HIGH VOLTAGE SWITCH

(HVS) IGNITION

GM 4.3L EPA COMPLIANT ENGINES

S6.00-7.00XL (S135-155XL, S155XLS,

S135-155XL

) [C024];

S3.50-5.50XM (S70-120XM) [F004];

H6.00-7.00XL (H135-155XL, H135-155XL

) [G006];

H3.50-5.50XM (H70-120XM) [L005]

PART NO. 1559550

2200 SRM 1097

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!

High Voltage Switch (HVS) Ignition

Table of Contents

TABLE OF CONTENTS

Description .........................................................................................................................................................

Distributor Ignition (DI) System ..................................................................................................................

Crankshaft Position (CKP) Sensor ...............................................................................................................

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

Ignition Coil and Ignition Control Module (ICM) ........................................................................................

Secondary Ignition Components ...................................................................................................................

Spark Plugs and Wires ......................................................................................................................................

Spark Plug Wire Inspection ..........................................................................................................................

Spark Plug Wire Replacement ......................................................................................................................

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

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

Spark Plug Inspection ...................................................................................................................................

Usage..........................................................................................................................................................

Inspection...................................................................................................................................................

Visual Inspection .......................................................................................................................................

Spark Plug Replacement ...............................................................................................................................

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

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

Distributor Repair..............................................................................................................................................

Inspect ............................................................................................................................................................

Overhaul.........................................................................................................................................................

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

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

Replace ...........................................................................................................................................................

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

Install Procedure 1 ....................................................................................................................................

Install Procedure 2 ....................................................................................................................................

Ignition Coil Replacement .................................................................................................................................

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

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

Ignition Control Module Replacement..............................................................................................................

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

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

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

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

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

Crankshaft Position (CKP) Sensor Replacement .............................................................................................

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

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

Wire Harness Repair .........................................................................................................................................

On Vehicle Service Wiring Harness Repair..................................................................................................

Connectors and Terminals ............................................................................................................................

Twisted/Shielded Cable Repair.................................................................................................................

Twisted Leads Repair................................................................................................................................

Micro-Pack .................................................................................................................................................

Metri-Pack .................................................................................................................................................

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

Weather-Pack ............................................................................................................................................

Weather-Pack Terminal Repair............................................................................................................

Specifications and Special Tools........................................................................................................................

System Diagnosis ...............................................................................................................................................

Table of Contents

High Voltage Switch (HVS) Ignition

TABLE OF CONTENTS (Continued)

This section is for the following models:

S6.00-7.00XL (S135-155XL, S155XLS, S135-155XL

) [C024];

S3.50-5.50XM (S70-120XM) [F004];

H6.00-7.00XL (H135-155XL, H135-155XL

) [G006];

H3.50-5.50XM (H70-120XM) [L005]

2200 SRM 1097

Spark Plugs and Wires

Description

DISTRIBUTOR IGNITION (DI) SYSTEM

The distributor ignition (DI) system is responsi-
ble for producing and controlling a high energy
secondary spark. This spark is used to ignite the
compressed air/fuel mixture at precisely the correct
time. This provides optimal performance, fuel econ-
omy, and control of exhaust emissions. This ignition
system consists of a single ignition coil and ignition
control module (ICM). Spark energy is delivered via
a distributor cap, rotor, and secondary spark plug
wires. The driver module within the ICM is com-
manded to operate the coil by the electronic control
module (ECM), that has complete control over spark
timing.

The DI system consists of a Crankshaft

Position (CKP) Sensor, Camshaft Position (CMP)
Sensor, Ignition Coil and Ignition Control Module
(ICM), and Secondary Ignition Components.

CRANKSHAFT POSITION (CKP) SENSOR

The CKP sensor is a three-wire sensor based on the
magneto-resistive principle.

A magneto-resistive

sensor uses two magnetic pickups between a per-
manent magnet. As an element such as a reluctor
wheel passes the magnets, the resulting change in
the magnetic field is used by the sensor electronics
to produce a digital output pulse. The ECM supplies
a 5-volt, low reference and signal circuit to the CKP
sensor. The sensor returns a digital ON/OFF pulse
3 times per crankshaft revolution. The CKP sensor

reads the crankshaft mounted reluctor wheel to
identify pairs of cylinders at top dead center (TDC).

CAMSHAFT POSITION (CMP) SENSOR

The CMP sensor is a hall-effect sensor located in the
ignition distributor base, and uses the same type of
circuits as the CKP sensor. The CMP sensor signal is
a digital ON/OFF pulse, output once per revolution of
the camshaft. The CMP sensor information is used
by the ECM to determine the position of the valve
train relative to the CKP.

IGNITION COIL AND IGNITION CONTROL
MODULE (ICM)

The ICM is connected to the ECM by an ignition con-
trol (IC) circuit. The ICM also has a ground circuit
and shares an ignition 1 voltage supply with the igni-
tion coil. The coil driver in the ICM controls current
through the ignition coil based on signal pulses from
the ECM. There is no backup or bypass function in
the ICM.

SECONDARY IGNITION COMPONENTS

The distributor is only used as a means to operate
the CMP sensor and to distribute spark in the cor-
rect sequence. Since the distributor has no influ-
ence on base timing, the distributor is not adjustable.
The spark is distributed through conventional car-
bon core wires to the spark plugs.

Spark Plugs and Wires

SPARK PLUG WIRE INSPECTION

Spark plug wire integrity is vital for proper engine
operation. A thorough inspection will be necessary to
accurately identify conditions that may affect engine
operation. Inspect for the following conditions:

Correct routing of the spark plug wires. Incorrect
routing may cause cross-firing.

Any signs of cracks or splits in the wires.

Inspect each boot for the following conditions:
• Tearing
• Piercing
• Arcing
• Carbon tracking
• Corroded terminal

If corrosion, carbon tracking, or arcing are indicated
on a spark plug wire boot or on a terminal, replace
the wire and the component connected to the wire.

SPARK PLUG WIRE REPLACEMENT

Remove

Disconnect the spark plug wire at each spark
plug. See Figure 1.

a. Twist the boots 1/2 turn before removing the

boots.

b. Pull only on the boot or use a tool designed

for this purpose in order to remove the wire
from each spark plug.

Spark Plugs and Wires

2200 SRM 1097

Figure 1. Spark Plug Wire Remove/Install

Disconnect the spark plug wire from the distrib-
utor.

a. Twist each spark plug boot 1/2 turn.

b. Pull only on the boot or use a tool designed

for this purpose in order to remove the wires
from the distributor.

Install

NOTE: If the boot-to-wire movement has occurred,
the boot will give a false visual impression of being
fully seated. Ensure that the boots have been prop-
erly assembled by pushing sideways on the installed
boots. Failure to properly seat the terminal onto the
spark plug will lead to wire core erosion and result in
an engine misfire or crossfire condition and possible
internal damage to the engine.

Install the spark plug wires at the distributor.

Install the spark plug wire to each spark plug.
See Figure 1.

Inspect the wires for proper installation:

a. Push sideways on each boot in order to in-

spect the seating.

b. Reinstall any loose boot.

Wire routings must be kept intact during ser-
vice and followed exactly when wires have
been disconnected or when replacement of
the wires is necessary. Failure to route the

wires properly can lead to radio ignition noise
and cross firing of the plugs or shorting of the
leads to the ground.

d. Any time the spark plug wires or boots are

installed on the spark plugs, new dielectric
grease needs to be applied inside the boot.

SPARK PLUG INSPECTION

Usage

Ensure that the correct spark plug is installed.
An incorrect spark plug causes driveability con-
ditions. Refer to Table 1 for the correct spark
plug.

Ensure that the spark plug has the correct heat
range. An incorrect heat range causes the follow-
ing conditions:
• Spark plug fouling - Colder plug
• Pre-ignition causing spark plug and/or engine

damage - Hotter plug

Inspection

Inspect the terminal post for damage. See Fig-
ure 2.

a. Inspect for a bent or broken terminal post.

TERMINAL POST

INSULATOR

ELECTRODE

Figure 2. Spark Plug

2200 SRM 1097

Spark Plugs and Wires

b. Test for a loose terminal post by twisting and

pulling the post. The terminal post should
NOT move.

Inspect the insulator for flashover or carbon
tracking, soot. See Figure 3. This is caused by
the electrical charge traveling across the insu-
lator between the terminal post and ground.
Inspect for the following conditions:

TERMINAL POST

INSULATOR

ELECTRODE

Figure 3. Spark Plug With Flashover or Carbon

Tracking

a. Inspect the spark plug boot for damage.

b. Inspect the spark plug recess area of the

cylinder head for moisture, such as oil,
coolant, or water. A spark plug boot that is
saturated causes arcing to ground.

Inspect the insulator for cracks. All or part of
the electrical charge may arc through the crack
instead of the electrodes. See Figure 4.

Inspect for evidence of improper arcing. See Fig-
ure 5.

a. Measure the gap between the center elec-

trode (4) and the side electrode (3) terminals.
An excessively wide electrode gap can pre-
vent correct spark plug operation.

b. Inspect for the correct spark plug torque. Re-

fer to Table 1. Insufficient torque can pre-
vent correct spark plug operation. An over-
torqued spark plug causes the insulator to
crack.

TERMINAL POST

INSULATOR

ELECTRODE

Figure 4. Spark Plug Arcing Through a Crack

TERMINAL POST

INSULATOR

ELECTRODE

Figure 5. Spark Plug Arcing Improperly

Spark Plugs and Wires

2200 SRM 1097

Inspect for signs of tracking that occurred
near the insulator tip instead of the center
electrode (4).

d. Inspect for a broken or worn side electrode

(3).

Inspect for a broken, worn, or loose center
electrode (4) by shaking the spark plug.

(1)

A rattling sound indicates internal
damage.

(2)

A loose center electrode (4) reduces the
spark intensity.

Inspect for bridged electrodes (3, 4). Deposits
on the electrodes (3, 4) reduce or eliminate
the gap.

g. Inspect for worn or missing platinum pads on

the electrodes (3, 4) if equipped.

h. Inspect for excessive fouling.

Inspect the spark plug recess area of the cylinder
head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during
installation.

Visual Inspection

Normal operation - Brown to grayish-tan with
small amounts of white powdery deposits are
normal combustion by-products from fuels with
additives.

Carbon fouled - Dry, fluffy black carbon, or soot
caused by the following conditions:
• Rich fuel mixtures

– Leaking fuel injectors
– Excessive fuel pressure
– Restricted air filter element
– Incorrect combustion

• Reduced ignition system voltage output

– Weak coils
– Worn ignition wires
– Incorrect spark plug gap

• Excessive idling or slow speeds under light

loads can keep spark plug temperatures so low

that normal combustion deposits may not burn
off.

Deposit Fouling - Oil, coolant, or additives that
include substances such as silicone, very white
coating, reduces the spark intensity. Most pow-
dery deposits will not effect spark intensity un-
less they form into a glazing over the electrode.

SPARK PLUG REPLACEMENT

Remove

Remove the spark plug wires. Refer to Spark
Plug Wire Replacement.

Loosen each spark plug 1 or 2 turns.

Brush or air blast away any dirt from around the
spark plugs.

Remove the spark plugs 1 at a time. Place each
plug in a tray marked with the corresponding
cylinder numbers. See Figure 6.

Figure 6. Spark Plug Remove/Install

Install

Properly position each spark plug washer.

Inspect each spark plug gap. Adjust each plug as
needed.

Specification
Spark plug gap: 0.89 mm (0.035 in.)

2200 SRM 1097

Distributor Repair

CAUTION

Late model engines use a combination of stan-
dard and metric fasteners.

The components

affected are the starter motor, engine mounts,
and flywheel housing mounting. Other compo-
nents may also have a combination of fasten-
ers. Always verify that the proper fasteners are
used whenever removing or replacing any com-
ponents.

Hand start the spark plugs in the corresponding
cylinders. See Figure 6.

Tighten the spark plugs.

a. For used heads, tighten the spark plugs to

15 N•m (11 lbf ft).

b. For new aluminum heads, tighten the spark

plugs to 20 N•m (15 lbf ft).

For new iron heads, tighten the spark plugs
to 30 N•m (22 lbf ft).

Distributor Repair

INSPECT

Remove the engine cover. Refer to the Frame
section for your lift truck.

NOTE: Discoloration of the cap and some whitish
buildup around the cap terminals is normal. Yel-
lowing of the rotor cap, darkening, and some carbon
buildup under the rotor segment is normal. Replace-
ment of the cap and the rotor is not necessary unless
there is a driveability concern.

Inspect the cap for cracks, tiny holes, or carbon
tracks between the cap terminal traces. Diag-
nose the carbon tracks using the following pro-
cedure:

a. Remove the cap. Refer to Distributor, Re-

place.

b. Place 1 lead from the DMM on a cap termi-

nal.

Use the other lead in order to probe all other
terminals and the center carbon ball.

d. Move the base lead to the next terminal.

Probe all other leads.

Continue this procedure until you test all the
secondary terminals.

If there are any non-infinite readings, re-
place the cap.

Inspect the cap for excess buildup of corrosion on
the terminals. Scrape clean the terminals. Re-
place the cap if the corrosion is excessive. Some
buildup is normal.

Inspect the rotor segment for excess wear. Re-
place the rotor if excess looseness in the rotor seg-
ment is present. See Figure 8.

Inspect the shaft for shaft-to-bushing looseness:

a. Inspect the housing for cracks or damage.

b. Insert the shaft in the housing.

If the shaft wobbles, replace the housing as-
sembly.

Install the engine cover. Refer to the Frame sec-
tion for your lift truck.

OVERHAUL

Disassemble

Remove the engine cover. Refer to the Frame
section for your lift truck.

NOTE: The ignition system distributor driven gear
and rotor may be installed in multiple positions. In
order to avoid mistakes, mark the distributor on the
following components in order to ensure the same
mounting position upon reassembly:
• Distributor driven gear
• Distributor shaft
• Rotor holes

Installing the driven gear 180 degrees out of align-
ment, or locating the rotor in the wrong holes, will
cause a no-start condition. Premature engine wear
or damage may result.

Distributor Repair

2200 SRM 1097

Align white paint mark on the bottom stem of the
distributor and the pre-drilled indent hole in the
bottom of the gear. See Figure 7.

ROTOR SEGMENT POSITIONING

INDENT HOLE IN BOTTOM OF GEAR

Figure 7. Rotor Segment and Distributor

Alignment

With the gear in this position, the rotor segment
should be positioned as shown in Figure 7. If not,
replace the distributor.

Remove the 2 screws from the rotor. See Figure 8.

Figure 8. Rotor

Remove the rotor.

Note the locating holes that the rotor was re-
moved from (see Figure 9):
• Rotor screw holes (1)
• Rotor locator pin holes (2)

ROTOR SCREW HOLE

ROTOR LOCATOR PIN HOLE

Figure 9. Rotor Mounting Holes

Line up the square-cut hole in the vane wheel
with the camshaft position (CMP) sensor. See
Figure 10.

Figure 10. Camshaft Position (CMP) Sensor

Alignment

2200 SRM 1097

Distributor Repair

Remove the 2 screws that hold the CMP sensor.
See Figure 11.

Figure 11. Camshaft Position (CMP) Sensor

Mounting Screws

Discard the screws.

10. Remove the CMP sensor. See Figure 12.

Figure 12. Camshaft Position (CMP) Sensor

11. Note the dimple located below the roll pin hole

on one side of the gear. The dimple will be used
to properly orient the gear onto the shaft during
reassembly.

12. Support the distributor drive gear in a V-block or

similar fixture.

WARNING

To prevent serious eye injury, always wear safe
eye protection when performing vehicle main-
tenance or service.

13. Drive out the roll pin with a suitable punch. See

Figure 13.

Figure 13. Roll Pin Location

14. Remove the driven gear from the distributor

shaft.

15. Remove the round washer.

16. Remove the tang washer.

17. Remove the shim washer. See Figure 14.

SHIM WASHER

Figure 14. Shim Washer Location

Distributor Repair

2200 SRM 1097

18. Remove the old oil seal. See Figure 15.

Figure 15. Oil Seal Remove/Install

Assemble

CAUTION

Installing the driven gear 180 degrees out of
alignment or locating the rotor in the wrong
holes, will cause a no-start condition. Prema-
ture engine wear or damage may result.

Line up the square-cut hole in the vane wheel for
the CMP sensor. See Figure 10.

Insert the sensor into the housing. See Figure 12.

CAUTION

Late model engines use a combination of stan-
dard and metric fasteners.

The components

Install two new screws for the CMP sensor.
Tighten the screws to 2.2 N•m (19 lbf in). See
Figure 11.

Identify the correct rotor mounting position (see
Figure 9):
• At the rotor screw holes (1)
• At the rotor locator pin holes (2)

Install the distributor rotor according to the in-
dex marks.

Install two rotor hold down screws. Tighten the
screws to 1.9 N•m (17 lbf in). See Figure 8.

Install the shim washer on the bottom of the dis-
tributor shaft. See Figure 14.

Install the tang washer.

Install the round washer.

10. Install the driven gear according to the index

marks.

11. Align the rotor segment as shown in Figure 7.

12. Install the gear and align white paint mark on

the bottom stem of the distributor and the pre-
drilled indent hole in the bottom of the gear.

13. Check to see if the driven gear is installed incor-

rectly. On an incorrectly installed driven gear,
the dimple will be approximately 180 degrees op-
posite the rotor segment when the gear is in-
stalled in the distributor.

14. Support the distributor drive gear in a V-block or

similar fixture.

WARNING

To prevent serious eye injury, always wear safe
eye protection when performing vehicle main-
tenance or service.

15. Install the roll pin with a suitable punch and

hammer in order to hold the driven gear in the
correct position. See Figure 13.

16. Install the new oil seal under the mounting

flange of the distributor base. See Figure 15.

17. Install the distributor.

18. Install the engine cover. Refer to the Frame sec-

tion for your lift truck.

REPLACE

Remove

NOTE: There are two procedures available to install
the distributor.

Use Install Procedure 1 when the crankshaft has
NOT been rotated from the original position.

Use Install Procedure 2 when any of the following
components are removed:

2200 SRM 1097

Distributor Repair

• Intake manifold
• Cylinder head
• Camshaft
• Timing chain or sprockets
• Complete engine

If the malfunction indicator lamp (MIL) turns on and
DTC P1345 sets after installing the distributor, this
indicates an incorrectly installed distributor.

Engine damage or distributor damage may occur.
Use Install Procedure 2 in order to install the dis-
tributor.

Turn OFF the ignition.

Remove the engine cover. Refer to the Frame
section for your lift truck.

Remove air cleaner assembly.

Remove the air intake resonator assembly.

Remove the ignition coil wire. Note the correct
orientation of the wire boot. See Figure 16.

Figure 16. Ignition Coil Wire

Remove the spark plug wires from the distributor
cap.

a. Twist each spark plug 1/2 turn.

b. Pull only on the wire boot in order to remove

the wire from the distributor cap.

Remove the electrical connector from the base of
the distributor.

Remove the 2 screws that retain the distributor
cap to the housing. See Figure 17.

Figure 17. Distributor Cap Remove/Install

Discard the screws.

10. Remove the distributor cap from the housing.

11. Use a grease pencil in order to mark the position

of the rotor in relation to the distributor housing
shown in Figure 18.

MARK SHOWING POSITION OF ROTOR IN
RELATION TO DISTRIBUTOR HOUSING

Figure 18. Rotor Position Mark

Distributor Repair

2200 SRM 1097

12. Mark the distributor housing and the intake

manifold with the grease pencil.

13. As the distributor is being removed from the en-

gine, watch the rotor move in a counterclockwise
direction about 42 degrees. This will appear as
slightly more than one o’clock position. See Fig-
ure 19.

MARK SHOWING POSITION OF ROTOR IN
RELATION TO DISTRIBUTOR HOUSING

MARK ON BASE OF DISTRIBUTOR

Figure 19. Rotor Position in Distributor

Housing

14. Note the position of the rotor segment.

15. Place a second mark on the base of the distribu-

tor.

This will aid in achieving the proper rotor align-
ment during the distributor installation.

16. Remove the mounting clamp holddown bolt. See

Figure 20.

17. Remove the distributor. See Figure 21.

Install Procedure 1

If installing a new distributor assembly, place
2 marks on the new distributor housing in the
same location as the marks on the original hous-
ing. See Figure 19.

Figure 20. Distributor Mounting Clamp Bolt

Figure 21. Distributor Remove/Install

Remove the new distributor cap if necessary.

Align the rotor with the second mark.

Guide the distributor into the engine. See Fig-
ure 21.

Align the hole in the distributor holddown base
over the mounting hole in the intake manifold.

As the distributor is being installed, observe the
rotor moving in a clockwise direction about 42
degrees. See Figure 18.

2200 SRM 1097

Distributor Repair

Once the distributor is completely seated, the ro-
tor segment should be aligned with the mark on
the distributor base.
• If the rotor segment is not aligned with the

mark, the driven gear teeth and the camshaft
have meshed one or more teeth out of align-
ment.

• In order to correct this condition, remove and

reinstall the distributor.

CAUTION

Late model engines use a combination of stan-
dard and metric fasteners.

The components

Install the distributor mounting clamp bolt.
Tighten the bolt to 25 N•m (18 lbf ft). See Fig-
ure 20.

Install the distributor cap. See Figure 17.

10. Install the new distributor capscrews. Tighten

the capscrews to 2.4 N•m (21 lbf in).

11. Install the electrical connector to the distributor.

12. Install the spark plug wires to the distributor

cap.

13. Install the ignition coil wire. Note the correct

orientation of the wire boot. See Figure 16.

CAUTION

If the malfunction indicator lamp illuminates
after installing the distributor and DTC P1345
is set, the distributor has been installed incor-
rectly.

14. Refer to Install Procedure 2 if the malfunction in-

dicator lamp illuminates after installing the dis-
tributor.

15. Install the engine cover. Refer to the Frame sec-

tion for your lift truck.

Install Procedure 2

NOTE: Rotate the number 1 cylinder to top dead
center (TDC) of the compression stroke. The engine
front cover has 2 alignment tabs and the crankshaft
balancer has 2 alignment marks spaced 90 degrees
apart which are used for positioning the number 1
piston at TDC. See Figure 22. With the piston on
the compression stroke and at TDC, the crankshaft
balancer alignment mark (1) must align with the en-
gine front cover tab (2) and the crankshaft balancer
alignment mark (4) must align with the engine front
cover tab (3).

Rotate the crankshaft balancer clockwise until
the alignment marks on the crankshaft balancer
are aligned with the tabs on the engine front
cover and the number 1 piston is at TDC of the
compression stroke. See Figure 22.

CRANKSHAFT BALANCER ALIGNMENT MARK

ENGINE FRONT COVER TAB

CRANKSHAFT BALANCER ALIGNMENT MARK

Figure 22. Crankshaft Balancer and Engine

Front Cover Alignment Marks

Align the white paint mark on the bottom stem
of the distributor and the pre-drilled indent hole
in the bottom of the gear. See Figure 7.

Distributor Repair

2200 SRM 1097

Installing the driven gear 180 degrees out of align-
ment or locating the rotor in the wrong holes, will
cause a no-start condition. Premature engine wear
or damage may result.

With the gear in this position, the rotor segment
should be positioned as shown in Figure 7.

Use a long screw driver in order to align the oil
pump drive shaft to the drive tab of the distribu-
tor.

Guide the distributor into the engine. See Fig-
ure 21.

Ensure the flat portion of the distributor housing
is facing toward the front of the engine.

Once the distributor is fully seated, the rotor seg-
ment should be aligned with the pointer cast into
the distributor base. See Figure 23.

Figure 23. Rotor Segment in Distributor Base

If the rotor segment does not come within a few
degrees of the pointer, repeat the procedure in
order to achieve the proper alignment.

CAUTION

Late model engines use a combination of stan-
dard and metric fasteners.

The components

Install the distributor mounting clamp bolt.
Tighten the bolt to 25 N•m (18 lbf ft). See Fig-
ure 20.

Install the distributor cap.

Install the new distributor cap screws. Tighten
the screws to 2.4 N•m (21 lbf in). See Figure 17.

10. Install the electrical connector to the distributor.

11. Install the spark plug wires to the distributor

cap.

12. Install the ignition coil wire. Note the correct

orientation of the wire boot. See Figure 16.

CAUTION

If the malfunction indicator lamp illuminates
after installing the distributor and DTC P1345
is set, the distributor has been installed incor-
rectly.

13. Repeat Install Procedure 2 if the malfunction in-

dicator lamp illuminates after installing the dis-
tributor.

14. Install the engine cover. Refer to the Frame sec-

tion for your lift truck.

2200 SRM 1097

Ignition Coil Replacement

REMOVE

Remove the engine cover. Refer to the Frame
section for your lift truck.

Disconnect the electrical connectors.

Remove the ignition coil wire to the distributor.
See Figure 24.

Remove the studs holding the bracket and the ig-
nition coil to the intake manifold. See Figure 25.

Remove the bracket and the ignition coil.

Drill and punch out the two rivets holding the
ignition coil to the bracket.

Remove the ignition coil from the bracket.

INSTALL

NOTE: A replacement ignition coil kit comes with
2 screws in order to attach the ignition coil to the
bracket.

Install the ignition coil to the bracket with the 2
screws.

CAUTION

Late model engines use a combination of stan-
dard and metric fasteners.

The components

Install the ignition coil and the bracket to the
intake manifold with studs. Tighten the studs
to 11 N•m (97 lbf in). See Figure 25.

Install the ignition coil wire. See Figure 24.

The wire must not touch anything like the dip-
stick. Rubbing will make a ground or short after
time of use.

Install the electrical connectors.

Install the engine cover. Refer to the Frame sec-
tion for your lift truck.

Figure 24. Ignition Coil Wire

Figure 25. Ignition Coil

Camshaft Position (CMP) Sensor Replacement

2200 SRM 1097

Ignition Control Module Replacement

REMOVE

Remove the engine cover. Refer to the Frame
section for your lift truck.

Disconnect the electrical connector.

See Fig-

ure 26.

Remove the screws holding the ignition control
module and the heat sink to the bracket.

Remove the ignition control module and the heat
sink.

INSTALL

CAUTION

Late model engines use a combination of stan-
dard and metric fasteners.

The components

Install the ignition control module and the heat
sink on the bracket with the screws. Tighten the
screws to 3.5 N•m (31 lbf in). See Figure 26.

Reconnect the electrical connectors.

Install the engine cover. Refer to the Frame sec-
tion for your lift truck.

HEAT SINK

IGNITION CONTROL MODULE

ELECTRICAL CONNECTOR

SCREW

Figure 26. Ignition Control Module Assembly

Camshaft Position (CMP) Sensor Replacement

REMOVE

Disconnect the spark plug wires and ignition coil
wire from the distributor. Refer to Spark Plug
Wire Replacement and Figure 27.

Disconnect the camshaft position (CMP) sensor
harness connector from the distributor. See Fig-
ure 28.

Remove the capscrews retaining the distributor
cap. Remove the distributor cap. See Figure 29.

Remove the rotor retaining screws.

See Fig-

ure 30.

Remove the rotor. See Figure 31.

Align the square slot in the reluctor wheel with
the CMP sensor. See Figure 32.

Figure 27. Distributor Cap and Spark Plug

Wires

2200 SRM 1097

Camshaft Position (CMP) Sensor Replacement

Figure 28. Camshaft Position (CMP) Wire

Harness

Figure 29. Distributor Cap Remove/Install

Figure 30. Rotor Retaining Screws

Figure 31. Rotor Remove/Install

Figure 32. Camshaft Position (CMP) Sensor

and Reluctor Wheel Alignment

Crankshaft Position (CKP) Sensor Replacement

2200 SRM 1097

Remove the CMP retaining screws. Remove the
CMP. See Figure 33.

INSTALL

CAUTION

Do not use the old cap, CMP sensor, and rotor
screws. Use the replacement screws that have
been coated with a thread locking compound.

Insert the CMP sensor through the reluctor
wheel slot. See Figure 33.

Install new CMP mounting screws and tighten to
2.2 N•m (19 lbf in). See Figure 33.

Install the rotor onto the reluctor wheel. See Fig-
ure 31.

Install new rotor retaining screws and tighten to
2 N•m (18 lbf in). See Figure 30.

Install the distributor cap and new distributor
capscrews. See Figure 29.

Connect the CMP sensor harness connector. See
Figure 28.

Connect the spark plug wires and ignition coil
wire. Refer to Spark Plug Wire Replacement and
Figure 27.

Figure 33. Camshaft Position Sensor

Remove/Install

Crankshaft Position (CKP) Sensor Replacement

REMOVE

Disconnect the crankshaft position (CKP) sensor
harness connector. See Figure 34.

Remove the CKP sensor mounting bolt. See Fig-
ure 35.

Remove the CKP sensor. See Figure 36.

INSTALL

CAUTION

When installing the CKP sensor, make sure
the sensor is fully seated before tightening the
mounting bolt.

A poorly seated CKP sensor

may perform erratically and may set false
DTCs.

NOTE: Do not reuse the original O-ring.

Replace the CKP sensor O-ring.

Figure 34. Crankshaft Position (CKP) Sensor

Harness

2200 SRM 1097

Crankshaft Position (CKP) Sensor Replacement

Lubricate the O-ring with clean engine oil before
installing the CKP sensor.

NOTE: Make sure the CKP sensor mounting surface
is clean and free of burrs.

Install the CKP sensor. See Figure 36.

CAUTION

Late model engines use a combination of stan-
dard and metric fasteners.

The components

Install the CKP sensor mounting bolt and
tighten the CKP sensor mounting bolt to 9 N•m
(80 lbf in). See Figure 35.

Connect the CKP sensor harness connector. See
Figure 34.

Figure 35. Crankshaft Position (CKP) Sensor

Mounting Bolt

Figure 36. Crankshaft Position (CKP) Sensor

Remove/Install

Wire Harness Repair

2200 SRM 1097

Wire Harness Repair

ON VEHICLE SERVICE WIRING HARNESS
REPAIR

NOTE: The most common fault that occurs in an
electronic engine control system is caused by a bad
connection in the wiring. Work carefully and make
sure that connectors are not damaged during trou-
bleshooting.

The ECM wire harness electrically connects the ECM
to solenoids, switches, and sensors in the engine and
passenger compartment. A wiring harness must be
replaced with a wire harness that has the same part
number. If a repair (wire splice) must be made to a
wiring harness, replacement wire must have a high-
temperature insulation.

The signal wires in the electronic control system have
a low voltage and low current. All splice wires must
be high quality so that a fault is not made in the cir-
cuit by the wire splice. Use solder on the wire splices
when possible. See Figure 37.

SPLICE AND SOLDER

Figure 37. Splice and Solder

Some connectors are made as a one-piece unit. A
damaged one-piece connector must be replaced with
a wire splice into the wiring harness. Some connec-
tors can be replaced or a terminal within the connec-
tors can be replaced. These connectors are described
in the paragraphs under Connectors and Terminals.

CONNECTORS AND TERMINALS

CAUTION

Use care when probing a connector or replac-
ing terminals in them. It is possible to short
between opposite terminals. If this happens to
the wrong terminal pair, it is possible to dam-
age certain components. Always use jumper
wires between connectors for circuit checking.
NEVER probe through the Weather-Pack seals.

Be careful when using a probe to check the voltages
on the terminals in a connector. It is easy to cause
a short circuit between two terminals with opposite
voltages. Electronic components can be easily dam-
aged by a short circuit. Always use a Jumper With
A 15 Amp Fuse between connectors when check-
ing circuits. Never damage the insulation or a seal
on a connector when making a check or doing trou-
bleshooting. The Connector Test Adapter Kit has
a variation of adapters and connectors that can be
used when troubleshooting a circuit.

When Troubleshooting, open circuits are often diffi-
cult to see because of dirt, corrosion, or a terminal
that is not in alignment in its socket. When Trou-
bleshooting for an open circuit, always check for loose
connections and a terminal that can have corrosion.
A fault that is not regular nor constant can also be
caused by a loose connection or a terminal that has
corrosion.

Always verify the type of connector to be repaired.
Some smaller models of connectors look similar but
have a different construction.

2200 SRM 1097

Wire Harness Repair

Twisted/Shielded Cable Repair

STEP 1.
Remove outer jacket.

STEP 2.
Unwrap aluminum mylar tape. Do not remove mylar
tape.

DRAIN WIRE

OUTER JACKET

MYLAR

STEP 3.
Untwist conductors and strip insulation as necessary.

STEP 4.
Splice wires using splice clips and rosin core solder.
Wrap each splice to insulate.

STEP 5.
Wrap with mylar and drain (uninsulated) wire.

DRAIN WIRE

STEP 6.
Tape over whole bundle to secure.

Wire Harness Repair

2200 SRM 1097

Twisted Leads Repair

STEP 1.
Locate damaged wire and remove insulation as re-
quired.

STEP 2.
Splice the two wires together using splice clips and
rosin core solder. See Figure 37.

SPLICE AND SOLDER

STEP 3.
Cover splice with tape to insulate from other wires.

STEP 4.
Twist and tape with electrical tape.

Figure 38. Micro-Pack Connector

Legend for Figure 38

CABLE

TERMINAL

LOCKING TAB

HYSTER TOOL KIT HYS1004

Micro-Pack

The Micro-Pack connector is shown in Figure 38.
This connector is normally used to connect the wire
harness to the ECM.

Metri-Pack

Some connectors use terminals called Metri-Pack Se-
ries 150. See Weather-Pack Terminal Repair. These
may be used at the coolant sensor, as well as TBI
units.

2200 SRM 1097

Wire Harness Repair

They are also called pull-to-seat terminals because to
install a terminal on a wire, the wire is first inserted
through the seal and connector. The terminal is then
crimped on the wire and the terminal pulled back
into the connector to seat it in place.

Remove

Slide the seal back on the wire.

Hold the wire and use it to push the terminal to
its forward position in the connector body. Hold
the terminal in this position. See Figure 39.

Find the lock tab for the terminal in the connec-
tor channel. Push a removal tool (pick) of the
correct size into the connector channel. See Fig-
ure 40 and Figure 41.

Use the removal tool to move the lock tab to re-
lease the terminal from its seat.

Push-to-Seat - Gently pull the wire to remove
the terminal from the back of the connector.

Pull-to-Seat - Gently push the wire to remove
the terminal through the front of the connector.
See Figure 42.

CAUTION

Work carefully and do not use enough force to
damage the terminal or the connector.

Inspect the terminal and connector for damage.
See Figure 43.

FEMALE TERMINAL

LOCKING TAB

HYSTER TOOL KIT HYS1004

CONNECTOR BODY

SEAL

Figure 39. Metri-Pack Terminal Removal

TOOL (PICK)

LOCK TAB

TERMINAL

CONNECTOR
BODY

Figure 40. Metri-Pack Push-to-Seat Connector

TOOL (PICK)

LOCK TAB

TERMINAL

CONNECTOR
BODY

Figure 41. Metri-Pack Pull-to-Seat Connector

Wire Harness Repair

2200 SRM 1097

TERMINAL

LOCK TAB

HYSTER TOOL KIT HYS1004

CONNECTOR BODY

SEAL

Figure 42. Metri-Pack Pull-to-Seat Terminal

Removal

Figure 43. Metri-Pack Terminal Inspection

Legend for Figure 43

NOTE: THE GREATER DISTANCE D, A FAULT CAN
OCCUR IN THE CONNECTION.

CONTACT TAB

NOTE: If reusing the terminal, reshape the locking
tab.

If the terminal will be used again, make sure the
lock tab is correctly bent so that the terminal will
be locked in the connector again.

Push the terminal into the connector channel.
Make sure that the lock tab correctly locks the
terminal in position.

Push the seals into their position and install any
secondary locks.

Weather-Pack

A Weather-Pack connector can be identified by a rub-
ber seal at the rear of the connector. This connector,
which is used in the engine compartment, protects
against moisture and dirt, which could create oxida-
tion and deposits on the terminals. This protection
is important because of the very low voltage and cur-
rent levels found in the electronic system.

Repair of a Weather-Pack terminal is shown in
Weather-Pack Terminal Repair. Use Hyster tool kit
HYS1004 to remove the pin and sleeve terminals.

If removal is attempted with an ordinary pick, there
is a good chance that the terminal will be bent or de-
formed. Unlike standard blade-type terminals, these
terminals cannot be straightened once they are bent.

Make certain that the connectors are properly seated
and all of the sealing rings are in place when connect-
ing leads. The hinge-type flap provides a backup or
secondary locking feature for the connector. They are
used to improve the connector reliability by retaining
the terminals if the small terminal lock tabs are not
positioned properly.

Weather-Pack connections cannot be replaced with
standard connections.

Instructions are provided

with Weather-Pack connector and terminal pack-
ages.

2200 SRM 1097

Wire Harness Repair

Weather-Pack Terminal Repair

STEP 1.
Open secondary lock hinge on connector.

FEMALE CONNECTOR

MALE CONNECTOR

SECONDARY LOCK HINGE

STEP 2.
Remove terminal using tool.

TERMINAL

TOOL

STEP 3.
Cut wire immediately behind cable seal.

WIRE

SEAL

STEP 4.
Replace terminal.

a. Slip new seal onto wire.

b. Strip 5 mm (0.2 in.) of insulation from wire.

Crimp terminal over wire and seal.

STEP 5.
Push terminal and connector onto wire and engage locking tabs.

Specifications and Special Tools

2200 SRM 1097

STEP 6.
Close secondary lock hinge.

SEAL

Specifications and Special Tools

Table 1. Ignition System Specifications

Specification

Application

Metric

English

Firing Order

1-6-5-4-3-2

Spark Plug Wire Resistance

1,000 ohms per ft

Spark Plug Torque

15 N•m

11 lbf ft

Spark Plug Gap

0.89 mm

0.035 in.

Spark Plug Type

R42LTS (AC plug type)

Table 2. Fastener Tightening Specifications

Specification

Application

Metric

English

Distributor Cap Screws

2.4 N•m

21 lbf in

Distributor Mounting Clamp Bolt

25 N•m

18 lbf ft

Distributor Rotor Retaining Screws

1.9 N•m

17 lbf in

Ignition Coil Bracket Stud

11 N•m

97 lbf in

Ignition Coil Mounting Screws

11 N•m

97 lbf in

Ignition Module Mounting Screws

3.5 N•m

31 lbf in

Spark Plug-New Iron Head

30 N•m

22 lbf ft

Spark Plug-Used Head

15 N•m

11 lbf ft

2200 SRM 1097

Specifications and Special Tools

Table 3. Special Tools

Illustration

Tool Number/Description

OTC Part No. 7230 Spark Tester

OTC Part No. KMJ35616A Connector

Test Adapter Kit

Tool Kit for Terminal Repair

Terminals cannot be removed from their connectors

nor repaired without special tools. This kit

has the special removal and installation tools

and crimping tools required to make repairs

in Micro-Pack, Metri-Pack, and Weather-Pack

connectors. This repair kit does not have the

terminals nor the connectors.

System Diagnosis

2200 SRM 1097

System Diagnosis

Table 4. Distributor Ignition (DI)

Step

Action

Value(s)

Yes

Did you perform the On-Board
Diagnostic Check - Engine Controls?

–

Go to Step 2

Electronic Control

Module (ECM)

Diagnostic

Troubleshooting

GM 3.0L and 4.3L

EPA Compliant

Engines 2200 SRM

1090

Crank the engine

Observe the Engine Speed parameter
with the SCAN Tool.

Does the SCAN Tool display RPM?

–

Go to Step 3

Go to Step 19

Inspect the spark plug wires for open
circuits, cracks, or improper seating
of terminals at the spark plugs, dis-
tributor, and ignition coil before pro-
ceeding with the test.

Inspect the spark at the plug with
the J26792 Spark Tester or equiva-
lent while cranking. If there is no
spark on one wire, check a second
wire. A few sparks then nothing is
considered no spark.

Does spark occur on all cylinders?

–

Go to

Intermittent

Conditions

Go to Step 4

Remove the coil wire from the distrib-
utor cap.

Insert the J 26792 into coil wire and
clamp the tester onto a ground.

Crank the engine.

Does spark occur?

–

Go to Step 13

Go to Step 5

Measure the coil wire resistance.

Does the resistance measure
approximately the specified value?

1,000

/ft

Go to Step 6

Go to Step 32

Disconnect the ignition coil harness
connector.

Probe the harness ignition coil driver
circuit with a test lamp connected to
battery positive voltage.

Crank the engine.

Does the test lamp flash while cranking
the engine?

–

Go to Step 8

Go to Step 7

2200 SRM 1097

System Diagnosis

Table 4. Distributor Ignition (DI) (Continued)

Step

Action

Value(s)

Yes

Turn OFF the ignition.

Probe the harness ignition coil driver
circuit with a test lamp connected to
battery positive voltage.

Does the test lamp illuminate?

–

Go to Step 29

Go to Step 9

Turn ON the ignition, with the en-
gine OFF.

Measure the coil ignition 1 voltage
with a DMM connected to a ground.

Does the voltage measure above the
specified value?

10 V

Go to Step 22

Go to Step 18

Turn OFF the ignition.

Inspect for an open or short to voltage
between the ignition coil and the IC
module.

Did you find the condition?

–

Go to Step 28

Go to Step 10

Turn ON the ignition, with the en-
gine OFF.

Measure the ignition 1 voltage at the
IC module harness connector with a
DMM connected to a ground.

Does the voltage measure above the
specified value?

10 V

Go to Step 11

Go to Step 20

Probe the IC module harness connector
ground circuit with a test lamp connected
to battery positive voltage.

Does the test lamp illuminate?

–

Go to Step 12

Go to Step 24

Probe the IC timing control circuit
with a DMM set to the AC scale con-
nected to a ground.

Crank the engine.

Observe the voltage while the engine
is being cranked.

Does the voltage measure within the
specified values?

1-4 V

Go to Step 21

Go to Step 15

System Diagnosis

2200 SRM 1097

Table 4. Distributor Ignition (DI) (Continued)

Step

Action

Value(s)

Yes

Remove the distributor cap.

Inspect the cap for the following con-
ditions:
• Cracks
• Moisture
• Carbon tracks
• Physical damage

For more in-depth procedures, refer
to Distributor Repair, Inspect.

Did you find any of these conditions?

–

Go to Step 34

Go to Step 14

Crank the engine.

Observe the distributor rotor while
the engine is being cranked.

Did the distributor rotor turn?

–

Go to Step 33

Refer to Engine

repair section for

your lift truck

Turn OFF the ignition.

Disconnect the PCM.

Inspect the ignition timing control
circuit for an open between the PCM
and the IC module.

Did you find the condition?

–

Go to Step 25

Go to Step 16

Probe the ignition timing control circuit
at the ECM with a test lamp connected
to battery voltage.

Does the test lamp illuminate?

–

Go to Step 26

Go to Step 17

Turn ON the ignition with the engine
OFF.

Probe the ignition timing control cir-
cuit at the ECM with a test lamp con-
nected to a ground.

Does the test lamp illuminate?

–

Go to Step 27

Go to Step 23

Inspect for an open or short to ground
ignition 1 voltage circuit at the igni-
tion coil.

Repair as necessary. Refer to Wire
Harness Repair.

Did you complete the repair?

–

Go to Step 37

–

2200 SRM 1097

System Diagnosis

Table 4. Distributor Ignition (DI) (Continued)

Step

Action

Value(s)

Yes

Inspect for a short to ground on the
CKP 5-volt reference circuit.

Repair as necessary. Refer to Wire
Harness Repair.

Did you find and correct the condition?

–

Go to Step 37

Go to Step 36

Inspect for an open or a short to
ground on the ignition 1 voltage cir-
cuit at the IC module.

Repair as necessary. Refer to Wire
Harness Repair.

Did you complete the repair?

–

Go to Step 37

–

Inspect for a poor IC module connection.

Did you find a problem?

–

Go to Step 30

Go to Step 35

Inspect for a poor coil connection.

Did you find a problem?

–

Go to Step 30

Go to Step 31

Inspect for a poor ECM connection.

Did you find a problem?

–

Go to Step 30

Go to Step 36

Repair the open IC module ground
circuit. Refer to Wire Harness Repair.

Did you complete the repair?

–

Go to Step 37

–

Repair the open ignition timing control
circuit. Refer to Wire Harness Repair.

Did you complete the repair?

–

Go to Step 37

–

Repair the grounded ignition timing
control circuit. Refer to Wire Harness
Repair.

Did you complete the repair?

–

Go to Step 37

–

Repair the short to voltage in the ignition
timing control circuit. Refer to Wire
Harness Repair.

Did you complete the repair?

–

Go to Step 37

–

System Diagnosis

2200 SRM 1097

Table 4. Distributor Ignition (DI) (Continued)

Step

Action

Value(s)

Yes

Repair the open or short to voltage in the
coil driver circuit between the ignition
coil and the IC module. Refer to Wire
Harness Repair.

Did you complete the repair?

–

Go to Step 37

–

Repair the short to ground in the coil
driver circuit between the ignition
coil and the IC module. Refer to Wire
Harness Repair.

Did you complete the repair?

–

Go to Step 37

–

Repair the circuit as necessary. Refer to
Wire Harness Repair.

Did you complete the repair?

–

Go to Step 37

–

Replace the ignition coil. Refer to
Ignition Coil Replacement.

Did you complete the replacement?

–

Go to Step 37

–

Replace the coil wire. Spark Plug Wire
Replacement.

Did you complete the replacement?

–

Go to Step 37

–

Replace the distributor rotor. Distributor
Repair, Overhaul.

Did you complete the replacement?

–

Go to Step 37

–

Replace the distributor cap.

Did you complete the replacement?

–

Go to Step 37

–

Replace the IC module. Refer to Ignition
Control Module Replacement.

Did you complete the replacement?

–

Go to Step 37

–

Replace the ECM.

Did you complete the replacement?

–

Go to Step 37

–

Operate the vehicle within the conditions
under which the original symptom was
noted.

Does the system now operate properly?

–

System OK

Go to Step 1

TECHNICAL PUBLICATIONS

2200 SRM 1097

10/04 (12/03) Printed in United Kingdom

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