LPG FUEL SYSTEM

GM 2.4L ENGINE

S2.0-3.5FT (S40-70FT, S55FTS) [F187];

H2.0-3.5FT (H40-70FT) [L177]

PART NO. 1580506

900 SRM 1124

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 Mainte-
nance 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 when making 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.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING

Indicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

LPG Fuel System

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

Hoses Replacement ............................................................................................................................................

LPG Tank Replacement.....................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Fuel Filter Unit Repair......................................................................................................................................

Fuel Filter Element .......................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Fuel Filter Housing .......................................................................................................................................

Remove.......................................................................................................................................................

Disassemble ...............................................................................................................................................

Assemble ....................................................................................................................................................

Install .........................................................................................................................................................

Electronic Throttle Body Repair .......................................................................................................................

Electronic Throttle Body ...............................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Electronic Throttle Body Adapter Plate .......................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Fuel Injector Repair ...........................................................................................................................................

Fuel Rail.........................................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Fuel Injector...................................................................................................................................................

Remove.......................................................................................................................................................

Clean ..........................................................................................................................................................

Install .........................................................................................................................................................

Fuel Injector Adapters...................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Vaporizer Repair ................................................................................................................................................

Vaporizer ........................................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Vaporizer Fuel Filter .....................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Lock-Off Solenoid and Cartridge ..................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Control System...................................................................................................................................................

Electronic Control Unit (ECU)......................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Power Latch Relay.........................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Injector Driver Module ..................................................................................................................................

Remove.......................................................................................................................................................

Table of Contents

LPG Fuel System

TABLE OF CONTENTS (Continued)

Install .........................................................................................................................................................

Camshaft Position (CMP) Sensor .................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor .........................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Engine Coolant Temperature (ECT) Sensor.................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Oxygen Sensor ...............................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

This section is for the following models:

S2.0-3.5FT (S40-70FT, S55FTS) [F187];

H2.0-3.5FT (H40-70FT) [L177]

900 SRM 1124

LPG Tank Replacement

General

This section has the repair procedures for the parts of the LPG fuel system used on the GM 2.4 liter engines.

Hoses Replacement

The hoses installed on LPG systems are special.
Hoses that are made for use with hydraulic oil are
damaged by LPG. When replacing the LPG hoses,
make sure to use only Hyster Approved LPG
hoses. Make sure to use the correct size of hose.

When replacing the hose to the quick-disconnect
fitting, make sure it is the same length as the hose
it replaces. A longer hose permits the tank to be
installed in an incorrect position. If a fuel hose has
a restriction, it is coldest around the restriction.

LPG Tank Replacement

REMOVE

WARNING

LPG can cause an explosion.

Do not cause

sparks or permit flammable material near the
LPG system. LPG fuel systems can be discon-
nected indoors only if the lift truck is at least
8 m (26 ft) from any open flame, motor vehicles,
electrical equipment, or ignition source.

Close the shutoff valve on the LPG tank before
any part of the engine fuel system is discon-
nected. Run the engine until the fuel in the sys-
tem is used and the engine stops.

If the engine will not run, close the shutoff
valve on the LPG tank. Loosen the fitting on
the supply hose from the LPG tank where it
enters the filter unit. Permit the pressure in
the fuel system to decrease slowly. Fuel leav-
ing the fitting removes heat.

Use a cloth to

protect your hands from the cold fitting.

NOTE: The LPG tank bracket used on this line of
trucks to mount the LPG tank onto the counter-
weight comes in two styles.

One style of bracket

swings out to the side of the truck and the other
swings out to the side and drops down (EZ Lift LPG
tank brackets). See Figure 1.

LPG tanks can be removed and replaced indoors
only if the lift truck is at least 8 m (26 ft) from
any flame or ignition source. Move the lift truck
to an the area where LPG tanks are changed.

Turn the shutoff valve clockwise until the valve
is completely closed.

Run the engine until it stops. If truck is equipped
with a key switch, turn the key switch to the
OFF position. If truck is equipped with a Power
ON/OFF button, press the Power ON/OFF but-
ton to turn engine off.

Disconnect the quick-disconnect fitting on the
LPG tank. See Figure 1.

Push in the bracket release pin, grab the bracket
handle, and swing the tank and bracket out
to the side of the lift truck.

If your truck is

equipped with a swing-out and drop-down LPG
tank bracket (EZ Lift), drop the tank down to
the side of the truck for ease of removal. See
Figure 2.

Unlatch the tank strap and remove the LPG tank
from the bracket.

INSTALL

NOTE: The LPG bracket must be in the swing-out
position to install the LPG tank. If your lift truck
has the swing-out and drop-down bracket (EZ Lift),
position the bracket in the drop-down position.

WARNING

When closing the LPG tank strap, do not wrap
your fingers around the strap handle.

The

strap can close quickly and with enough force
to cause injury to the fingers and hand.

Place the LPG tank into the bracket. Secure the
tank strap around the tank and close the strap.

LPG Tank Replacement

900 SRM 1124

A. SWING-OUT LPG BRACKET

B. SWING-OUT AND DROP-DOWN LPG BRACKET

(EZ LIFT)

LPG TANK

TANK STRAP

QUICK DISCONNECT FITTING

HYDROSTATIC RELIEF VALVE

MANIFOLD BLOCK

ALIGNMENT PIN

STOP PIN

BRACKET HANDLE

BRACKET PIVOT

10. GAS SPRING (DROP-DOWN BRACKET ONLY)
11. BRACKET RELEASE PIN (BUTTON)

Figure 1. LPG Tank and Bracket

900 SRM 1124

Fuel Filter Unit Repair

QUICK-DISCONNECT CONNECTION

HOSE ASSEMBLY

CAPSCREW

LPG TANK

HOSE ASSEMBLY TO LPG
REGULATOR/LOCK-OFF

LPG REGULATOR CONNECTION

LPG REGULATOR

Figure 2. LPG Tank Hose Connections

Pull the stop pin (see Figure 1) and swing the
LPG tank bracket into the resting position on the
counterweight. Be sure that the bracket locks
into position.

Connect the hose to the LPG fuel lock-off connec-
tion on the LPG regulator. See Figure 2.

Connect the quick-disconnect fitting on the LPG
tank. See Figure 1.

Turn the fuel valve counterclockwise to open the
fuel valve.

Inspect the fuel system for leaks when the fuel
valve is open. There are four methods used to
inspect the fuel system for leaks:

a. Sound - Listen for sound of LPG escaping

from a tank fitting or hose connection.

b. Smell - LPG has a very distinctive odor. If

you smell LPG, DO NOT start the engine.

Soapy Water - This method is used in con-
junction with Step b above. If the odor of LPG
is present, but escaping fuel cannot be heard,
apply soapy water to the fittings and observe
for bubbles.

d. Frost - If the amount of LPG escaping is suf-

ficient, frost may appear on the fittings.

Fuel Filter Unit Repair

FUEL FILTER ELEMENT

Remove

WARNING

LPG can cause an explosion. Do not permit any
sparks or open flames in the work area.

Close fuel valve on tank. Run engine until it
stops.

Disconnect negative battery cable.

WARNING

A small amount of fuel may still be present in
the fuel line. Use gloves to prevent burns and

wear eye protection. If liquid fuel continues
to flow from the connections when loosened,
check to make sure the manual valve is fully
closed.

Remove the bolt and seal washer retaining the
top section of the fuel filter housing. Discard seal
washer. See Figure 3.

Remove top section of fuel filter housing.

Remove and discard housing O-ring.

Remove fuel filter and fuel filter O-ring.

Fuel Filter Unit Repair

900 SRM 1124

BOLT*

SEAL WASHER

FUEL FILTER HOUSING TOP SECTION*

FUEL FILTER

FUEL FILTER O-RING

HOUSING O-RING

FUEL FILTER HOUSING BOTTOM SECTION*

*NOT SERVICED SEPARATELY

Figure 3. Fuel Filter Removal/Installation

Install

Clean and inspect the fuel filter housing for con-
tamination or damage.

Install the new fuel filter and fuel filter O-ring.
See Figure 3.

Install new housing O-ring.

Install top section of fuel filter housing.

Install bolt and new seal washer. Tighten bolt to
13 N•m (115 lbf in).

NOTE: Opening the fuel valve too quickly can cause
the internal excess flow valve to close, restricting the
flow of fuel. If this happens, close the fuel valve, wait
a few seconds, and then slowly open the fuel valve
again. This will reset the excess flow valve.

Slowly open the fuel valve on tank.

Turn the key to the ON position and back to
the OFF position to pressurize the fuel system.
Check for leaks.

Check for leaks at connections by using soapy
solution or electron leak detector. If leaks are
detected, make proper repairs.

FUEL FILTER HOUSING

Remove

WARNING

LPG can cause an explosion. Do not permit any
sparks or open flames in the work area.

Close fuel valve on tank. Run engine until it
stops.

Disconnect negative battery cable.

WARNING

A small amount of fuel may still be present in
the fuel line. Use gloves to prevent burns and
wear eye protection. If liquid fuel continues
to flow from the connections when loosened,
check to make sure the manual valve is fully
closed.

Slowly loosen and disconnect inlet and outlet fit-
tings.

Disconnect low pressure switch from engine wire
harness.

Remove the socket head capscrews retaining the
fuel filter housing to the mounting bracket and
remove fuel filter assembly. See Figure 4.

900 SRM 1124

Fuel Filter Unit Repair

FUEL FILTER ASSEMBLY

MOUNTING BRACKET

SOCKET HEAD CAPSCREWS

Figure 4. Fuel Filter Assembly Removal/

Installation

Disassemble

Remove the fuel filter. See Fuel Filter Element,
Remove.

Remove the inlet fitting. See Figure 5.

Remove the low pressure switch fitting.

Figure 5. Fuel Filter Assembly

Legend for Figure 5

BOLT*

SEAL WASHER

FUEL FILTER HOUSING TOP SECTION*

FUEL FILTER

HOUSING O-RING

INLET FITTING*

LOW PRESSURE SWITCH

LOW PRESSURE SWITCH FITTING*

LOW PRESSURE SWITCH ADAPTER*

10. FUEL FILTER HOUSING BOTTOM SECTION*
11. O-RING*
12. OUTLET ADAPTER FITTING*
13. ELBOW FITTING*
14. FUEL FILTER O-RING

*NOT SERVICED SEPARATELY

Remove the outlet elbow fitting.

Assemble

CAUTION

Do not use Teflon tape on any fuel fitting. Use
a liquid pipe thread sealant when installing fit-
tings.

Apply pipe thread sealant to the threads of the
outlet elbow fitting and install the outlet elbow
fitting and O-ring.

Install the low pressure switch fitting.

Apply pipe thread sealant to the threads of the
inlet fitting and install the inlet fitting.

Install the fuel filter. See Fuel Filter Element,
Install.

Install

Place the fuel filter assembly in position on the
mounting bracket.

Install the socket head capscrews to retain the
fuel filter housing to the mounting bracket.
Tighten socket head capscrews to 6 N•m
(53 lbf in).

Connect low pressure switch to engine wire har-
ness.

Connect the inlet and outlet fuel lines.

Electronic Throttle Body Repair

900 SRM 1124

Slowly open the fuel valve on tank.

Turn the key to the ON position and back to
the OFF position to pressurize the fuel system.
Check for leaks.

Check for leaks at connections by using soapy
solution or electron leak detector. If leaks are
detected, make proper repairs.

Electronic Throttle Body Repair

ELECTRONIC THROTTLE BODY

Remove

Disconnect the negative battery cable.

Remove the clean air tube from the throttle body
to the air filter assembly.

Disconnect the electrical connector from the
throttle body.

Remove the socket head capscrews and lock-
washers retaining the throttle body to the
adapter plate. See Figure 6.

Remove the throttle body and gasket. Discard
gasket.

Install

Clean the mating surfaces of the adapter plate
and the throttle body.

Place the new gasket and throttle body in posi-
tion on the adapter plate.

Install the lockwashers and socket head cap-
screws. Tighten the socket head capscrews to
10 N•m (88.5 lbf in).

Install the clean air tube.

Connect the battery negative cable.

Key ON the vehicle and with the PC service tool
send a "Restore ECU Defaults" command via the
CAN communication bus.

Key OFF the vehicle and wait 30 seconds.

Connect the electrical connector to the throttle
body. Verify that the connector clicks/locks into
place.

WARNING

Do not insert fingers or foreign objects into the
throttle body.

Start the vehicle and check for proper operation
of the throttle body and the ECU by exercising
the accelerator pedal with the vehicle in neutral.
The engine should idle at 775 to 825 rpm with no
pedal to the governor speed of 2675 to 2725 rpm
at full pedal.

ADAPTER PLATE

GASKET

ELECTRONIC THROTTLE BODY

SOCKET HEAD CAPSCREWS

LOCKWASHER

Figure 6. Electronic Throttle Body

900 SRM 1124

Fuel Injector Repair

ELECTRONIC THROTTLE BODY ADAPTER
PLATE

Remove

Remove the throttle body. See Electronic Throt-
tle Body, Remove.

Remove the socket head capscrews and lock-
washers retaining the adapter plate to the
intake manifold. See Figure 7.

Remove the adapter plate and gasket.

Install

Clean the mating surfaces of the adapter plate
and the intake manifold.

Place the new gasket and adapter plate in posi-
tion on the intake manifold.

Install the lockwashers and socket head cap-
screws. Tighten the socket head capscrews to
10 N•m (88.5 lbf in).

Install the throttle body. See Electronic Throttle
Body, Install.

INTAKE MANIFOLD

GASKET

ADAPTER PLATE

SOCKET HEAD CAPSCREWS

LOCKWASHER

Figure 7. Electronic Throttle Body

Fuel Injector Repair

FUEL RAIL

Remove

WARNING

LPG can cause an explosion. Do not permit any
sparks or open flames in the work area.

Close fuel valve on tank. Run engine until it
stops.

Disconnect negative battery cable.

Disconnect the fuel line from the fuel rail.

Disconnect the four electrical connectors from
the fuel injectors. See Figure 8.

Disconnect the two hoses from the positive
crankcase ventilation (PCV) valve.

Remove the two capscrews and lockwashers re-
taining the fuel rail to the mounting bracket. See
Figure 9.

ELECTRICAL CONNECTORS

FUEL INJECTORS

Figure 8. Fuel Injector Electrical Connectors

Fuel Injector Repair

900 SRM 1124

CAPSCREW

LOCKWASHER

FUEL RAIL

Figure 9. Fuel Rail Capscrews

Move the fuel rail away from the injectors.

CAUTION

When cutting the clamps, use caution not to cut
the hoses or the fuel rail barbs.

Carefully cut the clamps holding the hoses to the
fuel rail barbs. See Figure 10.

Disconnect each hose from the fuel rail by work-
ing each hose back and forth while pulling the
hose outward, away from the fuel rail.

Install

Place the fuel rail in position on the mounting
bracket.

Install two capscrews and washers to retain the
fuel rail to the mounting bracket. Tighten cap-
screws to 10 N•m (88.5 lbf in).

Place new screw-type clamps over each of the
hoses. Push the hoses onto the fuel rail barbs.

Verify that all fuel hoses are in correct position
and not kinked. Tighten each clamp screw to 2.45
to 2.77 N•m (22 to 25 lbf in).

Connect the four electrical connectors to the fuel
injectors. Verify that the connectors click/lock
into place.

Connect the two hoses to the PCV valve.

Connect the fuel line to the fuel rail.

Connect the negative battery cable.

Slowly open the fuel valve on tank.

10. Turn the key to the ON position and back to

the OFF position to pressurize the fuel system.
Check for leaks.

11. Check for leaks at connections by using soapy

solution or electron leak detector. If leaks are
detected, make proper repairs.

HOSE

CLAMP

FUEL RAIL

Figure 10. Fuel Rail Hose Clamp

900 SRM 1124

Fuel Injector Repair

FUEL INJECTOR

Remove

CAUTION

The fuel injectors are held in place with an
internal "C" ring. When removing the fuel in-
jectors, pull the injectors straight out. Do not
pry the injectors with a screwdriver or prybar,
as this can damage the injectors or injector
adapters.

NOTE: Do not cut the clamps for the hoses attaching
the fuel injectors to the fuel rail. Remove the fuel
injectors and fuel rail as an assembly.

Remove the fuel rail with the injectors attached
by pulling the injectors straight out of the
adapters. See Fuel Rail, Remove, Step 1 through
Step 6, and Figure 11.

FUEL RAIL

FUEL INJECTOR

CLAMP

HOSE

Figure 11. Fuel Injectors and Fuel Rail

CAUTION

When cutting the clamps, use caution not to cut
the hoses or the fuel injector barbs.

Carefully cut the clamps holding the hoses to the
fuel injector barbs.

Disconnect hoses from the fuel injectors by hold-
ing hose and rotating fuel injector back and forth
while pulling the fuel injector outward, away
from the hose.

Remove O-rings from fuel injectors and discard.

Clean

WARNING

Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel.

Wear protective

goggles or a face shield to prevent injury to the
eyes.

CAUTION

Do not use any solvents or cleaners when clean-
ing the fuel injectors.

Remove any debris on the open end (outlet toward
engine) of the fuel injector. Cleaning is only done by
carefully inserting a pick type tool into the passage
and scraping out debris. Only use compressed air for
blowing away any loose particles.

Install

Install new O-rings on fuel injectors.

CAUTION

When installing the fuel injectors, install using
hand pressure only. Do not use an object or
tool to hit the injectors to force them into the
adapters.

Install the fuel injectors into the fuel injector
adapters. Push the injectors into the adapters
using hand pressure only. See Figure 12.

Place the fuel rail in position on the mounting
bracket.

Install two capscrews and washers to retain the
fuel rail to the mounting bracket. Tighten cap-
screws to 10 N•m (88.5 lbf in).

Fuel Injector Repair

900 SRM 1124

ADAPTERS

FUEL INJECTORS

Figure 12. Fuel Injectors and Adapters

Place new screw-type clamps over each of the
hoses.

Insert the hoses onto the fuel injector

barbs.

Verify that all fuel hoses are in correct position
and not kinked. Tighten each clamp screw to 2.45
to 2.77 N•m (40 to 45 lbf in).

Connect the four electrical connectors to the fuel
injectors. Verify that the connectors click/lock
into place.

Connect the two PCV hoses.

Connect the fuel line to the fuel rail.

10. Connect the negative battery cable.

11. Slowly open the fuel valve on tank.

12. Turn the key to the ON position and back to

the OFF position to pressurize the fuel system.
Check for leaks.

13. Check for leaks at connections by using soapy

solution or electron leak detector. If leaks are
detected, make proper repairs.

FUEL INJECTOR ADAPTERS

Remove

CAUTION

NOTE: Do not cut the clamps for the hoses attaching
the fuel injectors to the fuel rail. Remove the fuel
injectors and fuel rail as an assembly.

Remove the fuel rail with the injectors attached
by pulling the injectors straight out of the
adapters. See Fuel Rail, Remove, Step 1 through
Step 6, and Figure 11.

Remove the two capscrews and lockwashers re-
taining the fuel injector adapter retaining plate
and remove retaining plate. See Figure 13.

Figure 13. Fuel Injector Adapter Retaining

Plate

900 SRM 1124

Vaporizer Repair

Legend for Figure 13

RETAINING PLATE

CAPSCREWS

LOCKWASHERS

Remove the fuel injector adapters by using a
slight twisting motion to pull the adapters out of
the intake manifold. See Figure 14.

FUEL INJECTOR ADAPTERS

INTAKE MANIFOLD

Figure 14. Fuel Injector Adapters

Remove the O-rings from the adapters and dis-
card O-rings. See Figure 15.

FUEL INJECTOR ADAPTER

O-RING

Figure 15. Fuel Injector Adapter and O-ring

Install

Install new O-rings on adapters.

Lubricate the O-rings on the adapters with clean
engine oil and install the adapters into the intake
manifold. See Figure 14.

Place the fuel injector adapter retaining plate
in position on the intake manifold. Install the
two capscrews and lockwashers. Tighten the cap-
screws to 20 N•m (14.75 lbf ft).

Install the fuel injectors and fuel injector rail.
See Fuel Injector, Install.

Vaporizer Repair

VAPORIZER

Remove

WARNING

LPG can cause an explosion. Do not permit any
sparks or open flames in the work area.

Close fuel valve on tank. Run engine until it
stops.

Disconnect negative battery cable.

Vaporizer Repair

900 SRM 1124

WARNING

DO NOT remove the radiator cap from the radi-
ator when the engine is hot. When the radiator
cap is removed, the pressure is released from
the system. If the system is hot, the steam and
boiling coolant can cause burns.

Put a drain pan under drain valve for radiator.
Open drain valve so coolant drains into pan. Re-
move radiator cap.

Slowly disconnect fuel line fitting from filter unit
to vaporizer. See Figure 16.

FUEL FILTER TO FUEL TANK FUEL LINE

FUEL FILTER ASSEMBLY

FUEL FILTER TO VAPORIZER FUEL LINE

LOCK-OFF SOLENOID

MOUNTING BRACKET

VAPORIZER

BALANCE LINE

COOLANT HOSE

10. VAPORIZER TO FUEL RAIL FUEL LINE

Figure 16. Vaporizer and Hose Assembly

Disconnect the fuel line from vaporizer to fuel
rail.

Tag and disconnect coolant hoses to vaporizer.
Cap coolant hoses.

Disconnect balance line from vaporizer.

Disconnect electrical connector to lock-off sole-
noid.

Remove capscrew retaining vaporizer to mount-
ing bracket. Remove vaporizer. See Figure 17.

MOUNTING BRACKET

CAPSCREW

VAPORIZER

Figure 17. Vaporizer Mounting Bracket

Install

Place the vaporizer in position on mounting
bracket and install capscrew to retain vaporizer
to the mounting bracket. Tighten capscrew to
20 N•m (14.75 lbf ft).

Connect electrical connector to lock-off solenoid.

Connect balance line to vaporizer.

Remove caps from coolant hoses and connect
coolant hoses to vaporizer.

Connect the fuel line to vaporizer from fuel rail.

Connect fuel line fitting from filter unit to vapor-
izer.

Fill the cooling system. Refer to the section Pe-
riodic Maintenance 8000 SRM 1150.

Install radiator cap.

Connect negative battery cable.

900 SRM 1124

Vaporizer Repair

10. Slowly open the fuel valve on tank.

11. Turn the key to the ON position and back to

the OFF position to pressurize the fuel system.
Check for leaks.

12. Check for leaks at connections by using soapy

solution or electron leak detector. If leaks are
detected, make proper repairs.

VAPORIZER FUEL FILTER

Remove

WARNING

LPG can cause an explosion. Do not permit any
sparks or open flames in the work area.

Close fuel valve on tank. Run engine until it
stops.

Disconnect the negative battery cable.

Disconnect the fuel inlet and outlet lines from the
vaporizer.

Remove the fuel inlet fitting and O-ring. See Fig-
ure 18.

Figure 18. Vaporizer Fuel Filter

Legend for Figure 18

VAPORIZER

OUTLET FILTER

O-RING

OUTLET FITTING

SCREW

FILTER GASKET

PAPER FILTER ELEMENT

FOAM FILTER

PLASTIC BODY

10. O-RING
11. INLET FITTING

Remove the plastic body, foam filter, paper filter
element, and filter gasket.

Remove the screws retaining the fuel outlet fit-
ting.

Remove the fuel outlet fitting, O-ring, and filter.
Discard O-ring and filter.

Install

Install new filter in port for fuel outlet fitting.

Install new O-ring and fuel outlet fitting.

Install retaining screws for fuel outlet fit-
ting.

Tighten screws to 2 to 3 N•m (17.7 to

26.55 lbf in).

Install the filter gasket, new paper filter element,
new foam filter, and plastic body.

Install the fuel inlet fitting and O-ring. Tighten
to 18 to 20 N•m (13.3 to 14.75 lbf ft).

Connect the fuel inlet line to the vaporizer.

Connect the negative battery cable.

Slowly open the fuel valve on tank.

Turn the key to the ON position and back to
the OFF position to pressurize the fuel system.
Check for leaks.

Control System

900 SRM 1124

10. Check for leaks at connections by using soapy

solution or electron leak detector. If leaks are
detected, make proper repairs.

LOCK-OFF SOLENOID AND CARTRIDGE

Remove

WARNING

LPG can cause an explosion. Do not permit any
sparks or open flames in the work area.

Close fuel valve on tank. Run engine until it
stops.

Disconnect the negative battery cable.

Disconnect the electrical connector from the lock-
off solenoid.

Remove the nut retaining the solenoid to the car-
tridge. See Figure 19.

Slide the solenoid off the cartridge.

Remove the cartridge.

Install

Install new cartridge. Tighten cartridge to 16 to
24 N•m (11.8 to 17.7 lbf ft).

Slide solenoid onto cartridge.

Install nut to retain solenoid. Tighten nut to a
maximum of 7.85 N•m (69.5 lbf in).

Connect electrical connector to solenoid.

Connect the negative battery cable.

NOTE: Opening the fuel valve too quickly can cause
the internal excess flow valve to close, restricting the
flow of fuel. If this happens, close the fuel valve, wait

a few seconds, and then slowly open the fuel valve
again. This will reset the excess flow valve.

Slowly open the fuel valve on tank.

Turn the key to the ON position and back to
the OFF position to pressurize the fuel system.
Check for leaks.

Check for leaks at connections by using soapy
solution or electron leak detector. If leaks are
detected, make proper repairs.

VAPORIZER

CARTRIDGE

COIL

NUT

Figure 19. Lock-Off Solenoid

Control System

ELECTRONIC CONTROL UNIT (ECU)

Remove

Disconnect the negative battery cable.

Disconnect the throttle body electrical connector.

Remove the capscrews holding the air filter
mounting bracket to the ECU mounting bracket.
See Figure 20.

900 SRM 1124

Control System

CAPSCREW

AIR FILTER MOUNTING BRACKET

ECU MOUNTING BRACKET

WIRE HARNESS CLAMP

Figure 20. Air Filter Mounting Bracket and

ECU Mounting Bracket

Lower the ECU and mounting bracket assembly
down toward the frame.

Disconnect the hoses from the air filter assembly.

Remove the three bolts that attach the air filter
assembly mounting bracket to the frame and re-
move air filter assembly with mounting bracket.

Remove capscrew retaining wire harness clamp
to ECU mounting bracket.

Remove the capscrews and nuts holding the ECU
to the mounting bracket. See Figure 21.

Disconnect the electrical connectors from the
ECU. Rotate the locking tabs on each connector
to unlock the electrical connectors. Disconnect
the connector closest to the fan assembly first.
Disconnect the center connector second.

Dis-

connect the third connector. Remove ECU. See
Figure 22.

MOUNTING BRACKET

CAPSCREW

NUTS

ECU

Figure 21. ECU Mounting Bracket

MOUNTING BRACKET

LOCKING TAB

ECU

ELECTRICAL CONNECTORS

Figure 22. ECU and Electrical Connectors

Control System

900 SRM 1124

Install

Connect the electrical connectors to the ECU.
Connect the electrical connector furthest from
the fan assembly first. Connect the center con-
nector second. Connect the connector closest to
the fan assembly last. Rotate the locking tabs to
lock the electrical connectors in position.

Place the ECU in position on the mounting
bracket. Install the capscrews and nuts. Tighten
capscrews to 10 N•m (88.5 lbf in).

Position the wire harness and wire harness
clamp on the ECU mounting bracket.

Install

the capscrew to retain the wire harness clamp.
Tighten capscrew to 10 N•m (88.5 lbf in).

Place the air filter assembly with mounting
bracket in position on the frame. Install bolts
and tighten to 20 N•m (14.75 lbf ft).

Connect the hoses to the air filter assembly.

Slide the ECU and mounting bracket assembly
into position on the air filter mounting bracket.

Install the capscrews to retain the ECU mount-
ing bracket to the air filter mounting bracket.
Tighten capscrews to 20 N•m (14.75 lbf ft).

Connect the negative battery cable.

Key ON the vehicle and with the PC service tool
send a "Restore ECU Defaults" command via the
CAN communication bus.

10. Key OFF the vehicle and wait 30 seconds.

11. Connect the throttle body electrical connector.

12. Start the vehicle and check for proper operation

of the throttle body and the ECU by exercising
the accelerator pedal with the vehicle in neutral.
The engine should idle at 775 to 825 rpm with no
pedal to the governed speed of 2675 to 2725 rpm
at full pedal.

POWER LATCH RELAY

Remove

Disconnect the negative battery cable.

Remove the capscrews holding the air filter
mounting bracket to the ECU mounting bracket.
See Figure 20.

Lower the ECU and mounting bracket assembly
down toward the frame.

Disconnect the hoses from the air filter assembly.

Remove the three bolts that attach the air filter
assembly mounting bracket to the frame and re-
move air filter assembly with mounting bracket.

Remove the capscrews and nuts retaining the
power latch relay to the ECU mounting bracket.
See Figure 23.

CAPSCREWS

POWER LATCH RELAY

ELECTRICAL CONNECTOR

ECU MOUNTING BRACKET

NUTS

Figure 23. Power Latch Relay

Disconnect the electrical connector from the
power latch relay.

Install

Connect the electrical connector from the power
latch relay.

Place the power latch relay in position on the
ECU mounting bracket.

Install capscrews and nuts to retain the power
latch relay to the ECU mounting bracket.
Tighten capscrews to 10 N•m (88.5 lbf in).

900 SRM 1124

Control System

Place the air filter assembly with mounting
bracket in position on the frame. Install bolts
and tighten to 20 N•m (14.75 lbf ft).

Connect the hoses to the air filter assembly.

Slide the ECU and mounting bracket assembly
into position on the air filter mounting bracket.

Install the capscrews to retain the ECU mount-
ing bracket to the air filter mounting bracket.
Tighten capscrews to 20 N•m (14.75 lbf ft).

Connect the negative battery cable.

INJECTOR DRIVER MODULE

Remove

Disconnect the negative battery cable.

Remove the capscrews holding the air filter
mounting bracket to the ECU mounting bracket.
See Figure 20.

Lower the ECU and mounting bracket assembly
down toward the frame.

Disconnect the hoses from the air filter assembly.

Remove the three bolts that attach the air filter
assembly mounting bracket to the frame and re-
move air filter assembly with mounting bracket.

Remove the capscrew and nut retaining the injec-
tor driver module to the mounting bracket. See
Figure 24.

Figure 24. Injector Driver Module

Legend for Figure 24

CAPSCREW

NUT

INJECTOR DRIVER MODULE

Disconnect the electrical connector from the in-
jector driver module. See Figure 25.

ELECTRICAL CONNECTOR

INJECTOR DRIVER MODULE

Figure 25. Injector Driver Module Electrical

Connector

Install

Connect the electrical connector to the injector
driver module.

Place the injector driver module in position on
the mounting bracket.

Install the capscrew and nut to retain the injector
driver module to the mounting bracket. Tighten
the capscrew to 10 N•m (88.5 lbf in).

Place the air filter assembly with mounting
bracket in position on the frame. Install bolts
and tighten to 20 N•m (14.75 lbf ft).

Connect the hoses to the air filter assembly.

Slide the ECU and mounting bracket assembly
into position on the air filter mounting bracket.

Control System

900 SRM 1124

Install the capscrews to retain the ECU mount-
ing bracket to the air filter mounting bracket.
Tighten capscrews to 20 N•m (14.75 lbf ft).

Connect the negative battery cable.

CAMSHAFT POSITION (CMP) SENSOR

Remove

Disconnect the negative battery cable.

Disconnect the CMP sensor electrical connector.
See Figure 26.

CMP SENSOR

WIRE HARNESS CLAMP

ELECTRICAL CONNECTORS

Figure 26. CMP Sensor Electrical Connector

Remove harness clamp from CMP sensor support
plate.

Remove the screw and lockwasher retaining the
CMP sensor. See Figure 27.

Remove the CMP sensor and O-ring.

Remove O-ring from CMP sensor and discard.

Install

Install new O-ring on CMP sensor.

Lubricate O-ring with clean engine oil.

Install the CMP sensor into the CMP sensor sup-
port plate.

NOTE: Before installing retaining screw, verify the
CMP sensor is fully seated.

Install retaining screw and lockwasher. Tighten
retaining screw to 6 N•m (53 lbf in).

Connect the electrical connectors. Verify that the
connectors click/lock into place.

Install harness clamp to CMP sensor support
plate.

SCREW

LOCKWASHER

CMP SENSOR

O-RING

CMP SENSOR SUPPORT PLATE

Figure 27. CMP Sensor

MANIFOLD ABSOLUTE PRESSURE
(MAP)/MANIFOLD AIR TEMPERATURE
(MAT) SENSOR

Remove

Disconnect the negative battery cable.

Disconnect the electrical connector from the
MAP/MAT sensor. See Figure 28.

Remove the two screws retaining the MAP/MAT
sensor to the intake manifold.

Remove MAP/

MAT sensor.

900 SRM 1124

Control System

MAP/MAT SENSOR

SCREW

ELECTRICAL CONNECTOR

Figure 28. MAP/MAT Sensor

Install

Place the MAP/MAT sensor in position on the
intake manifold and install the two retaining
screws.

Tighten retaining screws to 6 N•m

(53 lbf in).

Connect

the

electrical

connector

the

MAP/MAT sensor.

Verify that the connector

clicks/locks into place.

Connect the negative battery cable.

ENGINE COOLANT TEMPERATURE (ECT)
SENSOR

Remove

Disconnect the negative battery cable.

Disconnect the electrical connector from the ECT
sensor. See Figure 29.

Remove the ECT sensor and washer.

ELECTRICAL CONNECTOR

ECT SENSOR

WASHER

Figure 29. ECT Sensor

Install

Install the new ECT sensor and washer. Tighten
the sensor to 20 N•m (14.75 lbf ft).

Connect the electrical connector to the ECT sen-
sor.

Connect the negative battery cable.

OXYGEN SENSOR

Remove

Disconnect the negative battery cable.

Disconnect the oxygen sensor electrical connec-
tor. See Figure 30.

Control System

900 SRM 1124

ELECTRICAL CONNECTORS

CLIP

NUT

THERMOSTAT HOUSING

Figure 30. Oxygen Sensor Electrical Connector

Remove nut and clip retaining the oxygen sensor
wiring harness and connector to the thermostat
housing.

Using a special tool, oxygen sensor socket, re-
move the oxygen sensor. See Figure 31 and Fig-
ure 32.

Figure 31. Oxygen Sensor Socket

EXHAUST MANIFOLD ADAPTER

OXYGEN SENSOR

Figure 32. Oxygen Sensor

Install

Before installing the sensor, coat sensor spar-
ingly with an antiseize compound, then install
oxygen sensor into exhaust manifold adapter.
Using a special tool, oxygen sensor socket,
tighten oxygen sensor to 40 to 60 N•m (30 to
44 lbf ft). See Figure 31 and Figure 32.

Install nut and clip to retain the oxygen sensor
wiring harness and connector to the thermostat
housing.

Connect the electrical connectors. Verify that the
connectors click/lock into place.

Verify that the wire is pulled up toward the ther-
mostat and away from any hot exhaust compo-
nents.

Connect the negative battery cable.

TECHNICAL PUBLICATIONS

900 SRM 1124

5/05 (12/04) Printed in United Kingdom

Document Outline

Wyszukiwarka

Podobne podstrony:
1580505 0700SRM1123 (05 2005) UK EN
1510466 1800SRM0985 (05 2005) UK EN
1580512 1600SRM1133 (05 2005) UK EN
1466229 1800SRM0734 (05 2005) UK EN
1495954 0900SRM0948 (09 2005) UK EN
1580526 8000SRM1151 (05 2005) UK EN
1580521 2200SRM1143 (05 2005) UK EN
1598591 8000SRM1208 (05 2005) UK EN
Gasoline Fuel System Mazda 0900SRM1127 (05 2005) US EN
Gasoline Fuel System GM 0900SRM1126 (05 2005) US EN

więcej podobnych podstron

1580506 0900SRM1124 (05 2005) UK EN

Document Outline