Kubota WG1605-E3 Diagnostic Manual
DIAGNOSIS
KiSC issued 12, 2016 A
MANUAL
ECM SYSTEM
WG1605-E3
Record of Revisions
KiSC issued 12, 2016 A
For pdf, use search function {Search word} to find all the revised locations.
Last digit
of the
Code No.
Issue
month
Main Revised Point and Corrective Measures {Search word}
1 2014.05 Added the models
(WG1605-N-E3, WG1605-LN-E3, WG1605-GLN-E3)
2 2016.05 Updated the DTC(s) –
3 2016.11 Added diagnostic procedure of DTC 87, 88
Correction the value of DTC list and Diagnostic procedure
Reference
Page
–
–
I INFORMATION
KiSC issued 12, 2016 A
INFORMATION
KiSC issued 12, 2016 A
CONTENTS
1. SAFETY FIRST .............................................................................................................................. I-1
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
SAFETY FIRST
DANGER
WARNING
CAUTION
IMPORTANT
NOTE
KiSC issued 12, 2016 A
INFORMATION
1. SAFETY FIRST
• This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the
machine itself to warn of the possibility of personal injury. Read these instructions carefully.
• It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
• Indicates that equipment or property damage could result if instructions are not followed.
• Gives helpful information.
BEFORE SERVICING AND REPAIRING
• Read all instructions and safety instructions in this
manual and on your machine safety decals.
• Clean the work area and machine.
• Park the machine on a firm and level ground.
• Allow the engine to cool before proceeding.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a "DO NOT OPERATE"tag in operator station.
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Unauthorized modifications to the engine may impair
the function and / or safety and affect engine life.
I-1
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
INFORMATION
SAFETY WORKING
• Do not work on the machine while under the
influence of alcohol, medication, or other substances
or while fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not touch the rotating or hot parts while the
engine is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise,
hot water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic or
fuel lines. Tighten all connections before applying
pressure.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
• Do not open high-pressure fuel system.
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt to repair
fuel lines, sensors, or any other components
between the high-pressure fuel pump and injectors
on engines with high pressure common rail fuel
system.
• High voltage exceeding 100 V is generated in the
ECM and injector.
Pay sufficient caution to electric shock when
performing work activities.
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the
engine.
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WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
INFORMATION
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains
poisonous carbon monoxide.
PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
DISPOSE OF FLUIDS PROPERLY
• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when
disposing of oil, fuel, coolant, electrolyte and other
harmful waste.
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
I-3
1 ECM SYSTEM
KiSC issued 12, 2016 A
SERVICING
KiSC issued 12, 2016 A
CONTENTS
1. OUTLINE ....................................................................................................................................... 1-1
[1] OVERALL DIAGONOSTIC PROCEDURE .............................................................................. 1-1
[2] QUESTIONING ....................................................................................................................... 1-2
[3] ABBREVIATIONS.................................................................................................................... 1-5
2. SYMPTOM CHARTS BY COMPONENTS .................................................................................... 1-9
[1] GASOLINE SYMPTOM CHARTS ........................................................................................... 1-9
[2] LPG / NATURAL GAS SYMPTOM CHARTS ........................................................................ 1-18
3. SET UP AND PROCEDURE DIAGNOSTIC TOOL ..................................................................... 1-28
[1] DIAGNOSTIC CONNECTOR POSITION .............................................................................. 1-28
[2] DIAGNOSTIC TOOL CONNECTION PROCEDURE ............................................................ 1-29
[3] SET UP AND PROCEDURE ................................................................................................. 1-30
(1) Overview.......................................................................................................................... 1-30
(2) Using the GCP Diagnostic Display Tool .......................................................................... 1-30
[4] DIAGNOSTIC TESTS............................................................................................................ 1-38
4. BASIC SYSTEM INFORMATION ................................................................................................ 1-42
[1] FUEL SYSTEM...................................................................................................................... 1-42
[2] Electrical System ................................................................................................................... 1-59
(1) System Wiring Diagram................................................................................................... 1-60
(2) ECU Terminal Layout ...................................................................................................... 1-72
(3) Connector Views ............................................................................................................. 1-74
(4) Repair of Wiring Harness ................................................................................................ 1-86
5. DIAGNOSIS................................................................................................................................. 1-89
[1] FUEL SYSTEM CHECKS...................................................................................................... 1-89
[2] FUEL SYSTEM DIAGNOSIS................................................................................................. 1-93
(1) Restricted Exhaust System Diagnosis........................................................................... 1-101
[3] DTC LIST............................................................................................................................. 1-102
[4] Diagnosis Procedure by DTC .............................................................................................. 1-123
(1) Crank/Cam Sensors (DTC 16, 336, 337, 341, 342) ...................................................... 1-123
(2) FP (Fuel Pressure Sensor) (DTC 87, 88, 91, 92) .......................................................... 1-130
(3) MAP (Manifold Absolute Pressure Sensor) (DTC 107, 108) ......................................... 1-136
(4) IAT (Intake Air Temperature Sensor) (DTC 111, 112, 113, 127, 129)........................... 1-139
(5) ECT (Engine Coolant Temperature) (DTC 116, 117, 118, 217) .................................... 1-144
(6) TPS (Throttle Position Sensor) (DTC 121 to 123, 221 to 223, 2111, 2112, 2135) ........ 1-149
(7) EGO Sensors ((Exhaust Gas Oxygen) Sensors) (DTC 134, 154)................................. 1-160
(8) Adaptive Learn (DTC 171, 172, 1161 to 1164).............................................................. 1-164
(9) Fuel Temp (Fuel Temperature Sensor) (DTC 182, 183, 187) ....................................... 1-169
(10)Engine Speed (DTC 219, 1111, 1112) .......................................................................... 1-174
(11)Injectors (DTC 261, 262, 264, 265, 267, 268, 270, 271) ............................................... 1-176
(12)Knock Sensor (DTC 326, 327) ...................................................................................... 1-179
(13)Catalyst Monitor (DTC 420, 1165, 1166) ...................................................................... 1-182
(14)Oil Pressure Sensor (DTC 524) .................................................................................... 1-183
(15)Battery Voltage (DTC 562, 563) .................................................................................... 1-185
(16)Internal Processor Diagnostics (DTC 601, 604, 606, 1612 to 1616, 1673)................... 1-188
(17)Fuel Pump Relay Control/Coil (DTC 627 to 629) .......................................................... 1-199
(18)5 V External (DTC 642, 643, 652, 653, 1611) ............................................................... 1-204
(19)Power Relay Control / Coil (DTC 686, 687) .................................................................. 1-209
(20)Closed Loop (DTC 1151 to 1156) ................................................................................. 1-212
(21)EPR (HD EPR) or CFV (DTC 1171 to 1177)................................................................. 1-215
(22)FPP (Foot Pedal Position Switch) (DTC 1121, 2121, 2126, 2122, 2123, 2127, 2128) . 1-220
(23)Spark Coil Primary (DTC 2300, 2301, 2303, 2304, 2306, 2307, 2309, 2310)............... 1-228
KiSC issued 12, 2016 A
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
1. OUTLINE
[1] OVERALL DIAGONOSTIC PROCEDURE
ECM SYSTEM
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WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
ECM SYSTEM
[2] QUESTIONING
• Use the trouble check sheet to ensure that the customer's explanation is fully understood.
• Accurately judge information concerning the malfunction.
Grasp the situation firmly, using five 5W1H (Who, What, When, Where, Why, How) as a basis.
Ex: Low ambient temperature, starting, normal conditions, proximity to engine, metallic noise, etc.
(Reference)
Do not ask random questions. Ask questions that will aid in narrowing down the possible malfunctioning system
while making educated guesses based on the malfunction symptoms.
Questioning Points
What? Malfunction symptom
When? Date, time, frequency of occurrence.
Where? Field conditions
What were conditions like at the time of
malfunction?
What happened? Type of malfunction.
Driving conditions, operating conditions,
weather.
Trouble Check Sheet for WG Engines
When the machine is received from the customer, it is
necessary to verify the "malfunction symptoms" and the "generated
malfunction data" with the customer. This is performed based on the
trouble check sheet.
(1) Trouble Check Sheet
Because:
• The malfunction symptom may not be reproduced at the
workshop.
• The customer's complaint does not always match the
malfunction.
• If the person performing repairs is not working from the correct
malfunction symptoms, man-hours will be wasted.
The question chart can aid the service person in diagnosing,
repairing and verifying repair work.
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KiSC issued 12, 2016 A
Trouble Check Sheet for WG Engines
Machine details
Customer name
Customer
address
Machine model
Engine serial
number
Repair date
Machine serial
number
Purchase date
Hourmeter
indicator
Warranty
Warranty Judgment Yes No
Injector Ignition Coil
Defective parts
Fuel Filter
Others ( )
Replace parts details
Quantity Units Part number
Cylinder 1 ( ) Cylinder 2 ( )
Cylinder 3 ( ) Cylinder 4 ( )
Injector 1 Injector 2
Injector 3 Injector 4
Injector
Actual part replacement
Serial number
Defective injector
Injector Ignition Coil
Fuel Filter
ECM Others ( )
Customer complaint
1. Engine no start
2. Difficult to start
3. Poor idling
4. Poor driveability
5. Abnormal smoke
6. Fuel leakage
7. Engine not stop
8. Engine stall
9. Others
a. No initial combustion b. No complete combustion
c. No cranking
a. Engine crank slowly
b. Others ( )
a. Incorrect first idle b. Noise
c. Hunting idle from ( ) to ( ) min
d. High idling ( ) min
e. Low idling ( ) min
f. Rough
g. Others ( )
a. Hesitation b. Surging
c. Knocking d. Lack of power
e. Others ( )
a. Black b. White
c. Others ( )
a. Large quantity b. Blurred
Leaking from:
-1
(rpm)
-1
(rpm)
Injector Ignition Coil
Others ( )
-1
(rpm)
ECM SYSTEM
hours
1-3
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
Condition when problem occurs (Duplicated answers can be possible)
a. Fine b. Cloudy
1. Weather
2. Outdoor temperature Approx. °C ( °F)
3. Altitude Approx. m
4. Engine coolant
5. Engine operation
6. Problem frequency
7. Engine warning light Turn on a light Turn off a light
8. Optional parts
c. Rainy d. Snow
e. Flood
f. Others ( )
a. Cold Write the position of the indicator on coolant
b. Warming up
c. After warming up
d. Any temperature
e. Others ( )
a. Starting b. Just after starting
c. Idling d. Racing
e. Acceleration f. Deceleration
g. While at work
h. Others ( )
a. Constant b. Once only
c. Sometime ( Time per day/month)
Fill the parts in if you use optional parts or non-genuine parts for electrical, intake/exhaust and fuel system.
( )
temperature gauge.
Dealer check
1. Duplicate the problem a. Yes (Duplicate) b. No (Not occur)
2. Diagnosis trouble code
3. Appearance
4. Fuel condition
a. Abnormal (What is code )
b. Normal (No code)
a. Normal b. Cracked
c. Discolored
d. Others ( )
a. Normal
b. Abnormal ( )
ECM SYSTEM
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KiSC issued 12, 2016 A
[3] ABBREVIATIONS
ACRONYM DEFINITION
AC Alternating Current
AF Air Fuel Ratio
AL Adaptive Learn
ATC After Top Center
ATDC After Top Dead Center
AVV Ai r Va lve Va c u um
BARO Barometric Pressure
BAT Battery
BHP Brake Horse Power
BL Block Learn
BP Barometric Pressure
BTU British Thermal Unit
°C Celsius
CC Cubic Centimeter
CAC Charged Air Cooler
CAN Controller Area Network
CARB California Air Resources Board
CAT Catalyst
CCP CAN Calibration Protocol
CFM Cubic Feet Per Minute
CHT Cylinder Head Temperature
CID Cubic Inch Displacement
CKP Crankshaft Position Sensor
CL Closed Loop
CMP Camshaft Position Sensor
CNG Compressed Natural Gas
CO Carbon Monoxide
CO
2 Carbon Dioxide
CPP Clutch Pedal Position Sensor
CTP Closed Throttle Position
DBW Drive-By-Wire
DC Direct Current
DFCO Decel Fuel Cut Off
DFI Direct Fuel Injection
DLC Data Link Connector
DM Diagnostic Message
DMM Digital Multi-Meter (high impedance)
DST Diagnostic Scan Tool
DTC Diagnostic Trouble Code
DVOM Digital Voltage and Ohm Meter (high imp.)
ECIPP EControls Proprietary Protocol
ECM Engine Control Module
ECT Engine Coolant Temperature
EDIS EControls Display and Interface Software
EGO Exhaust Gas Oxygen Sensor
EGR Exhaust Gas Recirculation
EI Electronic Ignition
ECM SYSTEM
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WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
EMI Electromagnetic Interference
EMWT Exhaust Manifold Water Temperature
EOBD Euro Onboard Diagnostic
EPR Electronic Pressure Regulator
ERWT Exhaust Manifold Riser Temperature
ETB Electronic Throttle Body
ETC Electronic Throttle Control
EVAP Evaporative Emissions
°F Fahrenheit
FC Fan Control
FDR Flight Data Recorder
FF Flex Fuel
FMI Failure Mode Indicator
FO Firing Order
FP Fuel Pressure
FPM Fuel Pressure Module
FPP Foot Pedal Position
FRP Fuel Rail Pressure
FRT Fuel Rail Temperature
FSS Fault Snapshot
FT Fuel Temperature
FT Fuel Trim
ft. lb. Foot Pounds
FTP Federal Test Procedure
GCP Global Control Platform
GEN Generator
GND Ground
GPM Grams Per Mile
HC Hydrocarbon
HVS High Voltage Switch
HDGCP Heavy-Duty Global Control Platform (On-Road Heavy-Duty)
HEGO Heated Exhaust Gas Oxygen Sensor (same as HO
2S Heated Oxygen Sensor
HO
HO
2S1 Upstream Heated Oxygen Sensor (Pre CAT)
HO
2S2 Downstream or Downstream Heated Oxygen Sensor (Pre CAT)
HP Horsepower
IAC Idle Air Control
IAT Intake Air Temperature
IC Ignition Control Circuit
ICM Ignition Control Module
ICAV Instant Crank Angle Velocity
ID Inside Diameter
IFI Indirect Fuel Injection
IGN Ignition
IP Instrument Panel
IPC Instrument Panel Cluster
IVS Idle Validation Switch
kHz Kilohertz
Km Kilometers
ECM SYSTEM
ACRONYM DEFINITION
2S)
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WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
kPa Kilopascals
KPH Kilometers Per Hour
KOEC Key On Engine Cranking
KOEO Key On Engine Off
KOER Key On Engine Running
KS Knock Sensor
KV Kilovolt
L. Liter
lb.ft. Pound Feet
LDGCP Light-Duty Global Control Platform (Industrial, Smart/Logic Coil)
LED Light Emitting Diode
LPG Liquefied Propane Gas
LTFT Long Term Fuel Trim
MAF Mass Airflow Sensor
MAP Manifold Absolute Pressure
MDGCP Medium-Duty Global Control Platform (Industrial, Dumb Coil)
MDP Manifold Differential Pressure
mP Microprocessor
Mfg Manufacture
MIL Malfunction Indicator Lamp
mm Millimeters
ms Millisecond
mV Millivolt
MPG Miles Per Gallon
MPH Miles Per Hour
NG Natural Gas
Nm Newton Meters
O
2 Oxygen Sensor
OBD On-Board Diagnostics
OBD I On-Board Diagnostics generation one
OBD II On-Board Diagnostics generation two
OBD III On-Board Diagnostics generation three
OBD IV On-Board Diagnostics generation four
OC Oxidation Catalyst
OD Outside Diameter
OEM Original Equipment Manufacture
OHC Overhead Cam
OL Open Loop
PC Personal Computer
PCM Powertrain Control Module
PCU Powertrain Control Unit
PCV Positive Crankcase Ventilation
PFI Port Fuel Injection
PGN Parameter Group Number
PPM Parts Per Million
PSA Pressure Switch Assembly
psi Pounds Per Square Inch
PWM Pulse Width Modulated
RAM Random Access Memory
ECM SYSTEM
ACRONYM DEFINITION
1-7
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
ACRONYM DEFINITION
RFI Radio Frequency Interference
RPM Revolutions Per Minute
Rx Receive
SA Source Address
SFI Sequential Fuel Injection
SOHC Single Overhead Cam
SPFI Sequential Port Fuel Injection
SPN Suspect Parameter Number
SRI Service Reminder Indicator
SRT System Readiness Test
Tach Tachometer
TBI Throttle Body Injection
TDC Top Dead Center
TIP Throttle Inlet Pressure
TPS1 Throttle Position Sensor One
TPS2 Throttle Position Sensor Two
TSC Torque/Speed Control
TWC Threeway Catalyst
TWC+OC Threeway Catalyst + Oxidation Catalytic Converter
Tx Transmit
UEGO Universal Exhaust Gas Oxygen Sensor (also called wide-range EGO)
VBAT Battery Voltage
VDC Voltage, Direct Current
VIN Vehicle Identification Number
VR Variable Reluctance
VSS Vehicle Speed Sensor
Vsw Switched, Ignition Voltage
WGP Waste-Gate Pressure
WOT Wide Open Throttle
ECM SYSTEM
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WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
IMPORTANT
KiSC issued 12, 2016 A
2. SYMPTOM CHARTS BY COMPONENTS
[1] GASOLINE SYMPTOM CHARTS
Important Preliminary Checks
Checks Action
Before using this section you should have performed On Board Diagnostic Checks and determined
that:
• The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly.
Before Using This Section
Important Question to Ask the
Operator
Gasoline Fuel System Check
Visual and Physical Checks
• There are no Diagnostic Trouble Codes (DTCs) stored or a DTC exists but without a MIL.
Several of the following symptom procedures call for a careful visual and physical check. The visual
and physical checks are very important. The checks can lead to correcting a problem, without further
checks, that may save valuable time. Most importantly talk to the operator about the failure this may
provide important information about the fault.
• When and how did the operator first notice the fault condition
• What engine speed and load condition did the fault occur at
• Did the fault occur just after or before refueling
• Did the fault occur at start up or shut down
• Did the fault occur at a particular time of day or during the shift
• Did the fault occur in a particular location
• Has there been any recent repair to the engine or vehicle
• Has the fault ever occurred before
• Has there been any new external customer installed devices added to the vehicle and or engine
Verify the customer complaint.
Locate the correct symptoms table.
• Check the items indicated under that symptom.
• Operate the vehicle under the conditions the symptom occurs. Verify HEGO switching between
lean and rich.
• Normal HEGO switching indicates the Gasoline fuel system is in closed loop and operating
correctly at that time.
• If a scan tool is available take a snapshot under the condition that the symptom occurs. Go to
Engine Scan Tool Data. List to verify normal sensor values and parameters.
• Check all ECM system fuses and circuit breakers.
• Check the ECM ground for being clean, tight and in its proper location.
• Check the vacuum hoses for splits, kinks and proper connections.
• Check thoroughly for any type of fuel leak or restriction.
• Check for air leaks at all the mounting areas of the intake manifold sealing surfaces.
• Check for proper installation of the Throttle Body assembly.
• Check for fuel leaks at the fuel rail and injectors.
• Check the wiring for the following items:
– Proper connections, pinches or cuts.
• The following symptoms table contains groups of possible causes for each symptom. The order of
these procedures is not important. If the scan tool readings do not indicate the problems, then
proceed in a logical order easiest to check or most likely to cause first.
ECM SYSTEM
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WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
Intermittent
Checks Action
DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL), or store a Diagnostic Trouble Code (DTC).
• Refer to Important Preliminary Checks.
Preliminary Checks
Faulty Electrical Connections or
Wiring
Operational Test
Intermittent Malfunction Indicator
Lamp (MIL)
Loss of DTC Memory
• Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables may result in the
replacement of good parts.
• Faulty electrical connections or wiring can cause most intermittent problems.
• Check the suspected circuit for the following conditions:
– Check for faulty fuses or circuit breakers.
– Check for poorly mated electrical connectors.
– Check for connector pin and terminals not fully seated.
– Check for terminal pin damaged or deformation.
– Check poor soldering in the joints and connectors.
– Check for excessive wire strain on the harness.
– Check for burned or damaged wiring.
– Check for recently added customer installed electrical options which may be improperly spliced
into the harness assembly.
• Carefully remove all the connector terminals in the problem circuit in order to ensure the proper
contact tension. If necessary, replace all the connector terminals in the problem circuit in order to
ensure the proper contact tension.
• Checking for poor terminal to wire connections requires removing the terminal from the connector
body.
If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan
tool. When the problem occurs, an abnormal voltage or scan reading indicates the problem may be in
that circuit.
The following components can cause intermittent MIL and no DTC(s):
• A defective relay Control Module driven solenoid, or a switch that can cause electrical system
interference. Normally, the problem will occur when the faulty component is operating.
• The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
• The ignition secondary voltage, shorted to a ground.
• The Malfunction Indicator Lamp (MIL) circuit or the Diagnostic Test Terminal intermittently shorted
to ground.
• The Control Module grounds.
To check for the loss of the DTC Memory:
1. Disconnect the TMAP sensor.
2. Idle the engine until the Malfunction Indicator Lamp illuminates.
The ECM should store a TMAP DTC. The TMAP DTC should remain in the memory, when the ignition
is turned OFF. If the TMAP DTC does not store and remain, the ECM is faulty.
ECM SYSTEM
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WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
Checks Action
DEFINITION: The engine cranks OK but does not start.
Preliminary Checks • Refer to Important Preliminary Checks.
• Check the battery cranking voltage, voltage should not be less then 9.0 VDC.
Control Module Checks
Sensor Checks
Fuel System Checks
Ignition System Checks
Engine Mechanical Checks
Exhaust System Checks
• Check the inline fuse in the ECM battery power circuit. Refer to Engine Controls Schematics.
• Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control
Schematics. Verify voltage and/or continuity for each circuit.
• Check the TMAP sensor.
• Check the Camshaft position (CMP) and Crankshaft (CKP) position sensors.
• Check the Gasoline pressure sensor.
• Check for fuel pump electrical circuit.
• Verify proper fuel pump pressure.
• Verify proper Fuel rail pressure.
• Refer to the Gasoline Fuel System Diagnosis.
• Check Electrical connections at the injectors.
• Check for the proper primary side ignition voltage output.
• Verify that the spark plugs are correct.
• Check the spark plugs for the following conditions:
– Wet plugs
– Cracks
–Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Check for loose ignition coil connections at the coil.
• Check for the following:
– Vacuum leaks
– Improper valve timing
– Low compression
– Bent pushrods
– Worn rocker arms
– Broken or weak valve springs
– Worn camshaft lobes
• Check the exhaust system for a possible restriction:
– Inspect the exhaust system for damaged or collapsed pipes.
– Inspect the muffler for signs of heat distress, or for possible internal failure.
• Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis.
ECM SYSTEM
No Start
1-11
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
IMPORTANT
KiSC issued 12, 2016 A
Hard Start
Checks Action
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies.
Preliminary Checks
Sensor Checks
Fuel System Checks
Ignition System Checks
Engine Mechanical Checks
Exhaust System Checks
• Refer to Important Preliminary Checks.
• Make sure the vehicle’s operator is using the correct starting procedure.
• Check the Throttle position (TPS) sensor.
• Check the Camshaft position (CMP) and Crankshaft (CKP) position sensors.
• Check for fuel pump electrical circuit.
• Verify proper fuel pump pressure.
• Verify proper fuel rail pressure.
• Refer to the Gasoline Fuel System Diagnosis.
• Check Electrical connections at the injectors.
• Check for the proper ignition voltage output.
• Verify that the spark plugs are correct.
• Check the spark plugs for the following conditions:
– Wet plugs
–Cracks
– Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Check for loose ignition, coil connections.
1. If the engine starts but then immediately stalls. Check the Crankshaft Position (CKP)
sensor.
2. Check for improper gap, debris or faulty connections.
• Check for the following:
– Vacuum leaks
– Improper valve timing
– Low compression
– Bent pushrods
– Worn rocker arms
– Broken or weak valve springs
• Check the intake and exhaust manifolds, for casting flash.
• Check the exhaust system for a possible restriction:
– Inspect the exhaust system for damaged or collapsed pipes.
– Inspect the muffler for signs of heat distress, or for possible internal failure.
• Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis.
ECM SYSTEM
1-12
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
Cuts Out, Misses
Checks Action
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases, which is not normally felt
above 1500 RPM. The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the
engine to cut-out.
Preliminary Checks • Refer to Important Preliminary Checks.
• Start the engine.
• Wet down the secondary ignition system with water from a spray bottle and look/listen for arcing or
misfiring as you apply water.
• Check for proper ignition output voltage with spark tester.
• Check for a cylinder misfire.
• Verify that the spark plugs are correct.
Ignition System Checks
Engine Mechanical Checks
Fuel System Checks
Additional Check
• Remove the spark plugs in these cylinders and check for the following conditions:
– Insulation cracks
–Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Visually/Physically inspect the secondary ignition for the following:
– Ignition coil for cracks or carbon tracking.
• Perform a cylinder compression check.
• Check the engine for the following:
– Improper valve timing
– Bent pushrods
– Worn rocker arms
– Worn camshaft lobes.
– Broken or weak valve springs.
• Check the intake and exhaust manifold passages, for casting flash.
• Check the fuel system-plugged fuel filter, low fuel pressure, etc. Refer to Gasoline Fuel System
Diagnosis.
• Check the condition of the wiring to the fuel pump and injectors.
Check for Electromagnetic Interference (EMI).
• EMI on the reference circuit can cause a missing condition.
• Monitoring the engine RPM with a scan tool, can detect an EMI.
• A sudden increase in the RPM with little change in the actual engine RPM, indicates EMI is present.
• If the problem exists, check the routing of the secondary wires and the ground circuit.
ECM SYSTEM
Hesitation, Sag, Stumble
Checks Action
DEFINITION: The vehicle has a momentary lack of response, when depressing the accelerator. The condition can occur at any vehicle speed.
The condition may cause the engine to stall, if it’s severe enough.
Preliminary Checks Refer to Important Preliminary Checks.
• Check the fuel pump electrical circuit.
• Verify proper fuel pump pressure.
Fuel System Checks
Ignition System Checks
Additional Check
• Verify proper fuel rail pressure.
• Refer to the Gasoline Fuel System Diagnosis.
• Check Electrical connections at the injectors.
• Check for the proper ignition voltage output.
• Verify that the spark plugs are correct.
• Check for fouled spark plugs.
• Check for manifold vacuum or air induction system leaks.
• Check the generator output voltage.
1-13
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
Backfire
Checks Action
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. A backfire which is heard in the
intake manifold and air stream indicates that the fuel is being ignited in the intake manifold and is a result of a spark igniting the fuel air mixture.
A backfire heard in the exhaust system indicates that there is an over fueling condition or a late spark event which ignites unburned fuel in the
exhaust.
Preliminary Check • Refer to Important Preliminary Checks.
• Check for the proper ignition coil output voltage using a spark tester.
• Check the connection at each ignition coil.
• Check the spark plugs.
• Remove the plugs and inspect them for the following conditions:
Ignition System Checks
Engine Mechanical Check
Fuel System Checks • Perform a fuel system diagnosis. Refer to Gasoline Fuel System Diagnosis.
– Wet plugs
–Cracks
– Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Check the engine for the following:
– Improper valve timing
– Engine compression
– Manifold vacuum leaks
– Intake manifold gaskets
– Sticking or leaking valves
– Exhaust system leakage
• Check the intake and exhaust system for casting flash or other restrictions.
ECM SYSTEM
Lack of Power, Sluggishness, or Sponginess
Checks Action
DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator
pedal.
• Refer to Important Preliminary Checks.
• Refer to the Gasoline Fuel system OBD System Check.
Preliminary Checks
Fuel System Checks
Sensor Checks
Exhaust System Checks
Engine Mechanical Check
Additional Check
• Compare the customer’s vehicle with a similar unit. Make sure the customer has an actual problem.
• Remove the air filter and check for dirt or restriction.
• Check the vehicle transmission. Refer to the OEM transmission diagnostics.
• Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to Gasoline
Fuel System Diagnosis.
• Check for the proper ignition output voltage, with the spark tester.
• Check the fuel pump electrical circuit.
• Verify proper fuel pump pressure.
• Verify proper fuel rail pressure.
• Refer to the Gasoline Fuel System Diagnosis.
• Check electrical connections at the injectors.
• Check the Heated Exhaust Gas Oxygen Sensor (HEGO) for contamination and performance.
Check for proper operation of the MAP sensor.
• Check for proper operation of the TPS sensor.
• Check the exhaust system for a possible restriction:
– Inspect the exhaust system for damaged or collapsed pipes.
– Inspect the muffler for signs of heat distress or for possible internal failure.
– Check for possible plugged catalytic converter.
• Check the engine for the following:
– Engine compression
– Valve timing
– Improper or worn camshaft. Refer to Engine Mechanical.
• Check the ECM grounds for being clean, tight, and in their proper locations.
• Check the generator output voltage.
• If all procedures have been completed, and no malfunction has been found, review and inspect the
following items:
– Visually and physically inspect all electrical connections within the suspected circuit and/or
systems.
– Check the brake system for sticking or dragging brakes.
1-14
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
Poor Fuel Economy
Checks Action
DEFINITION: Fuel economy, as measured by refueling records is noticeably lower than expected. Also, the economy is noticeably lower, than
it was on this vehicle at one time as previously shown by refueling records.
• Refer to Important Preliminary Checks.
• Check the air cleaner element (filter) for dirt or being plugged.
• Visually (Physically) check the vacuum hoses for splits, kinks and proper connections.
• Check the operators driving habits for the following items:
Preliminary Checks
Fuel System Checks
Sensor Checks • Check the Temperature Manifold Absolute Pressure (TMAP) sensor.
Ignition System Checks
Cooling System Checks • Check the engine thermostat for always being open or for the wrong heat range.
Engine Mechanical Check
Additional Check
– Is there excessive idling or stop and go driving
– Are the tires at the correct air pressure
– Are excessively heavy loads being carried
– Is there often rapid acceleration
• Suggest to the owner to fill the fuel tank and to recheck the fuel economy.
• Suggest that a different operator use the equipment and record the results.
• Check the fuel Rail pressure. Refer to Gasoline Fuel System Diagnosis.
• Check the fuel system for leakage.
• Verify that the spark plugs are correct.
• Check the spark plugs. Remove the plugs and inspect them for the following conditions:
– Wet plugs
– Cracks
–Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Check the engine for the following:
– Engine compression
– Valve timing
– Improper or worn camshaft. Refer to Engine Mechanical, in the Service Manual.
• Check the transmission shift pattern. Refer to the OEM Transmission Controls section in their
Service Manual.
• Check for dragging brakes.
ECM SYSTEM
1-15
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
Rough, Unstable or Incorrect Idle or Stalling
Checks Action
DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPMs.
Either condition may be severe enough to stall the engine.
Preliminary Check • Refer to Important Preliminary Checks.
• Check for silicon contamination from fuel or improperly used sealant. The sensor will have a white
powdery coating. The sensor will result in a high but false, signal voltage (rich exhaust indication).
Sensor Checks
Fuel System Checks
Ignition System Checks
Additional Checks
Engine Mechanical Check
The ECM will reduce the amount of fuel delivered to the engine causing a severe drivability
problem.
• Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance.
• Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.
• Check for rich or lean symptoms that causes the condition. Drive the vehicle at the speed of the
complaint. Monitoring the oxygen sensors will help identify the problem.
• Verify proper operation of the injectors.
• Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual.
• Check the fuel Rail pressure. Refer to the Gasoline Fuel System Diagnosis.
• Check injector electrical connections.
• Check for the proper ignition output voltage using the spark tester.
• Verify that the spark plugs are correct.
• Check the spark plugs. Remove the plugs and inspect them for the following conditions:
– Wet plugs
–Cracks
– Wear
– Improper gap
– Burned electrodes
– Blistered insulators
– Heavy deposits
• Check the ECM grounds for being clean, tight and in their proper locations.
• Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may
cause all sensor readings to be skewed, resulting in poor idle quality.
• Check the engine for the following:
– Broken motor mounts
– Improper valve timing
– Low compression
– Bent pushrods
– Worn rocker arms
– Broken or weak valve springs
– Worn camshaft lobes
ECM SYSTEM
1-16
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
Surges/Chuggles
Checks Action
DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no
change in the accelerator pedal.
Preliminary Checks
Sensor Checks Check the Heated Exhaust Gas Oxygen Sensor (HEGO), performance.
Fuel System Checks
Ignition System Checks
Additional Check
• Refer to Important Preliminary Checks.
• Be sure the driver understands "the Torque Converter Clutch operation"
• Check for Rich or Lean symptom that causes the condition. Drive the vehicle at the speed of the
complaint. Monitoring the oxygen sensors will help identify the problem.
• Check the fuel rail pressure while the condition exists. Refer to Gasoline Fuel System Diagnosis.
• Verify check injector electrical connections.
• Check the in-line fuel filter for restrictions.
• Check for the proper ignition output voltage using the spark tester.
• Verify that the spark plugs are correct.
• Check the spark plugs. Remove the plugs and inspect them for the following conditions:
– Wet plugs
– Cracks
–Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Check the Crankshaft Position (CKP) sensor.
• Check the ECM grounds for being clean, tight and in their proper locations.
• Check the generator output voltage.
• Check the vacuum hoses for kinks or leaks.
• Check Transmission.
ECM SYSTEM
1-17
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
IMPORTANT
KiSC issued 12, 2016 A
[2] LPG / NATURAL GAS SYMPTOM CHARTS
Important Preliminary Checks
Checks Action
Before using this section, you should have performed On Board Diagnostic Check and determined
that:
• The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly.
Before Using This Section
Important Question to Ask the
Operator
LPG / Natural Gas Fuel System
Check
Visual and Physical Checks
• There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists, but without a MIL.
Several of the following symptom procedures call for a careful visual and physical check. The visual
and physical checks are very important. The checks can lead to correcting a problem, without further
checks, that may save valuable time. Most importantly talk to the operator about the failure this may
provide important information about the fault.
• When and how did the operator first notice the fault condition
• What engine speed and load condition did the fault occur at
• Did the fault occur just after or before refueling
• Did the fault occur at start up or shut down
• Did the fault occur at a particular time of day or during the shift
• Did the fault occur in a particular location
• Has there been any recent repair to the engine or vehicle
• Has the fault ever occurred before
• Has there been any new external customer installed devices added to the vehicle and or engine
• Verify the customer complaint.
• Locate the correct symptom table.
• Check the items indicated, under that symptom.
• Operate the vehicle, under the condition the symptoms occurs. Verify HEGO is switching between
lean and rich.
• Normal HEGO switching, indicates the LPG / natural gas fuel system is in closed loop, and
operating correctly at that time.
• If a scan tool is available, take a snapshot, under the condition that the symptom occurs. Go to
Engine Scan Tool Data List, to verify normal sensor values and parameters.
• Check all ECM system fuses and/or circuit breakers.
• Check the ECM ground for being clean, tight, and in its proper location.
• Check the vacuum hoses for splits, kinks, and proper connections.
• Check thoroughly for any type of leak or restriction.
• Check for air leaks, at all the mounting areas, of the intake manifold sealing surfaces.
• Check for proper installation of the mixer module assembly.
• Check for air leaks, at the mixer assembly.
• Check the wiring, for the following items:
– Proper connections, pinches, or cuts.
• Check the fuel level and fuel delivery system for leaks
• Check the battery condition
• The following symptom tables contain groups of possible causes, for each symptom. The order of
these procedures is not important. If the scan tool readings do not indicate the problems, then
proceed in a logical order, easiest to check, or most likely to occur first.
ECM SYSTEM
1-18
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
KiSC issued 12, 2016 A
Intermittent
Checks Action
DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL), or store a Diagnostic Trouble Code (DTC).
• Refer to Important Preliminary Checks.
Preliminary Checks
Faulty Electrical Connections, or
Wiring
Operational Test
Intermittent Malfunction Indicator
Lamp (MIL)
Loss of DTC Memory
Additional Checks
• Do not use the DTC tables, if a fault is an intermittent, the use of the DTC tables may result in the
replacement of good parts.
• Faulty electrical connections, or wiring, can cause most intermittent problems.
• Check the suspected circuit for the following conditions:
– Faulty fuse, or circuit breaker
– Connectors poorly mated
– Corrosion or loose pins in the connectors
– Terminals not fully seated, in the connector (backed out)
– Terminals not properly formed, or damaged
– Terminal to wire joints poorly connected
– Terminal tension, insufficient
– Wire strain from improper wire routing
– Burned or damaged wires from contacting hot surfaces or rotating devices
• Improper splicing method used when optional equipment is installed to the vehicle.
• Carefully remove all the connector terminals in the problem circuit, in order to ensure the proper
contact tension. If necessary, replace all the connector terminals in the problem circuit, in order to
ensure the proper contact tension.
• Checking for poor terminal, to wire connections, requires removing the terminal from the connector
body.
If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan
tool. When the problem occurs, an abnormal voltage or scan reading indicates the problem may be in
that circuit.
The following components can cause intermittent MIL, and no DTC(s):
• A defective relay Control Module driven solenoid, or a switch that can cause electrical system
interference. Normally, the problem will occur when the faulty component is operating.
• The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
• The ignition, secondary voltage, is shorted to a ground.
• The Malfunction Indicator Lamp (MIL) circuit, or the Diagnostic Test Terminal, is intermittently
shorted to ground.
• The Control Module grounds.
To check for the loss of the DTC Memory:
1. Disconnect the TMAP sensor.
2. Idle the engine, until the Malfunction Indicator Lamp illuminates.
The ECM should store a TMAP DTC. The TMAP DTC should remain in the memory, when the ignition
is turned OFF. If the TMAP DTC does not store and remains, the ECM is faulty.
ECM SYSTEM
1-19
WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM
IMPORTANT
NOTE
IMPORTANT
KiSC issued 12, 2016 A
Checks Action
DEFINITION: The engine cranks OK, but does not start.
Preliminary Checks • Refer to Important Preliminary Checks.
• Check the battery charge condition.
Battery and Voltage Check
Control Module Checks
Sensor Checks
Fuel System Checks
• Check the battery cranking voltage, voltage less the 9.00 V are outside the parameters of
operation.
• Check Battery positive and negative cable ends for corrosion build up.
• Check the inline fuse in the ECM battery power circuit. Refer to Engine Controls Schematics.
• Check battery power, ignition power, and ground circuits, to the ECM.
Refer to Engine Control Schematics. Verify voltage and/or continuity, for each circuit.
• Crank sensor.
• Cam sensor.
• A closed LPG / natural gas manual fuel shut off valve, will create a no start condition. Check
the fuel supply line connection to ensure the Excess flow check valve has not set
• Check for air intake system leakage, between the mixer and the throttle body.
• Verify proper operation, of the low pressure lock-off solenoids.
• Fuel filter plugging.
• Check the fuel system pressures. Refer to the LPG / Natural Gas Fuel System Diagnosis.
• Check the low pressure fuel supply hose for restrictions and or blockage.
• Check for restrictions in the air intake system.
• Check for large vacuum leaks in the intake system.
• Check for proper mixer air valve operation.
• Check for exhaust pipe or catalyst restrictions.
ECM SYSTEM
No Start
Ignition System Checks
Engine Mechanical Checks
Exhaust System Checks
• LPG / natural gas, being a gaseous fuel, requires higher secondary ignition system
voltages, for the equivalent gasoline operating conditions.
• Check for the proper ignition voltage output.
• Verify that the spark plugs are correct, for use with LPG / natural gas.
• Check the spark plugs, for the following conditions:
– Wet plugs
–Cracks
– Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Check for loose ignition, coil connections, at the coil.
• The LPG / Natural Gas Fuel system works on a fumigation principle, of fuel introduction,
and is more sensitive, to intake manifold leakage, than the gasoline fuel supply system.
• Check for the following:
– Vacuum leaks
– Improper valve timing
– Low compression
– Bent pushrods
– Worn rocker arms
– Broken, or weak valve springs
– Worn camshaft lobes
• Check the exhaust system, for a possible restriction:
• Inspect the exhaust system, for damaged or collapsed pipes.
• Inspect the muffler, for signs of heat distress, or for possible internal failure.
• Check for, possible, plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis.
1-20
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