 1183
Table 126 DTC 134 – BP High Pressure (Motorola® TMAP) 1185
Table 127 DTC 135 – BP Low Pressure (Bosch® TMAP) 1186
Table 128 DTC 135 – BP Low Pressure (Motorola® TMAP) 1190
Table 129 DTC 142 – Crank Sync Noise 1194
Table 130 DTC 143 – Never Crank Synced At Start 1197
Table 131 DTC 144 – Camshaft Sensor Loss 1200
Table 132 DTC 145 – Camshaft Sensor Noise 1203
Table 133 DTC 211 – Closed Loop Multiplier High (LPG) 1207
Table 134 DTC 212 – HO 2 S Open/Inactive 1209
Table 135 DTC 221 – Closed Loop Multiplier High (Gasoline) 1213
Table 136 DTC 222 – Closed Loop Multiplier Low (Gasoline) 1216
Table 137 DTC 224 – Closed Loop Multiplier Low (LPG) 1218
Table 138 DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1220
Table 139 DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1223
Table 140 DTC 243 – Adaptive Learn High (LPG) 1226
Table 141 DTC 244 – Adaptive Learn Low (LPG) 1229
Table 142 DTC 261 – System Voltage High 1231
Table 143 DTC 262 – System Voltage Low 1233
Table 144 DTC 511 – COP Failure 1236
Table 145 DTC 512 – Invalid Interrupt 1238
Table 146 DTC 513 – A/D Loss 1240
Table 147 DTC 514 – RTI 1 Loss 1242
Table 148 DTC 515 – Flash Checksum Invalid 1244
Table 149 DTC 516 – Ram Failure 1246
Table 150 DTC 531 – External 5V Ref Lower Than Expected 1248
Table 151 DTC 532 – External 5 V Ref Higher Than Expected 1250
Table 152 DTC 555 – RTI 2 Loss 1253
Table 153 DTC 556 – RTI 3 Loss 1255
Table 154 DTC 611 – FPP High Voltage 1257
Table 155 DTC 612 – FPP Low Voltage 1261
Table 156 DTC 631 – TPS1 Signal Voltage High 1265
Table 157 DTC 632 – TPS1 Signal Voltage Low 1268
Table 158 DTC 638 – Throttle Unable To Close 1271
Table 159 DTC 651 – Maximum Govern Speed Override 1274
Table 160 DTC 652 – Fuel Rev Limit 1277
Table 161 DTC 653 – Spark Rev Limit 1279
524208014-2200YRM1097-(03-2020)-US-EN 1291
Series Code / Model Designation Reference Table 1295
Description 1296
Distributor Ignition (DI) System 1296
Crankshaft Position (CKP) Sensor 1296
Camshaft Position (CMP) Sensor 1296
Ignition Coil and Ignition Control Module (ICM) 1296
Secondary Ignition Components 1296
Spark Plugs and Wires 1297
Spark Plug Wire Inspection 1297
Spark Plug Wire Replacement 1297
Remove 1297
Install 1298
Spark Plug Inspection 1298
Usage 1298
Inspection 1298
Visual Inspection 1300
Spark Plug Replacement 1300
Remove 1300
Install 1300
Distributor Repair 1301
Inspect 1301
Overhaul 1301
Disassemble 1301
Assemble 1304
Replace 1305
Remove 1305
Install Procedure 1 1307
Install Procedure 2 1308
Ignition Coil Replacement 1309
Remove 1309
Install 1309
Ignition Control Module Replacement 1310
Remove 1310
Install 1310
Starter Replacement 1311
Remove 1311
Install 1314
Sensors and Switches 1315
Gas and LPG Trucks 1315
Crankshaft Position (CKP) Sensor 1315
Remove 1315
Install 1315
Camshaft Position (CMP) Sensor 1316
Remove 1316
Install 1318
Oil Pressure Sensor 1318
Remove 1318
Install 1319
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 1320
Remove 1320
Install 1320
Engine Coolant Temperature (ECT) Sensor 1321
Remove 1321
Install 1322
Air Flow Restriction Switch 1322
Remove 1322
Install 1323
Specifications and Special Tools 1324

S.V 06/24