Kubota WG972 Diagnose Manual

DIAGNOSIS MANUAL
ECU SYSTEM
WG972-E4
KiSC issued 09, 2021 A

Record of Revisions
For pdf, use search function {Search word} to find all the revised locations.
Last digit
Month of Reference
of the Main Revised Point and Corrective Measures {Search word}
Revision Page
Code No.
1 2016.11 Added the information of interface tool.
• Added DST-i for WG972 interface tool. 1-S34,
1-S44
2 2021.03 Changed the word "repair" to "replace" relating wiring harness –
sentence. Because Kubota does not approve wire harness repairs.
3 2021.09 Changed the wiring diagram. 1-S1 to
1-S6

I INFORMATION

INFORMATION
CONTENTS
1. SAFETY FIRST .............................................................................................................................. I-1

WG972-E4, DM INFORMATION
1. SAFETY FIRST
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.
DANGER
• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
• Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
IMPORTANT
• Indicates that equipment or property damage could result if instructions are not followed.
NOTE
• Gives helpful information.
9Y1200174INI0001US0
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.
9Y1200174INI0002US0
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.
9Y1200174INI0003US0
I-1
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
ECU and injector.
Pay sufficient caution to electric shock when
performing work activities.
9Y1200174INI0004US0
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.
9Y1200174INI0005US0
I-2
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.
9Y1200174INI0006US0
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.
9Y1200174INI0007US0
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.
9Y1200174INI0008US0
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.
9Y1200174INI0009US0
I-3
1 ECU SYSTEM

SERVICING
CONTENTS
1. WIRING DIAGRAM......................................................................................................................1-S1
2. OUTLINE .....................................................................................................................................1-S7
[1] OVERALL DIAGONOSTIC PROCEDURE ............................................................................1-S7
[2] QUESTIONING .....................................................................................................................1-S8
[3] ABBREVIATIONS................................................................................................................1-S11
3. SYMPTOM CHARTS BY COMPONENTS ................................................................................1-S14
[1] GASOLINE SYMPTOM CHARTS .......................................................................................1-S14
[2] GASEOUS SYMPTOM CHARTS ........................................................................................1-S23
4. SET UP AND PROCEDURE DIAGNOSIS TOOL .....................................................................1-S33
[1] DIAGNOSTIC CONNECTOR POSITION ............................................................................1-S33
[2] DIAGNOSTIC TOOL CONNECTION PROCEDURE ..........................................................1-S33
[3] SET UP AND PROCEDURE ...............................................................................................1-S34
(1) Introduction....................................................................................................................1-S34
(2) Recommended PC Hardware/Software Environment ...................................................1-S34
(3) How to Install the Software and Interface Driver ...........................................................1-S34
[4] HOW TO USE DIAGNOSIS SOFTWARE ...........................................................................1-S35
(1) Start Up .........................................................................................................................1-S35
(2) User Authentication .......................................................................................................1-S35
(3) Description of Monitor Command ..................................................................................1-S36
(4) Model Screen ................................................................................................................1-S37
(5) Faults Screen ................................................................................................................1-S40
(6) Tests Screen .................................................................................................................1-S42
5. BASIC SYSTEM INFORMATION ..............................................................................................1-S43
[1] FUEL SYSTEM....................................................................................................................1-S43
[2] ELECTRICAL SYSTEM.......................................................................................................1-S53
(1) ECU Terminal Layout ....................................................................................................1-S53
(2) Connector Views ...........................................................................................................1-S54
6. DIAGNOSIS...............................................................................................................................1-S65
[1] FUEL SYSTEM CHECKS....................................................................................................1-S65
[2] FUEL SYSTEM DIAGNOSIS...............................................................................................1-S67
(1) Restricted Exhaust System Diagnosis...........................................................................1-S72
[3] DTC LIST.............................................................................................................................1-S73
[4] DIAGNOSIS PROCEDURE BY DTC ..................................................................................1-S92
(1) Crank/Cam Sensors (DTC 335, 341) ............................................................................1-S92
(2) MAP (Manifold Absolute Pressure Sensor) (DTC 237, 238) .........................................1-S97
(3) IAT (Intake Air Temperature Sensor) (DTC 111, 112, 113, 127).................................1-S100
(4) ECT (Engine Coolant Temperature) (DTC 116, 117, 118, 217) ..................................1-S104
(5) TPS (Throttle Position Sensor) (DTC 122, 123, 222, 223, 1618, 1619, 2135) ............1-S108
(6) EGO Sensors ((Exhaust Gas Oxygen) Sensors) (DTC 130, 134, 135, 140, 141).......1-S116
(7) Engine Speed (DTC 219) ............................................................................................1-S119
(8) Injectors (DTC 201, 202, 203) .....................................................................................1-S120
(9) Oil Pressure Switch (DTC 524, 1609) .........................................................................1-S122
(10)Battery Voltage (DTC 562, 563) ..................................................................................1-S124
(11)Internal Processor Diagnostics (DTC 601, 604, 605, 606, 1616, 1621)......................1-S127
(12)Fuel Pump (DTC 627) .................................................................................................1-S133
(13)5 V External (DTC 642) ...............................................................................................1-S135
(14)Power Relay (DTC 687) ..............................................................................................1-S137
(15)ETV (Electronic Throttle Valve) (P1601 to P1608)......................................................1-S139
(16)Fuel System (DTC 1617) ............................................................................................1-S141

(17)Lock Off Valve Fuel Shutoff Solenoid (DTC 1624) ......................................................1-S142
(18)Solenoid Valve (DTC 1628).........................................................................................1-S143
(19)APS (Accelerator Position Sensor) (DTC 2122, 2123, 2127, 2128, 2138)..................1-S144
(20)Ignition Coil (DTC 351, 352, 353) ................................................................................1-S150

WG972-E4, DM ECU SYSTEM
1. WIRING DIAGRAM
WG972-G-E4
1-S1
1-S2
WG972-GL-E4
1-S3
1-S4
WG972-L-E4, WG972-N-E4
1-S5
1-S6
2. OUTLINE
[1] OVERALL DIAGONOSTIC PROCEDURE
9Y1200311EUS0004US0
1-S7
[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.
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Questioning Points
What? Malfunction symptom
When? Date, time, frequency of occurrence.
Where? Field conditions
What were conditions like at the time of Driving conditions, operating conditions,
malfunction? weather.
What happened? Type of malfunction.
9Y1200311EUS0006US0
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.
9Y1200311EUS0007US0
1-S8
Trouble Check Sheet for WG Engines

Machine details
Customer name
Customer
address
Machine serial
Machine model
number
Engine serial
Purchase date
number
Hourmeter
Repair date hours
indicator
Warranty
Warranty Judgment Yes No
Injector Ignition Coil
Defective parts Fuel Filter
Others ( )
Replace parts details
Quantity Units Part number
Supply Pump
Serial number
Quantity Units Part number
Injector Injector 1 Injector 2
Defective injector
Injector 3
Injector Ignition Coil
Actual part replacement Fuel Filter
ECU Others ( )
Customer complaint
a. No initial combustion b. No complete combustion
1. Engine no start
c. No cranking
a. Engine crank slowly
2. Difficult to start
b. Others ( )
a. Incorrect first idle b. Noise
c. Hunting idle from ( ) to ( ) min-1 (rpm)
-1
d. High idling ( ) min (rpm)
3. Poor idling
e. Low idling ( ) min-1 (rpm)
f. Rough
g. Others ( )
a. Hesitation b. Surging
4. Poor driveability c. Knocking d. Lack of power
e. Others ( )
a. Black b. White
5. Abnormal smoke
c. Others ( )
a. Large quantity b. Blurred
6. Fuel leakage Injector Ignition Coil
Leaking from:
Others ( )
7. Engine not stop
8. Engine stall
9. Others
9Y1200311EUS0008US0
1-S9
Condition when problem occurs (Duplicated answers can be possible)

a. Fine b. Cloudy
c. Rainy d. Snow
1. Weather
e. Flood
f. Others ( )
2. Outdoor temperature Approx. °C ( °F)
3. Altitude Approx. m
a. Cold Write the position of the indicator on coolant
temperature gauge.
b. Warming up
c. After warming up
4. Engine coolant d. Any temperature
e. Others ( )
a. Starting b. Just after starting

c. Idling d. Racing
5. Engine operation e. Acceleration f. Deceleration
g. While at work
h. Others ( )
a. Constant b. Once only
6. Problem frequency
c. Sometime ( Time per day/month)
7. Engine warning light Turn on a light Turn off a light
Fill the parts in if you use optional parts or non-genuine parts for electrical, intake/exhaust and fuel system.
8. Optional parts
( )
Dealer check
1. Duplicate the problem a. Yes (Duplicate) b. No (Not occur)
a. Abnormal (What is code )
2. Diagnosis trouble code
b. Normal (No code)
a. Normal b. Cracked
3. Appearance c. Discolored
d. Others ( )
a. Normal
4. Fuel condition
b. Abnormal ( )
9Y1200311EUS0009US0
1-S10
[3] ABBREVIATIONS
ACRONYM DEFINITION
AC Alternating Current
AF Air Fuel Ratio
AL Adaptive Learn
ATC After Top Center
ATDC After Top Dead Center
CAN Controller Area Network
CARB California Air Resources Board
CAT Catalyst
CCP CAN Calibration Protocol
CKP Crankshaft Position Sensor
CL Closed Loop
CMP Camshaft Position Sensor
CPP Clutch Pedal Position Sensor
CTP Closed Throttle Position
DBW Drive-By-Wire
DC Direct Current
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.)
ECU Engine Control Unit
ECT Engine Coolant Temperature
EGO Exhaust Gas Oxygen Sensor
ERWT Exhaust Manifold Riser Temperature
ETB Electronic Throttle Body
ETC Electronic Throttle Control
EVAP Evaporative Emissions
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
FTP Federal Test Procedure
GCP Global Control Platform
HVS High Voltage Switch
HDGCP Heavy-Duty Global Control Platform (On-Road Heavy-Duty)
HEGO Heated Exhaust Gas Oxygen Sensor (same as HO2S)
HO2S Heated Oxygen Sensor
HO2S1 Upstream Heated Oxygen Sensor (Pre CAT)
HO2S2 Downstream or Downstream Heated Oxygen Sensor (Pre CAT)
1-S11
ACRONYM DEFINITION
IAC Idle Air Control
IAT Intake Air Temperature
IC Ignition Control Circuit
ICM Ignition Control Module
ICAV Instant Crank Angle Velocity
IFI Indirect Fuel Injection
IP Instrument Panel
IPC Instrument Panel Cluster
IVS Idle Validation Switch
LDGCP Light-Duty Global Control Platform (Industrial, Smart/Logic Coil)
LED Light Emitting Diode
LTFT Long Term Fuel Trim
MAP Manifold Absolute Pressure
MDGCP Medium-Duty Global Control Platform (Industrial, Dumb Coil)
MDP Manifold Differential Pressure
MIL Malfunction Indicator Lamp
O2 Oxygen Sensor
OBD On-Board Diagnostics
OL Open Loop
PCM Powertrain Control Module
PCU Powertrain Control Unit
PFI Port Fuel Injection
PGN Parameter Group Number
PPM Parts Per Million
PSA Pressure Switch Assembly
PWM Pulse Width Modulated
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
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
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
1-S12
ACRONYM DEFINITION
Vsw Switched, Ignition Voltage
WOT Wide Open Throttle
9Y1200311EUS0010US0
1-S13
3. 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.
• There are no Diagnostic Trouble Codes (DTCs) stored or a DTC exists but without a MIL.
Before Using This Section
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
Important Question to Ask the
• Did the fault occur at a particular time of day or during the shift
Operator
• 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.
Gasoline Fuel System Check
IMPORTANT
• 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 ECU system fuses and circuit breakers.
• Check the ECU 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.
Visual and Physical Checks
• 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.
9Y1200311EUS0011US0
1-S14
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 • 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.
Faulty Electrical Connections or – Check for excessive wire strain on the harness.
Wiring – 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
Operational Test 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.
Intermittent Malfunction Indicator • The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
Lamp (MIL) • 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.
Loss of DTC Memory 2. Idle the engine until the Malfunction Indicator Lamp illuminates.
The ECU 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 ECU is faulty.
9Y1200311EUS0012US0
1-S15
No Start
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.
• Check the inline fuse in the ECU battery power circuit. Refer to Engine Controls Schematics.
Control Module Checks
• Check battery power, ignition power and ground circuits to the ECU. Refer to Engine Control
Schematics. Verify voltage and/or continuity for each circuit.
• Check the TMAP sensor.
Sensor Checks • 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.
Fuel System Checks • 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
Ignition System Checks
– 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
Engine Mechanical Checks
– 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.
Exhaust System Checks
– 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.
9Y1200311EUS0013US0
1-S16
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
• Make sure the vehicle's operator is using the correct starting procedure.
• Check the Throttle position (TPS) sensor.
Sensor Checks
• Check the Camshaft position (CMP) and Crankshaft (CKP) position sensors.
• Check for fuel pump electrical circuit.
Fuel System Checks • Verify proper fuel rail pressure.
• Check for the proper ignition voltage output.
• Check the spark plugs for the following conditions:
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
• Check for loose ignition, coil connections.
IMPORTANT
1. If the engine starts but then immediately stalls. Check the Crankshaft Position (CKP)
sensor.
2. Check for improper gap, debris or faulty connections.
– Vacuum leaks
– Low compression
– Bent pushrods
• Check the intake and exhaust manifolds, for casting flash.
– 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.
9Y1200311EUS0014US0
1-S17
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.
• 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.
• Remove the spark plugs in these cylinders and check for the following conditions:
– Insulation cracks
– Wear
– Improper gap
– 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:
– Bent pushrods
– 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
Fuel System Checks 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.
Additional Check • 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.
9Y1200311EUS0015US0
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.
Fuel System Checks • Verify proper fuel rail pressure.
Ignition System Checks • Verify that the spark plugs are correct.
• Check for fouled spark plugs.
• Check for manifold vacuum or air induction system leaks.
Additional Check
• Check the generator output voltage.
9Y1200311EUS0016US0
1-S18
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:
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
– Engine compression
– Manifold vacuum leaks
Engine Mechanical Check
– Intake manifold gaskets
– Sticking or leaking valves
– Exhaust system leakage
• Check the intake and exhaust system for casting flash or other restrictions.
Fuel System Checks • Perform a fuel system diagnosis. Refer to Gasoline Fuel System Diagnosis.
9Y1200311EUS0017US0
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 the Gasoline Fuel system OBD System Check.
Preliminary Checks • 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.
Fuel System Checks
• Verify proper fuel rail pressure.
• Check electrical connections at the injectors.
• Check the Heated Exhaust Gas Oxygen Sensor (HEGO) for contamination and performance.
Sensor Checks • Check for proper operation of the MAP sensor.
• Check for proper operation of the TPS sensor.
– Inspect the muffler for signs of heat distress or for possible internal failure.
– Check for possible plugged catalytic converter.
– Valve timing
– Improper or worn camshaft. Refer to Engine Mechanical.
• Check the ECU grounds for being clean, tight, and in their proper locations.
• If all procedures have been completed, and no malfunction has been found, review and inspect the
Additional Check 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.
9Y1200311EUS0018US0
1-S19
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.
• 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:
– Is there excessive idling or stop and go driving
Preliminary Checks
– 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.
Fuel System Checks
• Check the fuel system for leakage.
Sensor Checks • Check the Temperature Manifold Absolute Pressure (TMAP) sensor.
• Check the spark plugs. Remove the plugs and inspect them for the following conditions:
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
Cooling System Checks • Check the engine thermostat for always being open or for the wrong heat range.
– 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
Additional Check Service Manual.
• Check for dragging brakes.
9Y1200311EUS0019US0
1-S20
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.
• 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).
The ECU will reduce the amount of fuel delivered to the engine causing a severe drivability
Sensor Checks
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.
Fuel System Checks
• 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.
– Wet plugs
– Cracks
– Wear
– Improper gap
– Blistered insulators
– Heavy deposits
• Check the ECU grounds for being clean, tight and in their proper locations.
Additional Checks • 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.
– Broken motor mounts
– Low compression
– Bent pushrods
9Y1200311EUS0020US0
1-S21
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
• Be sure the driver understands "the Torque Converter Clutch operation"
Sensor Checks Check the Heated Exhaust Gas Oxygen Sensor (HEGO), performance.
• 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.
Fuel System Checks • 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.
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
• Check the Crankshaft Position (CKP) sensor.
• Check the ECU grounds for being clean, tight and in their proper locations.
Additional Check
• Check the vacuum hoses for kinks or leaks.
• Check Transmission.
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1-S22
[2] GASEOUS 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.
• There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists, but without a MIL.
Before Using This Section
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
Important Question to Ask the
• Did the fault occur at a particular time of day or during the shift
Operator
• 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.
LPG/NG Fuel System Check • Check the items indicated, under that symptom.
• 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 ECU system fuses and/or circuit breakers.
• Check the ECU 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.
Visual and Physical Checks
• 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.
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1-S23
Intermittent
Checks Action
DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL), or store a Diagnostic Trouble Code (DTC).
Preliminary 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
Faulty Electrical Connections, or
– Terminal tension, insufficient
Wiring
– 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
Operational Test 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.
Intermittent Malfunction Indicator • The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
Lamp (MIL) • 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.
Loss of DTC Memory 2. Idle the engine, until the Malfunction Indicator Lamp illuminates.
The ECU 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 ECU is faulty.
Additional Checks
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1-S24
No Start
Checks Action
DEFINITION: The engine cranks OK, but does not start.
• Check the battery charge condition.
• Check the battery cranking voltage, voltage less the 9.00 V are outside the parameters of
Battery and Voltage Check
operation.
• Check Battery positive and negative cable ends for corrosion build up.
• Check the inline fuse in the ECU battery power circuit. Refer to Engine Controls Schematics.
Control Module Checks • Check battery power, ignition power, and ground circuits, to the ECU.
Refer to Engine Control Schematics. Verify voltage and/or continuity, for each circuit.
• Crank sensor.
Sensor Checks
• Cam sensor.
IMPORTANT
• A closed LPG/NG 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.
Fuel System Checks
• Check the fuel system pressures. Refer to the LPG/NG 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.
NOTE
• LPG/NG, being a gaseous fuel, requires higher secondary ignition system voltages, for the
equivalent gasoline operating conditions.
• Verify that the spark plugs are correct, for use with LPG/NG.
• Check the spark plugs, for the following conditions:
Ignition System Checks – Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
• Check for loose ignition, coil connections, at the coil.
IMPORTANT
• The LPG/NG Fuel system works on a fumigation principle, of fuel introduction, and is
sensitive, to intake manifold leakage.
– Vacuum leaks
Engine Mechanical Checks – Improper valve timing
– Low compression
– Bent pushrods
– Broken, or weak valve springs
• Check the exhaust system, for a possible restriction:
Exhaust System Checks • Inspect the exhaust system, for damaged or collapsed pipes.
• Inspect the muffler, for signs of heat distress, or for possible internal failure.
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1-S25
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.
• Make sure the vehicle's operator is using the correct starting procedure.
Preliminary Checks
• Be sure that there is fuel in the fuel tank.
• Check to make sure the manual tank valve is fully open.
Sensor Checks
• Check the Camshaft sensor.
IMPORTANT
• A closed LPG/NG manual fuel shut off valve will create an extended crank, OR no start
condition.
• Verify the excess flow valve, in the LPG/NG manual shut-off valve, is not tripped.
Fuel System Checks
• Check mixer module assembly, for proper installation and leakage.
• Verify proper operation, of the low pressure lock-off solenoids.
• Check for air intake system leakage, between the mixer and the throttle body.
• Check the fuel system pressures. Refer to the Fuel System Diagnosis.
NOTE
• LPG/NG, being a gaseous fuel, requires higher, secondary ignition system voltages, for the
• Check for the proper ignition voltage output
• Check the spark plugs, for the following conditions:
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
• Check for loose ignition coil connections.
IMPORTANT
1. If the engine starts, but then immediately stalls, check Crankshaft Position (CKP).
2. Check for improper gap, debris, or faulty connections.
IMPORTANT
• The LPG/NG Fuel system, works on a fumigation principle of fuel introduction, and is
– Vacuum leaks
– Low compression
– Bent pushrods
– Worn camshaft lobes. Refer to Workshop Manual
• Check the intake and exhaust manifolds, for casting flash.
Additional Checks
9Y1200311EUS0025US0
1-S26
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.
• Check the battery condition.
• Check the positive and negative cable connections.
Preliminary Checks
• Check the ECU and system grounds for corrosion at the connectors.
• Check the coil electrical connections.
• Check the air filter for restriction.
• Start the engine.
• Check for proper ignition output voltage, with spark tester.
• Check for a cylinder misfire.
• Verify that the spark plugs are correct for use, with LPG/NG.
• Remove the spark plugs and check for the following conditions:
– Insulation cracks
– Wear
– Improper gap
– Heavy deposits
• Visually/Physically inspect the secondary ignition, for the following:
– Ignition coils, for cracks or carbon tracking.
• Wet down the secondary ignition system with water from a spray bottle and look / listen for arcing
or misfiring as you apply water.
• Perform a cylinder compression check.
– Bent pushrods
– 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 LPG/NG Fuel System
Fuel System Checks Diagnosis.
• Check the condition of the wiring, to the low pressure lock-off solenoid.
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.
Additional Check • 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.
• Check for secondary electrical equipment improperly spliced into the engine electrical system.
9Y1200311EUS0026US0
1-S27
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.
• Check the battery condition.
• Check the positive and negative cable connections.
Preliminary Checks
• Check the ECU and system grounds for corrosion at the connectors.
• Check the coil electrical connections.
• Check the air filter for restriction.
• Check the fuel pressure. Refer to LPG/NG Fuel System Diagnosis.
• Check for low fuel pressure, during a moderate, or full throttle acceleration. If the fuel pressure
drops below specification, there is a possibility of a faulty low pressure regulator, or a restriction, in
Fuel System Checks the fuel system.
• Check the Manifold Absolute Pressure (MAP) sensor response and accuracy.
• Check the mixer air valve for sticking or binding.
• Check the mixer module assembly, for proper installation and leakage.
NOTE
• Check for proper ignition output voltage, with spark tester.
• Check for fouled spark plugs.
• Check for manifold vacuum, or air induction, system leaks.
Additional Check
• Check the generator, output voltage.
9Y1200311EUS0027US0
Backfire
Checks Action
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise.
IMPORTANT
equivalent gasoline operating conditions. The ignition system must be maintained in peak
condition, to prevent backfire.
• Check for the proper ignition coil output voltage, using the spark tester.
• Check the connection, at each ignition coil.
• Check the spark plugs.
• Remove the plugs, and inspect them, for the following conditions:
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
IMPORTANT
• The LPG/NG, Fuel system, works on a fumigation principle, of fuel introduction, and is
Engine Mechanical Check – 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.
Fuel System Checks • Perform a fuel system diagnosis. Refer to LPG/NG Fuel System Diagnosis.
9Y1200311EUS0028US0
1-S28
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 the LPG/NG Fuel system, OBD System Check.
Preliminary Checks • Remove the air filter, and check for dirt or restriction.
• Check the vehicle transmission. Refer to the OEM transmission diagnostics.
• Verify the fuel tank has fuel.
• Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG/NG
Fuel System Diagnosis.
• Check for the proper ignition output voltage, with the spark tester.
• Check for proper installation, of the mixer module assembly.
Fuel System Checks
• Check all air inlet ducts, for condition and proper installation.
• Check for fuel leaks, between the DSR, and the mixer.
• Verify that the LPG/NG tank manual shut-off valve is fully open.
• Verify that liquid fuel (not vapor) is being delivered to the DSR.
• Check for proper operation of the MAP sensor.
Sensor Checks
• Check for proper operation of the TPS sensor.
• Check the exhaust system, for a possible restriction:
– Valve timing
• Improper or worn camshaft. Refer to Engine Mechanical, in the Service Manual.
• Check the ECU grounds, for being clean, tight, and in their proper locations.
Additional Check • Visually and physically, inspect all electrical connections, within the suspected circuit and/or
systems.
• Check the scan tool data.
9Y1200311EUS0029US0
1-S29
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.
• 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:
– Is there excessive idling, or stop and go driving?
Preliminary Checks
– Are the tires at the correct air pressure?
– Are excessively heavy loads being carried?
– Is their 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 DSR fuel pressure. Refer to LPG/NG Fuel System Diagnosis.
Fuel System Checks
• Check the fuel system for leakage.
Sensor Checks • Check the Temperature Manifold Absolute Pressure (TMAP) sensor.
• Verify that the spark plugs are correct, for use with LPG/NG. Check the spark plugs. Remove the
plugs, and inspect them, for the following conditions:
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
Cooling System Checks • Check the engine thermostat, for always being open, or for the wrong heat range.
– 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 of the
Additional Check Service Manual.
• Check for dragging brakes.
9Y1200311EUS0030US0
1-S30
Rough, Unstable, or Incorrect Idle, 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 RPM.
Either condition may be severe enough, to stall the engine.
• 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 The ECU will reduce the amount of fuel delivered to the engine, causing a severe driveability
problem.
• Check the Temperature Manifold Absolute Pressure (TMAP) sensor, response and accuracy.
• Check for a sticking mixer air valve.
• Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual.
Fuel System Checks
• Check the DSR fuel pressure. Refer to the LPG/NG Fuel System Diagnosis.
• Check mixer module assembly, for proper installation and connection.
• Check for the proper ignition output voltage, using the spark tester.
– Wet plugs
– Cracks
– Wear
– Improper gap
– Blistered insulators
– Heavy deposits
IMPORTANT
• The LPG/NG Fuel system works on a fumigation principle, of fuel introduction, and is
• Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle, and low throttle angle
Additional Checks
control command.
• 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.
– Broken motor mounts
– Low compression
– Bent pushrods
9Y1200311EUS0031US0
1-S31
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
• Be sure the driver understands the Torque Converter Clutch operation.
• Check the fuel pressure, while the condition exists. Refer to LPG/NG Fuel System Diagnosis.
• Verify proper fuel control solenoid operation.
Fuel System Checks
• Verify that the LPG/NG manual shut-off valve is fully open.
• Check the in-line fuel filter for restrictions.
• Check for the proper ignition output voltage, using a spark tester.
• Check the spark plugs. Remove the plugs, and inspect them for the following conditions:
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
Additional Check
• Check the vacuum hoses, for kinks or leaks.
• Check Transmission.
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1-S32
4. SET UP AND PROCEDURE DIAGNOSIS TOOL

[1] DIAGNOSTIC CONNECTOR POSITION
The connector for connecting the diagnostic tool is in the
position shown in the figure.
(A) Diagnostic Tool Connector
9Y1200311EUS0033US0
[2] DIAGNOSTIC TOOL CONNECTION PROCEDURE

NOTE
• At first time usage, it is necessary to install the software and interface driver with administrator user
account.
• Prepare a PC on which the diagnostic software and interface driver have been installed.
• When connecting the diagnostic cable, don't have to switch off the key of the vehicle.
9Y1200311EUS0034US0
1. Start up a PC on which diagnosis software and interface driver
have been installed with administrator user account.
2. Connect the vehicle-side connector to the interface (to vehicle)
with administrator user account.
3. Connect the cable (USB) to the interface (to PC) and then
connect the USB connector to the USB port on PC.
4. Turn the engine key on.
5. Start the diagnostic software.
NOTE
• The power of diagnostic tool is supplied by the USB port.
• After installed the software, all USB ports can be used to
connect the diagnosis cable.
• Connecting orders of diagnosis cables are not important.
(1) Interface (To Vehicle) (2) Interface (To PC)
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1-S33
[3] SET UP AND PROCEDURE

(1) Introduction
To diagnose ECU communication of WG972 engine, it is used the software Kubota Gasoline Service Tool and
interface driver ECom. From September 2016, you can also use interface tool DST-i instead of ECom.
When you diagnose the engine for the first time, you should install this software and interface driver before
diagnosing the engine.
9Y1200311EUS0036US0
(2) Recommended PC Hardware/Software Environment

The table 1 and 2 below indicate recommended PC hardware/software environment.
Table1: PC hardware environment
CPU Intel Pentium 4 or equivalent running at 1 GHz or higher.
Memory 512 MB or larger.
Hard disk drive capacity 500 MB or larger free space.
Display Display supporting screen resolution of XGA (1024 x 768) or higher/256 or more colors.
One port of version 1.1/2.0 to be occupied by the ECom interface connection.
USB port
Operation of the software cannot be guaranteed when the interface is connected via a hub.
Table2: PC software environment

32/64-bit version of Microsoft Windows XP (SP3 or higher) or Windows 7 in Japanese/English
OS edition.
 This software is not guaranteed to run on a 64-bit version of Windows XP.
Microsoft .NET Framework 4 Client Profile or higher.
Required components
ECom interface driver (made by EControls, Inc.) or DST-i interface driver.
9Y1200311EUS0037US0
(3) How to Install the Software and Interface Driver

To install diagnosis software, double-click setup.exe and when
the installation is successful, the icon (1) is placed on the desktop.
To install interface driver, double-click setup.exe and when the
installation successful, you can use all USB ports.
NOTE
• This software must be installed by the user with
administrator authority. If it is installed by any other user, it
may malfunction.
• Be sure to quit the other applications and virus detection
software before starting installation of this software.
Otherwise, the ongoing applications or software may
prevent normal installation of this software.
• When Microsoft .Net Framework of the specified version or
higher is not installed in the computer, installation of Net
Framework will start. Follow the instructions displayed on
the screen for installation.
• The ECom or DST-i interface driver and diagnosis software
is another setup.exe.
Separately execute and install Driver_Setup_V3.1.0.15.exe
existing on the same hierarchy as setup.exe.
(1) Desktop Icon
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1-S34
[4] HOW TO USE DIAGNOSIS SOFTWARE

(1) Start Up
a. Connect ECom/DST-i cable to the engine and USB port of the
computer.
b. Turn the engine key on. (It is not necessary to start the engine.)
c. Start the program and enter a password.
d. Execute an engine diagnosis using the Model/Tests/Faults
screens.
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(2) User Authentication

The following authentication screen is displayed at start up.
(1) Area where a password for authentication is entered.
(2) When the authentication is successful, the main screen of the
application appears.
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1-S35
(3) Description of Monitor Command

When you succeeded the authentication, follow window is appeared by the monitor.
The part in the frame located on the top of the screen is common to the respective screens of Model/Faults/Tests.
The following functions are available and freely operated during measurements.
(a) Load and save file and end operation.

• File:
– Setup:
Save: Save current monitor object settings* to a file.
Load: Load a previously saved settings file.
– Load Graph: Select a previously saved graph data file to display on the Graph screen.
– Exit: Close the application.
(*): Specifies items currently selected for monitoring and graphing and all monitor display item graph Y-axis
range and line segment color.
• Page: Switches the display menus (same function as (b))
• Log: Selects SPN or hex dump in log files.
(b) Switches display menu between the Models, Faults, and Tests screens.
(c) Displays transmission status of data between the program and ECU.
• Flashing green light: Data is being transmitted.
• Red: Indicates a transmission error or no transmission from the ECU for at least 3 seconds.
(d) Displays the name of the currently opened screen (Model, Faults, or Tests).
(e) Displays error data that occurred during ECOM device transmission.
(f) Displays the MIL lamp status.
• Green: Data is being transmitted at least every 3 seconds without errors.
• Red: Error data transmitted, error currently active.
• Gray: No data is received for 3 seconds or more.
(g) Button to start/stop acquisition of log.
• SPN mode requires selecting in advance with the mouse the item you want to log. Left click the name you want
with the mouse. The selected item turns green and can be saved to the log. You can select up to 20 items at a
time.
• HexDump mode saves all received transmissions.
(h) Button to open the graph screen.
• This requires selecting an item with the mouse in advance for display as a graph. Left click the item you want with
the mouse. The selected item turns green and a graph appears. You can work with a graph and log at the same
time.
(i) Select the unit of temperature and pressure.
• This function does not work while gobbling down the logging data and showing the graph monitor.
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(4) Model Screen

The Model screen displays the received data from ECU.
After left-clicking the name with the mouse, the item will be selected and added to the items whose graphs are
displayed/whose logs are output (green cells in the figure).
Selection operation by left-clicking is disabled while the graph screen is starting or a log is being acquired.
Information on ECU, etc. is displayed on the lower half of the screen. Only "Hour Meter" can be displayed on
graphs.
 Log Function
During transmission/reception of data between ECU, clicking
the [Start] button (a) allows you to acquire a log. The log will be
recorded in ¥log under the directory in which the program is located.
During acquisition of a log, the screen (c) switches as left figure.
Click the [Stop] button (e) to terminate recording the log.
If data is logging at SPN mode, the monitor changes (f), and if
data is logging at Hex Dump mode, the monitor changes (g).
There are two types of logs, including SPN mode and HexDump mode.
• Logs label data selected with the mouse at a fixed time interval, usually 100 msec.
• Switches data units to correspond with the content on the screen.
When fault data is included in Histeric Faults, logs the SPN-FMI
SPN mode
• To save as a file, after finishing logging, you need to click the Save button on the Graph
screen, and then specify a file name and save folder.
• Data saved in a file can be loaded as graph data.
When logging is finished, the file is automatically compiled in the directory ¥log in which the
program is saved and assigned the logging date as its name.
HexDump mode
The CAN signal received by the interface is not converted and output, regardless of the label
cricked with the mouse.
 Histogram button (d)

Speed Load Histogram content is output in CSV format.
Content includes date and time executed, serial number, and hour meter information.
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 Graph function
You can display data being transmitted from the ECU as a graph by clicking the Graph button.
(a) Select items to display in the graph from the items selected in the monitor display.
• From the maximum of 10 items displayed in the pull-down menu, select one.
• Click the checkbox to indicate whether or not to display an item.
(b) Specifies the Y-axis range for the item currently selected in (a).
(c) Specifies the time cycle in millisecond units for collecting the data value, usually 100 milliseconds.
(d) Specifies the elapsed time displayed in the X-axis.
(e) Displays a dialogue box for selecting color. You can change the graph color for the item currently
selected in (a).
(f) Specifies graph line thickness for the item currently selected in (a).
(g) Switches the display of the "Delta row" and "Average row" in the Graph (i).
(h) Specifies X-coordinates for drawing marker lines in the graph.
(i) Displays the value associated with the value 1 and Value 2 in (h) for the item selected in (a), and displays
the difference (or Delta), from subtracting Value 1 from Value 2, or the average value (or Average), adding
from Value 1 to Value 2.
(j) The start/stop button for drawing the graph.
This button also starts and stops logging.
Logging operates in SPN mode only.
(k) A track bar to specify the time frame displayed for all information contained in the graph. You can use the
track bar when (l) is off.
(l) When this function is on, the graphing time frame for collecting and displaying data is automatically
updated to the most recent time that it was collected. When this function is off, graphing is performed as
specified in (k).
(m) A text box for writing additional comments when saving graph data.
(n) Specify a file name and then save recorded graph data.
The Save button is available when you stop graphing by clicking the Stop button, as described in (j).
(o) Click this button to load previously recorded graph data.
This button is available before and after graphing.
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There are two types of logs, including SPN mode and HexDump mode.
Records data of the label clicked with the mouse at regular time intervals (normally, every 100
msec).
Converts the unit according to the contents displayed on the screen.
SPN mode
Records SPN-FMI if DM1 contains any fault information.
Measurement items are recorded on the second line and measurement units on third line of
the log.
Regardless of the label clicked with the mouse, CAN signals received by the interface are
HexDump mode
output without conversion.
(e) Select an item whose graph you want to display among the items selected as the monitor display items.
• Select one among up to 10 items displayed as pull-down menus.
• Check or uncheck the checkbox to show/hide the item.
(f) Determine the range of Y-axis of the item currently selected in (a).
(g) Specify the range of X-axis which represents time.
(h) The color selection dialog box appears, allowing you to change the graph display color of the item
currently selected in (a).
(i) Button to start/stop drawing a graph.
• The log function starts/stops when you click this button.
• This button functions only when the log function is in SPN mode.
(j) Track bar to specify the time period for displaying a graph among all the retained graph information.
When (k) is OFF, you can operate the bar.
(k) When this checkbox is ON, the time period for displaying a graph is automatically updated to the latest
acquisition time when the graph information is acquired. When this checkbox is OFF, specify the time
period with (j).
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(5) Faults Screen

The Faults screen displays the fault codes of ECU (DM1 and DM2).
The fault codes are displayed as P-codes.
(a) Displays historic faults (DM2). EU012US

While DTCs are displayed, double-clicking the relevant line displays the DTC Detail screen.
(b) Displays active faults (DM1).
While DTCs are displayed, double-clicking the relevant line displays the DTC Detail screen.
(c) Clears the fault information.
Clear Historic: Clear historic information
Depending on the data update time, clearing may require several seconds.
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 DTC Detail Screen
You can double-click a Historic Fault or Active Fault to display its fault diagnosis details.
(a) Displays the fault code (PCode) and basic text.

Displays the same content as the Faults screen.
(b) Displays details about the fault code (PCode).
(c) This area displays ECU data values (SnapShot) when the error occurred.
This area cannot be displayed when no data has been received.
Since more than one failure record cannot be saved in the ECU, the detailed information of P-Code error
displayed on the screen is only about the first failure even after the second or subsequent failures occur.
(d) Closes the screen.
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(6) Tests Screen
You perform function tests from the Tests screen.

Use this area to perform a Spark Kill Test.
(a) *Before performing the test, put the engine in idle.
From the pull-down menu, select a cylinder number, and then click the Start button to test the selected cylinder number.
Use this area to perform an Injector Kill Test.
(b) *Before performing the test, put the engine in idle.
From the pull-down menu, select a cylinder number, and then click the Start button to test the selected cylinder number.
(c) These tests are prohibited at service level.
Use this area to perform a DBW (Drive By Wire) Test.
*Before performing the test, turn the Key ON with the engine stopped. Then click the Start button to perform DBW Test.
(d) DBW Test will be kept performing unless you turn the engine powered-OFF or you click the Stop button in this area on the
screen.
While a test is in progress, you cannot perform a different test.
While a test is in progress, you cannot perform a different test or switch to a different screen.
 Confirming That a Test Has Been Performed
You can check the status of a test by referring to the Test screen.
Not Started The test is waiting to be performed.
The test is in progress.
Running
After the test is finished, the display returns to Not Started.
This indicates that the test could not be performed for some
reason.
N/A
Double-check the parameters for the test and the connection
with the ECU, and then start the test again.
Refer to the WorkShop manual for the engine being tested for
monitoring data items, engine equipment, and other details related
to test results.
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5. BASIC SYSTEM INFORMATION

[1] FUEL SYSTEM
KUBOTA Fuel Systems
Gasoline Schematic
(1) Fresh Air (9) Electric Fuel Pump (17) Fuel Rail (25) Camshaft Position Sensor
(2) Liquid Fuel High Pressure (10) Returnless Fuel Pressure (18) Ignition Coil (26) Battery
(3) Regulated Pressure Fuel Regulator (19) Footpedal Position Sensor (27) Exhaust Manifold
(4) Suction Fuel (11) Air Filtration System (20) Instrument Panel (28) Pre Oxygen Sensor
(5) Return Fuel (12) Air Filter (21) ECU (29) Catalyst
(6) Exhaust Gases (13) Electronic Throttle Body (22) Engine Coolant Temperature (30) Post Oxygen Sensor
(7) Gasoline Tank (14) Intake Manifold (23) Oil Temperature (31) Alternator
(8) Fuel Filter (15) Throttle Position Sensor (24) Crankshaft Position Sensor (32) Starter
(16) TMAP Sensor
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LPG/NG Schematic
(1) Fresh Air (9) Fuel Filter (16) TMAP Sensor (24) Crankshaft Position Sensor
(2) Liquid Fuel High Pressure (10) Electric Lock Off (17) Intake Manifold (25) Camshaft Position Sensor
(3) Low Pressure Fuel (11) Vaporizer (18) Ignition Coil (26) Battery
(4) Air Fuel Mixture (Dual Stage Regulator) (19) Footpedal Position Sensor (27) Exhaust Manifold
(5) Engine Coolant (12) Air Filtration System (20) Instrument Panel (28) Pre Oxygen Sensor
(6) Exhaust Gases (13) Mixer (21) ECU (29) Catalyst
(7) LPG/NG Tank (14) Electronic Throttle Body (22) Engine Coolant Temperature (30) Post Oxygen Sensor
(8) Manual Valve (15) Throttle Position Sensor Sensor (31) Alternator
(23) Oil Pressure SW (32) Starter
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Injectors and Injector Rail
Kubota fuel delivery system, utilizes a fuel rail, mounted with
injectors, for each cylinder. The fuel rail and injectors, are attached
by Kubota. During the design and calibration phase, the ECU fuel
delivery calibrations are developed. ECU will utilize these
calibrations, to pulse width modulate each injector, to deliver the
correct amount of gasoline, for optimized performance, and
reduced tail pipe emissions. The injector pulsing or "firing", is
accomplished by supplying a 12.0 V supply to the positive side of
the injector coil, and switching the ground circuit side, using the
injector drivers, internal to the ECU.
Because Kubota fuel system, utilizes the Fuel Pressure
Manifold, to control fuel delivery to the rail, Kubota fuel system does
not use a separate return line, from the fuel rail assembly. Gasoline
injectors are an emissions control device, and do not require
periodic adjustment. When serving or placing injectors, use only
Kubota replacement injectors, to insure the fuel system operates as
designed.
WARNING
• Never cut or weld on fuel tank. Repairs to the fuel tank
should only be made by a certified tank repair facility.
• Failure to observe this warning could result in serious
bodily injury and or death and could result in serious
property damage.
• Always wear protective eyewear and gloves when
performing maintenance on the fuel systems, to prevent
serious injury. Always perform maintenance procedures in
a well ventilated area and insure that there are no external
sources of ignition.
(1) Injector Rail (3) Injector
(2) Stopper (Injector)
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LPG MIXER
Mixer (3) is a device to mix air and gaseous fuel with proper ratio
required by the engine. The gaseous LPG or CNG fuel flows to the
mixer through main jet (1) from the Regulator with vaporizer.
When the engine starts, the LPG fuel flows out from main jet (1)
to venturi a constant amount and is mixed with air quantity
corresponding to the opening of the throttle valve and is supplied to
the cylinder.
(1) Main Jet (LPG / CNG) A: Gaseous Fuel (LPG / CNG)
(2) Regulator Reference Port B: Blow-by Gas (From Head Cover)
(Connecting with Secondary Stage C: Air
in Regulator) D: Mixture (Air and Fuel)
(3) Mixer a: Air
(4) Electronic Throttle Body b: Vapor Fuel
c: Mixture
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VAPORIZER
Regulator with vaporizer evaporates the liquid fuel (LPG / CNG)
into the gaseous fuel and then sends to the mixer. Regulator with
vaporizer has the following structures and functions.
 Evaporator
Evaporator has a long fuel passage to evaporate liquid fuel to
gaseous fuel.
 Hot Water Line
The coolant water of the engine is made to circulate as a heat
source to prevent freezing of vaporizer by latent heat of
vaporization.
 Primary Stage
There is a primary valve which is safety device for abnormal
pressure.
 Secondary Stage
Secondary stage has a secondary valve and controls the
quantity of gaseous fuel flowing to the mixer.
A: Secondary Stage C: Primary Stage
B: Evaporator D: Hot Water Line
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SERVICE LINE
Propane flows from the fuel tank to the electric lock, via the
service line. The service line is most commonly connected to the
tank, utilizing a quick coupler. The other end of the service line is
connected to a "bulkhead connector" which is used to allow the
service line, to pass through the metal enclosure, vehicle body
panels, or hoods. This hose is made of special material, which
protects the inner core of the hose, from chemicals contained within
the LPG, which could result in a failure of the hose. The hose should
never be kinked or allowed to come into contact with the chassis, or
other engine components, and electrical connection or wiring.
When replacing the fuel line, use care as there may be fuel retained
in the line between the tank manual valve connection, and the
electric lock off device.
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LPG/NG FUEL LOCK OFF
The LPG/NG Fuel Lock Off device is an integrated assembly.
The electric lock assembly is a 12.0 V, normally closed valve. The
solenoid is mounted to the valve body. When energized the
solenoid opens the pilot valve, within the lock off, which uses the
tank pressure, to assist in opening the valve. By using the pilot
valve, to help open the valve, the service life of the valve, is
extended, and requires less electrical energy, to open the valve.
The valve opens, during cranking, and remains open, during the run
cycles of the engine. The lock off supply voltage is controlled by the
Engine Control Unit (ECU), or may be energized by a relay, which
supplies battery voltage, when energized.
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Engine Control Module (ECU)
Gasoline ECU Input and Outputs

(1) Battery PLUS (7) Intake Air Temp (12) HEGO (17) MIL Light
(2) Battery MINUS (8) Manifold Pressure (13) Spark Control to Ignition Coils (18) Gage Output
(3) Engine RPM (9) Throttle Position 1 (14) Throttle Speed Control (19) Instrument Panel
(4) Engine Coolant (10) Throttle Position 2 (15) Data Link Connection (20) Gasoline Fuel Pump Control
(5) Engine Oil (11) Foot Pedal Position (16) Diagnostic Tool (21) Gasoline Injectors
(6) Crank Shaft Sensor
1-S47
LPG/NG ECU Input and Outputs

(1) Battery PLUS (6) Crank Shaft Sensor (11) Foot Pedal Position (15) Diagnostic Tool
(2) Battery MINUS (7) Intake Air Temp (12) Spark Control to Ignition Coils (16) MIL Light
(3) Engine RPM (8) Manifold Pressure (13) Throttle Speed Control (17) Gage Output
(4) Engine Coolant (9) Throttle Position 1 (14) Data Link Connection (18) Instrument Panel
(5) Engine Oil (10) Throttle Position 2
In Kubota fuel systems, the Engine Control Unit (ECU) provides total control, of the engine, fuel control, ignition
spark control, and auxiliary features. The ECU depends on Kubota designed wire harness, to receive the required
input data, from sensors, and sends the appropriate outputs. The harness is specifically designed to provide the
necessary electrical supply, to the engine, through the life of the equipment. All electrical connectors utilize sealed
connectors, to prevent damage from moisture intrusion, necessary shielding, when required, and protective covering,
to protect the wiring.
To obtain maximum effect from the catalyst and accurate control of the air fuel ratio, the emissions certified engine
is attached with an onboard computer known as the ECU. The ECU is a 32 bit controller, which receives input data
from sensors, fitted to the engine and fuel system, and then outputs various signals, to control engine operation.
Engine sensors are used for fuel calculation and control, and are also used for the gasoline diagnostics. Those
sensors are defined in the sensor group, in this section.
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Engine Sensor Group
To maintain fuel control, and insure the system provides the
optimum performance, the ECU depends on sensors installed in the
engine and fuel system, to provide input to the ECU, for calculating
fuel delivery, as well as fuel system diagnostics. This section will
provide the technician, with the understanding of the function of
each sensor.
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Temperature Manifold Absolute Pressure (TMAP)
The TMAP sensor is a combination sensor, and provides the
ECU with the Intake Air Temperature (IAT), and the Manifold
Absolute Pressure (MAP). The ECU uses the intake air temperature
to correct fueling based on the density of the air.
The MAP portion of the TMAP sensor provides the ECU with a
measurement of the pressure in the intake manifold. During the start
up, the MAP provides the ECU with the barometric pressure, to
allow the ECU to adjust fueling, based on barometric pressure.
Once the engine has started, the ECU uses the MAP to measure
the load on the engine, and make fuel and RPM corrections, to
compensate for changing load conditions.
In Kubota fuel system design, the TMAP is mounted to the
intake manifold, The TMAP is a 5.00 V reference signal sensor,
which operates by the resistance change in the sensor, to output a
reference voltage for the ECU to use. The sensor can be a 0 to 5.00
V which is supplied by the engine. During the development phase
of the system, the minimum and maximum thresholds of operation
are determined, and are part of the fuel calibration and diagnostics,
programmed into the ECU. These thresholds are used to establish
the point at which the ECU will set the MIL light, to indicate that a
fault has been detected in the fuel system.
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Engine Coolant Temperature (ECT)
The ECU monitors the engine coolant temperature, through the
ECT sensor mounted in the engine. The ECU uses this sensor input
to make corrections in fueling, and to protect the engine from
overheating during normal operation.
In Kubota fuel system designs, the ECT is mounted the engine
cylinder head, and is usually supplied by Kubota. The ECT is a
5.00 V reference signal sensor, which operates by the resistance
change in the sensor, to output a reference voltage for the ECU to
use. The sensor can be a 0 to 5.00 V which is supplied by the
engine. During the development phase of the system, the minimum
and maximum threshold of engine temperature, during normal
operation, are determined and are part of the fuel calibration and
diagnostics, programmed into the ECU. These thresholds are used
to establish the point at which the ECU will set the MIL light, to
indicate that a fault has been detected in the fuel system. Should the
temperature be exceeded, the ECU will first reduce the engine
performance capabilities, often referred to as "limp home", which
allows the operator to move the equipment to a facility for repair, or
safely shut down the system. In the event the temperature
continues to rise, the ECU will shut down the engine in a specified
period of time, after the "limp home" strategy has been activated.
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Engine Oil Pressure (EOP)
The ECU monitors the engine oil pressure, through the EOP
sensor, mounted in the engine. The ECU uses this sensor input, to
protect the engine from damage, from the lack of oil in the crank
case.
In Kubota fuel system designs, the EOP is mounted in the
cylinder block, and is supplied by Kubota. The EOP is a 5.00 V
reference signal sensor, which operates by the resistance change
in the sensor, to output a reference voltage for the ECU to use. The
sensor can be a 0 to 5.00 V which is supplied by the engine. During
the development phase of the system, the minimum and maximum
threshold of engine temperature, during normal operation are
determined, and are part of the fuel calibration and diagnostics,
programmed into the ECU. These thresholds are used to establish
the point, at which the ECU will set the MIL light, to indicate that a
fault has been detected in the engine. Should the pressure be
exceeded or fall below the minimum pressure, the ECU will shut
down the engine in a specified period of time.
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Throttle Position Sensors 1 and 2 (TPS 1 and 2)
Kubota fuel systems use an Electronic Throttle Body (ETB) for
speed and load control. Internal to the ETB, are two Throttle
Position Sensors (TPS), which provide an "actual position" of the
throttle plate. During the calibration development, the throttle blade
variation, from actual to command, is defined. A maximum variation
threshold is determined and included in the calibration, this
threshold insures that the variation between actual and command
do not vary above this threshold. In the event the variation exceeds
the threshold, the ECU will command the ETB to idle, or shutdown
the engine. The ECU will also set a diagnostic code, and turn on the
MIL light.
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Foot Pedal Position Sensors (FPP)
Kubota fuel systems, utilize a "drive by wire" technique, to allow
the operator to accelerate the engine. This type of technique does
not use a physical connection, between the operator foot pedal and
the throttle body. Therefore control of the engine is managed by
electrical signals, using a Foot Pedal Position Sensor (FPP), to
determine the location, or how much the pedal is being depressed
or released, which is relative to the command, that the operator
desires. The FPP is a reference voltage sensor, therefore changing
the voltage output level up or down, indicates a different desired
position to the ECU. The ECU then changes the output signal, to the
ETB, thus changing the throttle blade position, to correspond to the
desired foot pedal command. The FPP is generally integrated, in the
foot pedal mechanism, mounted in the operator's platform.
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Crankshaft Position Sensor (CKP)
To determine the engine RPM and piston position of number
one cylinder, the ECU receives this information from the Crankshaft
Sensor. The CKP is located near the flywheel at the rear of the
engine, and is supplied by the engine. CKPs vary in design,
depending on the signal that the sensor produces. Induction
sensors produce a sine wave signal, where as the pick-up crank
position sensor, which reads a notched metal "interrupter" ring, on
the back of the harmonic balancer, creates a square wave pattern.
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Camshaft Position Sensor (CMP)
The cam shaft sensor is used to determine which stroke of the
engine cycle the engine is running on for control of the fuel and
spark. The sensor is mounted at the front of the engine (gear case
side) and reads a pick up wheel mounted internally within the
engine. The pick up wheel can be of vary design and number of
pulses.
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Electronic Throttle Body (ETB)

The Kubota fuel systems utilize Drive By Wire (DBW), to control
engine speed, in this type of application. There is no direct
connection between the operator pedal, and the throttle shaft.
Speed and load control are determined by the ECU. Defaults
programmed into the ECU software, and throttle position sensors,
allow the ECU, to maintain safe operating control, over the engine.
In a drive by wire application, the Electronic Throttle Body (ETB)
device, or "throttle body assembly", is connected to the intake
manifold of the engine. The electronic throttle control device, utilizes
an electric motor, connected to the throttle shaft. In addition, a Foot
Pedal Position sensor (FPP) is located in the operator's
compartment. When the engine is running, electrical signals are
sent from the foot pedal position sensor, to the engine ECU, when
the operator depresses or release the foot pedal. The ECU then
sends an electrical signal to the motor, on the electronic throttle
control, to increase or decrease the angle of the throttle blade, thus
increasing or decreasing the air flow to the engine.
The electronic throttle control device also incorporates two
internal Throttle Position Sensors (TPS), which provide output
signals to the ECU, as to the location of the throttle shaft and blade.
The TPS information is used by the ECU, to correct for speed and
load control, as well as emission control, and engine protection.
The ETB utilized on USA emission certified engines do not
require any periodic adjustment.
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Heated Exhaust Gas Oxygen Sensor (Pre, Post) (All)
An Oxygen sensor is an essential element of a feedback control
of air-fuel ratio.
The sensor has a zirconia tube which is a solid electrolyte.
The outside of zirconia tube contacts with the exhaust gas and
the inside of zirconia tube contacts with?the atmosphere to know
each oxygen concentration.
The difference of oxygen concentration produced?between the
outside and inside of the zirconia tube causes electromotive force
to be generated.
Oxygen sensor should be installed at the both of inlet and outlet
of catalyst.
[Pre-Catalyst Oxygen Sensor]
When the air-fuel ratio is rich, HC, CO, and H2 etc. react with
the oxygen (O2) that remains in the exhaust gas.
This causes a significant reduction of the concentration of the
remaining oxygen, which considerably increases the ratio of it to the
concentration of oxygen contained in the atmosphere inside,
increasing the electromotive force.
When the air-fuel ratio is lean, the process is the other way
around, resulting in a significant drop in the electromotive force near
the stoichiometric ratio.
That is the feedback control functions as electronic control that
reduces the air-fuel ratio when it is judged to be on the rich side
based on the electromotive force and increases the ratio when it is
on the lean side.
Thus, pre-catalyst oxygen sensor is sensing the density of
oxygen in exhaust gas before passing of catalyst, and adjusts the
appropriate fuel injection quantity.
[Post-Catalyst Oxygen Sensor]
A post-catalyst oxygen sensor is sensing the density of oxygen
in exhaust gas after passing of three-way catalyst. Also the
post-catalyst oxygen sensor senses deterioration of catalyst, and
also keeps and improves the purification performance.
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[2] ELECTRICAL SYSTEM

(1) ECU Terminal Layout
Connector Number: C001
Name: ECU CONNECTOR
ECU PIN LOCATIONS
PIN DISCRIPTION PIN DISCRIPTION PIN DISCRIPTION

SENSOR
1 FUEL PUMP Black 24 OUTPUT 4 Gray 47 Yellow
POWER 1
SENSOR
2 PRE O2 HEATER Gray 25 STARTER SW White 48 Yellow
POWER 2
3 POST O2 HEATER Brown 26 INJECTOR 1 Yellow 49 TPS POWER Gray
4 ETV GND Black 27 IG COIL 1 Pink 50 APS 2 White
5 ETV POWER Yellow 28 POWER GND 1 Black 51 CAN 2 L Green
6 ETV MOTER + White 29 POWER GND 2 Black 52 ANALOG INPUT 3 Yellow
ENGINE
7 ETV MOTER − Gray 30 PRE O2 SENSOR Yellow 53 COOLANT Green
SENSOR
8 ETV RELAY Brown 31 POST O2 SENSOR Green 54 SENSOR GND 1 Black
9 POWER RELAY Gray 32 APS SW 1 Gray 55 SENSOR GND 2 Green
10 INJECTOR 3 Orange 33 APS SW 2 Blue 56 TPS GND Black
11 IG COIL 3 White 34 VBAT GND Black 57 TPS 2 Yellow
OUT PUT 1 /
12 LPG/NG CUT Blue 35 ANALOG INPUT 2 White 58 APS 2 GND Black
(LIQUID)
INLET AIR TEMP
13 OUTPUT 2 Red 36 Red 59 CAN 2 H Blue
SENSOR
INLET AIR
14 MIL Green 37 PRESSURE Gray 60 VBAT Red
SENSOR
CRANK
15 RPM OUT White 38 Blue 61 COMM.B White
SENSOR +
16 OIL SW Gray 39 CAM SENSOR + Pink 62 COMM.A Green
17 STARTER RELAY Brown 40 CAM SENSOR − Black 63 BLANK BLANK
18 INJECTOR 2 Green 41 CAN 1 L White 64 BLANK BLANK
19 IG COIL 2 Blue 42 CAN 1 H Green 65 APS 1 GND Brown
20 SOLENOID VALVE White 43 APS 2 POWER Red 66 APS 1 Yellow
21 BLANK BLANK 44 KEY SW Blue 67 APS 1 POWER Green
22 FUEL SELECT Yellow 45 ANALOG INPUT 1 Pink 68 TPS 1 Blue
CRANK
23 OUTPUT 3 Brown 46 White
SENSOR −
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(2) Connector Views

Connector Number: C002*1*2
Name: Starter Solenoid
Pin Number Description Wire Color

1 Starter Solenoid Unknown
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Connector Number: C003*1
Name: Crankshaft Sensor

1 CRANK − White
2 CRANK + Blue
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Name: Oil Pressure Switch

1 Oil Pressure Gray
9Y1200311EUS0068US0
NOTE
• *1: All connector views are the mating connector view.
• *2: This mark means that the connector is not supplied by Kubota.
9Y1200311EUS0069US0
1-S54
Connector Number: C005*1*2
Name: Heated O2 Sensor (Pre, Post)

A SENSOR GND Unknown
B PRE/POST O2 SENSOR Unknown
C VBAT Unknown
D PRE/POST O2 HEATER Unknown
9Y1200311EUS0070US0
NOTE
• *2: This mark means that the connector is not supplied by Kubota.
9Y1200311EUS0071US0
1-S55
Name: TMAP

INLET AIR TEMPERATURE
A Red
SENSOR
B SENSOR POWER 1 Yellow
C SENSOR GND 1 Green
D INLET AIR PRESSURE SENSOR Gray
9Y1200311EUS0072US0
Name: Engine Coolant Temperature

1 ENGINE COOLANT SENSOR Green / Orange
2 SENSOR GND 1 Black
9Y1200311EUS0073US0
NOTE
9Y1200311EUS0074US0
1-S56
Name: Vehicle Interface Connector1

1 VBAT GND Black
2 VBAT GND Black
3 PRE O2 HEATER Black
4 POST O2 HEATER Black
5 ETV POWER Yellow
6 ETV RELAY Brown
7 KEY SW Blue
8 BLANK BLANK
9 STARTER SW White
10 VBAT Red
11 VBAT Red
12 FUEL PUMP Black
13 APS 2 POWER Red
14 APS 2 White
15 APS 2 GND Black
16 APS 1 GND Brown
17 APS 1 Yellow
18 APS 1 POWER Green
19 STARTER RELAY Brown
20 POWER RELAY Gray
21 PRE O2 SENSOR Yellow
22 SENSOR GND 1, 2 Black
23 POST O2 SENSOR Green
24 SENSOR GND 1, 2 Black
25 APS SW 1 Gray
26 APS SW 2 Blue
27 MIL Green
28 CAN 2 H Blue
29 ANALOG INPUT 3 Yellow
30 SENSOR GND 1, Black
31 FUEL SELECT Yellow
32 ANALOG INPUT 1 Pink
33 SENSOR POWER 1, 2 Yellow
34 CAN 2 L Green
35 OUTPUT 4 Gray
36 RPM OUT White
37 OUTPUT 3 Brown
1-S57

38 ANALOG INPUT 2 White
39 BLANK BLANK
40 BLANK BLANK
41 OUT PUT 1 / LPG/NG FUEL CUT Blue
42 OUTPUT 2 Red
9Y1200311EUS0075US0
Name: System Ground Connection

1 Sys Ground Black
9Y1200311EUS0076US0
NOTE
9Y1200311EUS0077US0
1-S58
Name: 12 Volt Battery + Connection

1 Battery 12 V + Red
9Y1200311EUS0078US0
Name: Alternator Battery +

1 Battery 12 V + Red
9Y1200311EUS0079US0
1-S59
Name: CAN 1 CONNECTOR (FOR REPROGAMING)

A VBAT Red
B VBAT GND Black
C CAN1 H Green
D CAN1 L White
9Y1200311EUS0080US0
Name: CAN 1 CONNECTOR (FOR DIAGNOSTIC TOOL)

A VBAT Red
B VBAT GND Black
C CAN 2 H Blue
D CAN 2 L Green
9Y1200311EUS0081US0
NOTE
9Y1200311EUS0082US0
1-S60
Name: Alternator Connector

1 Charge Indication Unknown
2 12 V_RELAYED_POWER Unknown
3 BLANK BLANK
9Y1200311EUS0083US0
Name: Mitsubishi Electronic Throttle Connector

1 ETV MOTOR − Gray
2 ETV MOTOR + White
3 TPS POWER Gray
4 TPS GND Black
5 TPS 1 Blue
6 TPS 2 Yellow
9Y1200311EUS0084US0
NOTE
9Y1200311EUS0085US0
1-S61
Connector Number C016*1
Name: Camshaft Position Sensor Connector

1 VBAT Red
2 CAM SENSOR + Pink
3 CAM SENSOR − Black
9Y1200311EUS0086US0
Name: Ignition Coil Connector
Cylinder Number Pin Number Description Wire Color

1 to 3 (All) 1 VBAT Red
1 to 3 (All) 2 POWER GND 1 Black
1 3 IG COIL 1 Pink
2 3 IG COIL 2 Blue
3 3 IG COIL 3 White
9Y1200311EUS0087US0
NOTE
9Y1200311EUS0088US0
1-S62
Name: Injector Connector
Cylinder Number Pin Number Description Wire Color

1 1 INJ 1 Yellow
2 1 INJ 2 Green
3 1 INJ 3 Orange
1 to 3 (All) 2 VBAT Red
9Y1200311EUS0089US0
Name: LPG/NG FUEL CUT VAPOR

1 VBAT Red
2 PURGE/LPG/NG CUT (VAPOR) White
9Y1200311EUS0090US0
NOTE
9Y1200311EUS0091US0
1-S63
Name: Solenoid Valve

1 Solenoid valve White
2 VBAT Red
9Y1200311EUS0092US0
1-S64
6. DIAGNOSIS
[1] FUEL SYSTEM CHECKS
Introduction
The maintenance of the engine fitted with Kubota LPG/NG and
Gasoline fuel systems, and its related components, is critical to the
life of the engine and optimum performance, during its useful life. All
engines require a certain amount of maintenance. The suggested
maintenance requirements are contained in this section. Industrial
engines operate in various environmental conditions, and various
temperature ranges.
NOTE
• This is a recommended guide line only; each user must
assess the daily operational usage and environmental
conditions, and determine an appropriate schedule.
In addition, the owner may have installed additional equipment
to the vehicle, which may also increase the requirements for service
on certain components. Therefore, the owner and the service agent,
should review the operating condition of the equipment, and
determine if more frequent inspections, and maintenance cycles
maybe required.
This section of the service manual supplement, covers the
maintenance items of both the LPG/NG and Gasoline fuel systems,
which are designed and supplied by EControls, and general
information on those items which are supplied by Kubota, and
requires regularly scheduled maintenance. For maintenance of the
base engine and or chassis, refer to the Kubota manual which
covers the maintenance of the equipment.
9Y1200311EUS0093US0
Injector Rail and Injectors
The injector rail and injectors require no periodic adjustment.
You should annually inspect the following items on the fuel rails and
injectors.
• Check to make sure the rail bracket is securely attached to the
engine.
• Check to make sure the rail brackets have no cracking or
breaking.
• Check to make sure that each injector is securely attached to
the rail bracket.
• Check each injector electrical connection to insure the
connector is securely attached.
• Leak check all the connections on the manifold at each injector
connector, and the inlet and outlet fitting at the rail, using an
electronic leak detector or a soapy solution.
• Check the injector delivery hose (if used) for any cracking,
kinky, cuts, or deformation, and replace if necessary.
9Y1200311EUS0094US0
Electrical System Checks
The electrical system, sensors, wiring harness, and ECU do not
require any periodic adjustments. You should annually inspect the
following items.
9Y1200311EUS0095US0
1-S65
Battery
• Check and clean the battery terminal connections and insure
the connections are tight.
• Check the battery for any cracks or damage to the case.
• Check the Positive and Negative battery cables for any
corrosion build up, rubbing or chaffing, and check ground
connections on chassis, to insure they are tight.
9Y1200311EUS0096US0
ECU Checks
• Check the mounting bracket for the ECU, for cracks or breaking.
• Check the controller mounting bracket, securing bolts to insure
they are securely fastened.
• Check the rubber isolators for cracks or deterioration.
• Check the electrical connector and insure the connector is
securely attached, locked and the secondary lock is in position.
Check the connector for any corrosion in the connector, or on
the pins. Clean if observed.
9Y1200311EUS0097US0
Wire Harness Checks
• Check the wire harness routing, under the hood, to insure the
main harness and injector harness have not come into contact
with any rotating devices, hot surfaces, or have come loose
from their securing points, and are hanging in an unsafe
location.
• Check all wire ties and / or clamps used to secure the harness
for cracking, splitting, or breakage, replace if necessary.
• Check the harness routing and insure the harness is securely
attached to the frame and protected from any hot surfaces,
rotating devices or road debris, replace any unsafe condition.
9Y1200311EUS0098US0
Sensors
• While inspecting the wire harness connector for each sensor,
check for any damage to the sensor.
• If the sensor is retained by threads or by fasteners, insure the
retaining device is fully secured.
9Y1200311EUS0099US0
Ignition System
• Check ignition coil and spark plug cables for hardening,
cracking, chaffing, separation, split boot covers and properly
fitted.
• Replace spark plugs at the proper intervals, as prescribed in the
recommended maintenance.
• Check to make sure all electrical components are fitted
securely.
9Y1200311EUS0100US0
Miscellaneous Electrical
• Check the instrument panel to insure all warning lights are
functioning, MIL, oil pressure and temperature gauges are
registering.
• Check the ignition switch and electrical connectors to insure the
connections are fully seated and locked and the tumbler
mechanism is working properly.
9Y1200311EUS0101US0
1-S66
Recommended Maintenance
The maintenance schedule represents manufacturers
recommended maintenance intervals to maintain proper
engine/equipment function. Specific state and federal regulations
may require equipment operators to conduct comprehensive
engine/equipment inspections at more periodic intervals than those
specified above.
9Y1200311EUS0102US0
[2] FUEL SYSTEM DIAGNOSIS

Engines which use the EControls gasoline fuel injection system
will utilize a gasoline fuel tank which is either part of the chassis or
a standalone vessel for the storage of the gasoline. On EControls
USA emissions certified engines fuel tanks will not have a vented
gasoline tank as the design of the system does not require the use
of any vapor recovery from the fuel tank.
When the engine is operating the fuel is being drawn from the
tank by the suction created from the fuel pump. A inline fuel filter will
be installed either in-line or in the tank to filter out the small
contaminants which may be in the fuel prior to reaching the fuel
pump.
Pressure sensor mounted in the manifold measures the
gasoline pressure for feedback to the ECU. By controlling the fuel
pump outlet pressure, excess fuel is not being sent to the injector
rail and therefore the rail does not have a return line back to the
tank. Any excess pressure is allowed to "bleed back" to the tank
from the Fuel Pressure Regulator. This method of fuel delivery
prevents large amounts of hot fuel from being returned to the tank
from the injector rail which would normally cause a vapor build up in
the fuel tank and subsequently requiring the need for a vapor
recovery system on the engine.
9Y1200311EUS0103US0
1-S67
Gasoline Fuel System Diagnosis
Step Action Value(s) Yes No

Were you referred to this procedure by a DTC Go to Go to
G1 –
diagnostic chart? Step G3 Step G2
Connect the EControls GCP Display SW tool Perform
the On Board Diagnostic (OBD) System Check.
Key On Engine Off.
Go to the
System Stopped Mode. Go to
G2 – applicable
Check for DTC 87, 88, 91,92, 627,628,629. Step G3
DTC Table
Are any fuel pump DTCs present in the ECU?
If codes are present follow those procedures first.
Verify that the Gasoline fuel tank has a minimum of
1/4 tank of fuel. Go to Put fuel into
G3 –
Step G4 the fuel tank
Does the vehicle have fuel?
Check the fuel supply line from the tank to the fuel
pump for leakage, crimping, kinks or restriction. Go to Go to
G4 –
Step G2 Step G5
Was there a problem found?
Check the electrical connections at the fuel pump and
insure they are secured and tightened. Go to Go to
G5 –
Step G2 Step G6
Check the Fuel Temperature and Pressure electrical
connectors at the Fuel Pressure Manifold. Go to Go to
G6 –
Step G2 Step G7
Check the fuel delivery lines, to and from, the Fuel
Pressure Manifold for kinks, crimps or blockage of
Go to Go to
G7 fuel flow. –
Step G2 Step G8
Key Off Engine Off.
Remove the fuel inlet hose to the injector rail.
Place the hose end into a container Key On Engine
Go to Go to
G8 Off. –
Step G2 Step G9
Did fuel flow from the hose during the prime
sequence?
Key Off Engine Off.
Using a volt meter place one probe on the VBAT
connector to the fuel pump and ground Key On. Go to Go to
G9 > 80 % of VBAT
Engine Off. Step G16 Step G10
Was the voltage > 80 % of VBAT?

Check the 10 Amp fuel pump fuse.
Go to Go to
G10 –
Step G2 Step G11
Check the fuel pump relay power supply.
Key off Engine Off.
Using a DVOM place the positive probe on Pin 5 at
Go to Go to
G11 the fuel pump relay and battery ground Key On. > 80 % of VBAT
Step G16 Step G12
Engine Off.

Check the supply voltage to the relay.
Using a DVOM place the positive lead on Pin 3 at the
Go to Replace supply
G12 relay and battery ground. > 80 % of VBAT
Step G13 voltage wiring
1-S68

Check the fuel pump signal circuit at the ECU.
Using DVOM place the Positive probe at the relay
and ground. Go to Go to
G13 –
Key On Engine Off. Step G14 Step G15
Was the voltage present?

Replace fuel pump relay.
Go to
G14 – –
Step G2
Is this action Complete?
Replace the ECU.
Go to
G15 – –
Step G2
Check for restricted fuel pump strainer.
Check for plugged fuel filter. Go to
G16 – –
Step G2
Was a problem found?
Replace fuel pump.
Go to
G17 – –
Step G2
9Y1200311EUS0104US0
1-S69
LPG/NG Fuel System Diagnosis

Were you referred to this procedure by a DTC Go to Go to
L1 –
diagnostic chart? Step L3 Step L2
Connect the Diagnostic tool (KGST).
Go to the
Key On Engine Off System Mode Stopped Go to
L2 – applicable
Step L3
DTC Table
Are any DTCs present in the ECU?
Verify that the LPG/NG fuel tank has a minimum 1/4
Refuel tank
tank of fuel, and that the manual valve is open. Go to
L3 – and Open
Step L4
Valve
Is the tank valve open and fuel in the tank?
Connect a 0 to 69 kPa (0 to 0.70 kgf/cm2, 0 to10 psi)
gauge to the primary test port of the dual stage
regulator (DSR).Key On Engine Running System 14 to 24 kPa
Go to Go to
L4 Running ModeObserve the pressure reading, for the (0.14 to 0.24kgf/cm2,
Step L13 Step L5
DSR primary pressure. 2.0 to 3.5 psi)
Is the fuel pressure ABOVE the specified value?

Turn OFF the ignition.
Disconnect the LPG/NG Fuel lock Off electrical
connector.Install a test light between the 12 V supply
pin of the LPG/NG Fuel lock-off connector and Go to Go to
L5 12 V
battery ground, or connect a DVOM between the two Step L6 Step L12
pins. Crank the engine. The test light should
illuminate or 12 V should be present.Does the test
light illuminate?
Using a DVOM, check the resistance of the LPG/NG
fuel lock-off. Go to Go to
L6 12 to 24 W
Step L7 Step L14
Is the resistance within the specified range?
Turn the ignition OFF.
Close the manual shut-off valve on the LPG/NG tank.
CAUTION
• When disconnecting LPG/NG fuel lines,
Go to Go to
L7 LPG/NG may be present. Perform this step in –
Step L8B Step L8A
a well ventilated area.
Slowly loosen the fuel inlet hose fitting, at the inlet of
the LPL.
Was fuel present, when the fitting was loosened?

Engines fitted with a LPG/NG in-line fuel filter:
Go to Go to
L8A Slowly loosen the inlet to the fuel filter. –
Step L11 Step L9
Was fuel present, when the fitting was loosened?
Engines fitted with a integrated filter to the
LPL.Remove the filter from the LPL.Empty the
contents, of the inlet side of the LPG/NG fuel filter,
onto a clean surface.Inspect the contents of the
LPG/NG fuel filter, for an excessive amount of foreign
Go to Go to
L8B material or water. –
Step L11 Step L9
If necessary, locate and repair the source of
contamination.Verify if the LPG/NG fuel filter is not
restricted or plugged.
Was a problem found?

With the fuel line loose at the fuel filter inlet (in-line
filter) or at the LPL inlet.Slowly open and close the
manual valve. Go to Go to
L9 –
Step L14 Step L10
Did fuel begin to flow when the manual valve was
opened?
1-S70

Check the fuel supply system, the hoses are plugged
or restricted or the tank valve is not opening.
Go to
L10 Locate and repair the problem. – –
Step L16
Is the action complete?
Replace the fuel filter. Refer to Fuel Filter
Replacement. Go to
L11 – –
Step L16
Replace the open or short, in the lock-off circuit.
Go to
L12 – –
Step L16
Replace the dual stage regulator (DSR).
Refer to Dual Stage Regulator Replacement. Go to
L13 – –
Step L16
Replace the lock-off. Refer to Low Pressure Lock-off
(LPL) Replacement. Go to
L14 – –
Step L16
The fuel supply system is operating normally.
Install the test plug, in the DSR secondary chamber.If

L15 you were sent to this routine by another diagnostic – System OK –
chart, return to the previous diagnostic procedure.

Disconnect all test equipment. Install the primary and
secondary test port plugs, if removed.Start the
engine.Using SNOOP® ? or equivalent, leak check
L16 – System OK –
the test port plugs, if removed.
9Y1200311EUS0105US0
1-S71
(1) Restricted Exhaust System Diagnosis

Exhaust System Description
The emission certified engine has been designed and calibrated
to meet the emission standards in effect for 2010. To help meet the
emission requirements the vehicle has been attached with a three
way catalyst. The catalyst is a three way catalyst, sound damping
and spark arresting unit. Besides controlling the noise created from
the combustion process, and preventing sparks from escaping from
the exhaust system the most important function is treating the
exhaust gases which are created from the combustion process. The
three-way catalyst consists of a honeycomb core coated with a
mixture of precious metals. The hot gases flow through the catalyst
honeycomb core where an oxidation and reduction reactions take
place. These chemical reactions reduce the amount of CO, HC and
NOX in the engines exhaust. The Exhaust gas then flows through
the tailpipe outlet.
During normal operation the exhaust system could become
damaged. Damage which reduces the flow of the exhaust gas will
create increased back pressure in the engine. Reduction in exhaust
flow can result from crushed muffler outlets or melted catalyst brick
inside the converter.
It may be necessary to measure the back pressure in the
exhaust system. To determine if the back pressure in the engine is
correct use the following procedure.
 Diagnostic Aids
Tools Required:
• Back pressure gage 0 to 69 kPa (0 to 0.70 kgf/cm2, 0 to 10 psi)
Diagnostic Scan Tool:
• KGST Diagnostic Tool
9Y1200311EUS0106US0
Check at Heated Exhaust Gas Oxygen Sensor (HEGO)
1. Carefully remove the HEGO.
2. Install exhaust back pressure gage in place of the HEGO Refer
to Figure 1.
3. With the engine idling at normal operating temperature, observe
the exhaust system back pressure reading on the gage.
Reading should not exceed 8.6 kPa (0.088 kgf/cm2, 1.25 psi).
4. Increase engine speed to 2000 RPM and observe gage.
Reading should not exceed 20.7 kPa (0.21 kgf/cm2, 3 psi).
5. If the back pressure at either speed exceeds specification, a
restricted exhaust system is indicated.
6. Inspect the entire exhaust system for a collapsed pipe, heat
distress or possible internal muffler failure.
7. If there are no obvious reasons for the excessive back pressure,
the catalytic converter is suspected to be restricted and should
be replaced using the recommended procedures.
(1) Back Pressure Gage (3) Exhaust Manifold
(2) Oxygen Sensor (O2S)
9Y1200311EUS0107US0
1-S72
[3] DTC LIST

Name Intake Manifold Temp Tmap Sensor
DTC P0111 P0112 P0113
SPN 105 105 105
J1939
FMI 15 4 3
Intake Manifold Intake Manifold Intake Manifold
DTC Name Temperature Exceeds Temperature Voltage Low Temperature Voltage High
Stage1
• Intake air temperature • Sensor/Wiring harness • Sensor/Wiring harness
Detected Item abnormality open/short/damage short to power
(High side stage 1) • Sensor malfunction • Sensor malfunction
• Key On or Engine • Key On or Engine • Key On or Engine
Running Running Running
DTC Set
• Intake Manifold
Preconditions
Temperature Sensor is
Normal
• Depend on OEM • Intake Manifold • Intake Manifold
DTC Set Conditions Temperature Sensor Temperature Sensor
Voltage <= 0.1 volts Voltage >= 4.6 volts
Period for • 1.0 sec • 1.0 sec • 1.0 sec
Judgmentor or
Number of
Occurrence for
Judgment
• Depend on OEM • Simulate Intake Manifold • Simulate Intake Manifold
Temperature 30.0 °C Temperature 30.0 °C
(86.0 °F) (86.0 °F)
System Action
• O2 F/B Adaptive Learn • O2 F/B Adaptive Learn
Stop Stop
• Throttle Limit 30 % • Throttle Limit 30 %
Enable   
MIL Depend on OEM  
Lamp Depend on OEM – –
9Y1200311EUS0223US0
1-S73
Name Engine Over Heat Engine Coolant Sensor

DTC P0116 P0117 P0118
SPN 110 110 110
J1939
FMI 15 4 3
Engine Coolant Engine Coolant Sensor Engine Coolant Sensor
DTC Name Temperature Exceeds Voltage Low Voltage High
Stage1
• Engine coolant • Sensor/Wiring harness • Sensor/Wiring harness
Detected Item temperature abnormality open/short/damage short to power
(High side stage 1) • Sensor malfunction • Sensor malfunction
• Engine Running • Key On or Engine • Key On or Engine
DTC Set
• Engine Coolant Sensor Running Running
Preconditions
is Normal
• Depend on OEM • Engine Coolant Sensor • Engine Coolant Sensor
DTC Set Conditions
Voltage <= 0.1 volts Voltage >= 4.9 volts
Period for • 5 sec • 1.0 sec • 1.0 sec
Judgmentor or
Number of
Occurrence for
Judgment
• Depend on OEM • Simulate Engine • Simulate Engine
Coolant Temperature Coolant Temperature
70.0 °C (158.0 °F) 70.0 °C (158.0 °F)
System Action
Stop Stop
• Throttle Limit 30% • Throttle Limit 30%
Enable   
9Y1200311EUS0224US0
1-S74
Name TPS Intake Manifold Temp

DTC P0122 P0123 P0127
SPN 51 51 105
J1939
FMI 4 3 0
TPS1 Signal Voltage Low TPS1 Signal Voltage High Intake Manifold
DTC Name Temperature Exceeds
Stage2
• TPS circuit in the • TPS circuit in the • Intake air temperature
harness harness short to power abnormality
Detected Item
open/short/damage • TPS malfunction (High side stage 2)
• TPS malfunction
DTC Set
• Motor Power Supply is • Motor Power Supply is • Intake Manifold
Preconditions
Normal or TPS Power Normal or TPS Power Temperature Sensor is
Supply is Normal Supply is Normal Normal
• TPS1 Voltage <= • TPS1 Voltage >= • Depend on OEM
DTC Set Conditions
0.2 volts 4.8 volts
Judgmentor or
Number of
Occurrence for
Judgment
System Action • Engine Stop (Fuel Cut) • Engine Stop (Fuel Cut) • Depend on OEM
Enable   
MIL   Depend on OEM
Lamp – – Depend on OEM
9Y1200311EUS0225US0
1-S75
Name Heated O2 Sensor

DTC P0130 P0134 P0135
SPN 3217 3217 523719
J1939
FMI 2 5 2
Pre O2 Sensor Stay at one Pre O2 Sensor Non Activity Pre O2 Heater Error
DTC Name
side
• Exhaust leaks upstream • Open feed circuit to O2 • Wiring harness
or near the HEGO heater open/short/damage
sensor • Open heater ground • O2 heater malfunction
• Fuel pressure circuit
abnormality • Open or shorted to
Detected Item
• An injector that is stuck ground O2 signal wire
closed • Open sensor ground
• Wiring harness • Inoperative sensor
open/short/damage
• Sensor malfunction
DTC Set • Depend on OEM • Depend on OEM • Key On or Engine
Preconditions Running
• Judgment is Rich or • Pre O2 Sensor is Non • O2 Heater Running
Judgment is Lean Active Current <= 170 mA or
DTC Set Conditions Current >= 10.5 A
• O2 Heater Stop
• Voltage <= 3.0 volts
Period for • Depend on OEM • Depend on OEM • 1.0 sec
Judgmentor or
Number of
Occurrence for
Judgment
• O2 F/B Stop • None • O2 F/B Adaptive Learn
System Action
Stop
Enable   
MIL   
Lamp – – –
9Y1200311EUS0226US0
1-S76
Name Heated O2 Sensor

DTC P0140 P0141
SPN 3227 523726
J1939
FMI 5 2
DTC Name Pre O2 Sensor Non Activity Pre O2 Heater Error
• Open feed circuit to O2 heater • Wiring harness open/short/damage
• Open heater ground circuit • O2 heater malfunction
• Open or shorted to ground O2 signal
Detected Item
wire
• Open sensor ground
• Inoperative sensor
DTC Set • Depend on OEM • Key On or Engine Running
Preconditions
• Post O2 Sensor is Non Active • O2 Heater Running Current <= 170 mA
or Current >= 10.5 A
DTC Set Conditions
• O2 Heater Stop
• Voltage <= 3.0 volts
Period for • Depend on OEM • 1.0 sec
Judgmentor or
Number of
Occurrence for
Judgment
System Action • O2 F/B Adaptive Learn Stop • O2 F/B Adaptive Learn Stop
Enable  
MIL  
Lamp – –
9Y1200311EUS0227US0
1-S77
Name Injector Engine Over Heat

DTC P0201 P0202 P0203 P0217
SPN 651 652 653 110
J1939
FMI 2 2 2 0
Injector1 Error Injector2 Error Injector3 Error Engine Coolant
DTC Name Temperature
Exceeds Stage2
• Injector • Injector • Injector • Engine coolant
malfunction malfunction malfunction temperature
Detected Item abnormality
(High side stage
2)
• Engine Running • Engine Running • Engine Running • Engine Running
DTC Set • Battery Voltage • Battery Voltage • Battery Voltage • Engine Coolant
Preconditions is Normal is Normal is Normal Sensor is
Normal
• No Serge • No Serge • No Serge • Depend on OEM
DTC Set Conditions
Detection Detection Detection
Period for • 20 times • 20 times • 20 times • 5 sec
Judgmentor or
Number of
Occurrence for
Judgment
• O2 F/B Adaptive • O2 F/B Adaptive • O2 F/B Adaptive • Depend on OEM
System Action
Learn Stop Learn Stop Learn Stop
Enable    
MIL    Depend on OEM
Lamp – – – Depend on OEM
9Y1200311EUS0228US0
1-S78
Name Engine Over Run TPS

DTC P0219 P0222 P0223
SPN 190 3673 3673
J1939
FMI 0 4 3
Engine Speed Exceeds TPS2 Signal Voltage Low TPS2 Signal Voltage High
DTC Name
threshold Engine Speed
• Engine over speed • TPS circuit in the • TPS circuit in the
condition, stuck throttle, harness harness short to power
Detected Item large vacuum leak into open/short/damage • TPS malfunction
intake manifold after • TPS malfunction
throttle blade
• Engine Running • Key On or Engine • Key On or Engine
Running Running
DTC Set
• Motor Power Supply is • Motor Power Supply is
Preconditions
Normal or TPS Power Normal or TPS Power
Supply is Normal Supply is Normal
• Engine Speed > • TPS2 Voltage <= 0.2 • TPS2 Voltage >= 4.8
DTC Set Conditions
4300 rpm volts volts
Period for • 20 times within 10 sec • 0.5 sec • 0.5 sec
Judgmentor or
Number of
Occurrence for
Judgment
System Action • Depend on OEM • Engine Stop (Fuel Cut) • Engine Stop (Fuel Cut)
Enable   
MIL   
Lamp – – –
9Y1200311EUS0229US0
1-S79
Name Tmap Sensor Crank Sensor

DTC P0237 P0238 P0335 P0335
SPN 102 102 636 636
J1939
FMI 4 3 2 2
Intake Manifold Intake Manifold Crank Sensor Error Crank Sensor Error
DTC Name Pressure Voltage Pressure Voltage
Low High
• Sensor/Wiring • Sensor/Wiring • Loss of sensor • Loss of sensor
harness harness short to feed feed
open/short power • Open sensor • Open sensor
/damage • Sensor ground ground
Detected Item • Sensor malfunction • Open or shorted • Open or shorted
malfunction to ground signal to ground signal
wire wire
• Sensor • Sensor
malfunction malfunction
DTC Set • Key On or • Key On or • Engine Cranking • Engine Running
Preconditions Engine Running Engine Running
• Intake Manifold • Intake Manifold • No recognition of • Pulse count per
Pressure Sensor Pressure Sensor Crank sensor rotation is Error
DTC Set Conditions
Voltage <= Voltage >= pulse
0.1 volts 4.9 volts
Period for • 1.0 sec • 1.0 sec • 2.0 sec • 16 times
Judgmentor or
Number of
Occurrence for
Judgment
• Simulate Intake • Simulate Intake • Engine Stop • Engine Stop
Manifold Manifold (Fuel Cut) (Fuel Cut)
Pressure from Pressure from
Engine Speed Engine Speed
and Throttle and Throttle
Position Position
System Action
• O2 F/B Adaptive • O2 F/B Adaptive
Learn Stop Learn Stop
• Speed Limit • Speed Limit
2050 rpm 2500 rpm
• Throttle Limit • Throttle Limit
30 % 30 %
Enable    
MIL    
Lamp – – – –
9Y1200311EUS0230US0
1-S80
Name Cam Sensor IG Coil

DTC P0341 P0351 P0352 P0353
SPN 723 1268 1269 1270
J1939
FMI 2 2 2 2
DTC Name Cam Sensor Error Ignition Coil1 Error Ignition Coil2 Error Ignition Coil3 Error
• Loss of feed • A short to ground • A short to ground • A short to ground
voltage to Cam or open circuit in or open circuit in or open circuit in
sensor the harness the harness the harness
• Loss of sensor • An open internal • An open internal • An open internal
feed to the primary to the primary to the primary
• Open sensor coil coil coil
Detected Item
ground
• Open or shorted
to ground signal
wire
• Sensor
malfunction
DTC Set • Engine Running • Key On or • Key On or • Key On or
Preconditions Engine Running Engine Running Engine Running
• Pulse count per • System LSI • System LSI • System LSI
DTC Set Conditions rotation is Error detects Open or detects Open or detects Open or
Short to Power Short to Power Short to Power
Period for • 24 times • 1.0 sec • 1.0 sec • 1.0 sec
Judgmentor or
Number of
Occurrence for
Judgment
• Engine Stop • O2 F/B Adaptive • O2 F/B Adaptive • O2 F/B Adaptive
System Action
(Fuel Cut) Learn Stop Learn Stop Learn Stop
MIL    
Lamp – – – –
9Y1200311EUS0231US0
1-S81
Name Oil Pressure Battery

DTC P0524 P0562 P0563
SPN 100 168 168
J1939
FMI 1 17 15
DTC Name Oil Pressure Low Battery Voltage Low Battery Voltage High
• Oil pressure is low • Wiring harness • System voltage
Detected Item open/short/damage abnormality (High side)
• Battery abnormality
• Engine Speed >= • Engine Running • Key On or Engine
DTC Set
800 min-1 (rpm) Running
Preconditions
• Oil Switch is Normal
• Depend on OEM • Battery Voltage <= • Battery Voltage >=
DTC Set Conditions
8.0 volts 16.0 volts
Judgmentor or
Number of
Occurrence for
Judgment
• Depend on OEM • Throttle Limit 20% • Throttle Limit 20%
• Force Idle • Speed Limit 2500rpm
System Action
Stop Stop
Enable   
9Y1200311EUS0232US0
1-S82
Processor
Name Processor Diagnostics EEPROM
Diagnostics
DTC P0601 P0604 P0605 P0606
SPN 628 523720 523721 629
J1939
FMI 13 12 2 12
ROM Error RAM Error EEPROM Error Mutual surveillance
DTC Name Error
(Microprocessor)
• ROM • RAM • EEPROM • Microprocessor
Detected Item
malfunction malfunction malfunction malfunction
DTC Set • Key On or • Key On or • Key On or • Key On or
Preconditions Engine Running Engine Running Engine Running Engine Running
• Microprocessor • Microprocessor • Unique ID is • Microprocessor
DTC Set Conditions
Error Error incorrect Error
Period for • N/A • N/A • N/A • N/A
Judgmentor or
Number of
Occurrence for
Judgment
• Engine Stop • Engine Stop • None • Engine Stop
System Action
(Fuel Cut) (Fuel Cut) (Fuel Cut)
MIL    
Lamp – – – –
9Y1200311EUS0233US0
1-S83
Name Fuel Pump Sensor Power Source Power Relay

DTC P0627 P0642 P0687
SPN 1347 3509 1485
J1939
FMI 2 4 3
DTC Name Fuel Pump Error Sensor Power Source Error Power Relay Error
• Wiring harness • Wiring harness • Power Relay
Detected Item open/short/damage open/short/damage malfunction
• Fuel Pump malfunction • ECU malfunction
DTC Set • Key On • Key On or Engine • Key Off
Preconditions • Un-Driving Running
• Fuel Pump Voltage is • Sensor Power Source < • ECU is alive
DTC Set Conditions
Low 4.1 Volts
Period for • 1 sec • 1.0 sec • 30 sec
Judgmentor or
Number of
Occurrence for
Judgment
• None • Throttle Limit 30% • None
System Action • O2 F/B Adaptive Learn
Stop
Enable   
MIL   
Lamp – – –
9Y1200311EUS0234US0
1-S84
Name ETV
DTC P1601 P1602 P1603 P1604
SPN 523710 523710 523710 523711
J1939
FMI 2 0 1 2
F/B Error1 F/B Error2 F/B Error2 Motor Error
DTC Name
(Valve Open) (ISC Close)
Detected Item • ETV malfunction • ETV malfunction • ETV malfunction • ETV malfunction
• Key On or • Key On or • Key On or • Key On or
Engine Running Engine Running Engine Running Engine Running
DTC Set • Battery Voltage • Battery Voltage • Battery Voltage • ETV Power
Preconditions is Normal is Normal is Normal Supply Voltage
• TPS is Normal • TPS is Normal • TPS Adaptive is Normal
Completed
• The difference of • The difference of • The difference of • Short to Power
Target TPS and Actual TPS and Actual TPS and • Short to GND
Actual TPS >= Target TPS >= Target TPS >= • Temperature
0.6 volts and 0.5 volts 0.05 volts abnormality
Target TPS <
DTC Set Conditions
1.5 volts or the
difference of
Target TPS and
Actual TPS >=
1.0 volts
Period for • 1.3 sec • 0.5 sec • 10.0 sec • 0.3 sec
Judgmentor or
Number of
Occurrence for
Judgment
• Engine Stop • Engine Stop • Engine Stop • Engine Stop
System Action
(Fuel Cut) (Fuel Cut) (Fuel Cut) (Fuel Cut)
MIL    
Lamp – – – –
9Y1200311EUS0235US0
1-S85
Name ETV
DTC P1605 P1606 P1607 P1608
SPN 523712 523712 523712 523713
J1939
FMI 2 1 7 0
F/B Error3 Motor Current Open Return Spring DBW Open Stuck
DTC Name
Error Breakage
Detected Item • ETV malfunction • ETV malfunction • ETV malfunction • ETV malfunction
• Key On or • Key On or • Key On or • TPS is
Engine Running Engine Running Engine Running Abnormality
DTC Set • Battery Voltage • Battery Voltage (Except Power
Preconditions is Normal is Normal Supply Error)
• Motor drive
circuit is Normal
• ETV Drive Duty • Motor Power • Middle Valve • Filling-up
>= 100 % Supply Voltage Adaptive Value efficiency >=
DTC Set Conditions <= 6.0 volts >= 3.8 volts 50 %
• Engine Speed
>= 4000 rpm
Period for • 0.7 sec • 0.35 sec • 0 sec • 0.35 sec
Judgmentor or
Number of
Occurrence for
Judgment
• Engine Stop • Engine Stop • Speed Limit • Engine Stop
System Action
(Fuel Cut) (Fuel Cut) 1600 rpm (Fuel Cut)
MIL    
Lamp – – – –
9Y1200311EUS0236US0
1-S86
Name Oil Switch Processor Diagnostics Gasoline Fuel System

DTC P1609 P1616 P1617
SPN 523714 523715 523716
J1939
FMI 2 2 2
DTC Name Oil Switch Error A/D Converter Error Gasoline Fuel System Error
• Sensor malfunction • A/D Converter • Exhaust leaks upstream
malfunction or near the HEGO
sensor
• Fuel pressure
abnormality
Detected Item
• An injector that is stuck
closed
• Wiring harness
open/short/damage
• O2 sensor malfunction
DTC Set • Key On • Key On or Engine • Engine Running
Preconditions Running
• Oil Pressure SW Open • Microprocessor Error • Compensation value of
(Oil pressure is normal) O2 F/B and Adaptive
value of O2 F/B > 35%
DTC Set Conditions
• Compensation value of
O2 F/B and Adaptive
value of O2 F/B < -35%
Period for • 8.0 sec • N/A • 0 sec
Judgmentor or
Number of
Occurrence for
Judgment
• None • Engine Stop (Fuel Cut) • Throttle Limit = 30%
• Speed Limit = 2500 rpm
System Action • O2 F/B Stop
• O2 F/B Adaptive Learn
Stop
Enable   
MIL   
Lamp – – –
9Y1200311EUS0237US0
1-S87
Name TPS
DTC P1618 P1619
SPN 523717 523718
J1939
FMI 2 1
DTC Name TPS Main I/F Circuit Error TPS Power Supply Error
Detected Item • TPS malfunction • TPS malfunction
• Key On or Engine Running • Key On or Engine Running
• Motor Power Supply is Normal or TPS • Motor Power Supply is Normal
DTC Set
Power Supply is Normal
Preconditions
• TPS1 is Normal
• TPS2 is Normal
• Partial pressure terminal of TPS >= 4.8 • TPS Power Supply Voltage <= 4.1 volts
DTC Set Conditions volts or Partial pressure terminal of TPS
<= 0.2 volts
Period for • 0.45 sec • 0.5 sec
Judgmentor or
Number of
Occurrence for
Judgment
System Action • Engine Stop (Fuel Cut) • Engine Stop (Fuel Cut)
Enable  
MIL  
Lamp – –
9Y1200311EUS0238US0
1-S88
Processor
Name Lock Off Valve Solenoid Valve LPG Fuel System
Diagnostics
DTC P1621 P1624 P1628 P1629
SPN 523722 523724 523728 523729
J1939
FMI 12 31 2 2
Mutual surveillance Lock Off Valve Error Solenoid Valve LPG Fuel System
DTC Name
Error (System LSI) Error Error
• System LSI • Wiring harness • Wiring harness • Exhaust leaks
malfunction short to power open/short/ upstream or near
• Lock Off Valve damage the HEGO
malfunction • Solenoid Valve sensor
• Lock Off Valve malfunction • Fuel pressure
Relay abnormality
malfunction • Fuel property
abnormality
Detected Item • Mixier
malfunction
• Vaporizer
malfunction
• Wiring harness
open/short/dama
ge
• O2 sensor
malfunction
DTC Set • Key On or • Engine Running • Key On or • Engine Running
Preconditions Engine Running Engine Running
• System LSI Error • Engine Keeps • Solenoid Valve • Gaseous
Running after Voltage is Low Solenoid > 98%
Key Off • Gaseous
DTC Set Conditions * Error is Solenoid < 2%
canceled by 3
normal
engine-stops.
Period for • N/A • Depend on OEM • 1 sec • Depend on OEM
Judgmentor or
Number of
Occurrence for
Judgment
• Engine Stop • Engine Stop • O2 F/B Stop • Depend on OEM
System Action (Fuel Cut) (Spark Cut) • O2 F/B Adaptive
Learn Stop
Enable    
MIL    
Lamp – – – –
9Y1200311EUS0239US0
1-S89
Name APS
DTC P2122 P2123 P2127 P2128
SPN 91 91 29 29
J1939
FMI 4 3 4 3
APS1 Signal APS1 Signal APS2 Signal APS2 Signal
DTC Name
Voltage Low Voltage High Voltage Low Voltage High
• Wiring harness • Wiring harness • Wiring harness • Wiring harness
open/short open/short open/short open/short
Detected Item
/damage /damage /damage /damage
• APS malfunction • APS malfunction • APS malfunction • APS malfunction
DTC Set • Key On or • Key On or • Key On or • Key On or
Preconditions Engine Running Engine Running Engine Running Engine Running
• APS1 Voltage • APS1 Voltage • APS2 Voltage • APS2 Voltage
DTC Set Conditions
<= 0.1 volts >= 4.9 volts <= 0.1 volts >= 4.9 volts
Period for • 1.0 sec • 1.0 sec • 1.0 sec • 1.0 sec
Judgmentor or
Number of
Occurrence for
Judgment
System Action • Idle • Idle • Idle • Idle
Enable    
MIL    
Lamp – – – –
9Y1200311EUS0240US0
1-S90
Name TPS APS CAN Frame

DTC P2135 P2138 U1001
SPN 51 91 695
J1939
FMI 2 2 9
DTC Name TPS Correlation Error APS Correlation Error CAN Frame Error
• TPS malfunction • APS malfunction • Wiring harness
open/short/damage
Detected Item
• CAN System
malfunction
• Motor Power Supply is • APS1 is Normal
Normal or TPS Power • APS2 is Normal
DTC Set
Supply is Normal
Preconditions
• TPS1 is Normal
• TPS2 is Normal
• TPS Main I/F Circuit is
Normal
• TPS1 Voltage + TPS2 • The difference of APS1 • CAN_TSC1 Frame time
Voltage <= 4.1 volts or and APS2 > 20 % out Error
DTC Set Conditions
TPS1 Voltage + TPS2
Voltage >= 5.5 volts
Period for • 0.9 sec • 1.5 sec • 1000 ms
Judgmentor or
Number of
Occurrence for
Judgment
• Engine Stop (Fuel Cut) • Idle • Force Idle
• Throttle Limit 15%
System Action
• O2 F/B Adaptive Learn
Stop
Enable   
MIL   
Lamp – – –
9Y1200311EUS0241US0
1-S91
[4] DIAGNOSIS PROCEDURE BY DTC

(1) Crank/Cam Sensors (DTC 335, 341)
DTC 335-Crank Sensor Error

• Hardware: Crankshaft Position sensor
• Enabling Conditions: Engine cranking or engine running
• Set Conditions: Pulse count per rotation is Error more than 16 times, No recognition of crank sensor pulse for
longer 2 seconds
• Corrective Action(s): Illuminate MIL, Engine stop (Fuel cut)
• Emissions related fault
• Possible Causes: Loss of sensor feed, open sensor ground, open or shorted to ground signal wire, sensor
malfunction
9Y1200311EUS0108US0
The crankshaft position sensor is a magnetic pick-up sensor installed in the engine block adjacent to a "coded"
trigger wheel located on the flywheel. The sensor-trigger wheel combination is used to determine crankshaft position
(with respect to TDC cylinder #1 compression) and the rotational engine speed. Determination of the crankshaft
position and speed is necessary to properly activate the ignition, fuel injection, and throttle governing systems for
precise engine control.
The ECU must see a valid crankshaft position signal while running. The engine typically stalls or dies as a result
of this fault condition due to the lack of crankshaft speed input resulting in the inability to control ignition timing.
9Y1200311EUS0109US0
1-S92
Diagnostic Aids Chart
9Y1200311EUS0110US0
1-S93
9Y1200311EUS0111US0
1-S94
DTC 341-Camshaft Input Signal Noise

• Hardware: Camshaft Position sensor
• Enabling Conditions: Engine Running
• Set Conditions: Pulse count per rotation is error more than 24 times
• Possible Causes: CMP+ or CMP− circuits in wrong connector terminal slot, improper CMP signal due to sensor
air gap too large, Loss of feed voltage to cam sensor, Loss of sensor feed, Open sensor ground, Open or shorted
to ground signal wire, Sensor malfunction
9Y1200311EUS0112US0
The camshaft position sensor is a magnetic pick-up sensor installed in the engine block or valve train adjacent to
a "coded" trigger wheel located on or off of the camshaft. The sensor-trigger wheel combination is used to determine
cam position so the ECU can determine which piston is coming up on TDC. Determination of the camshaft position
is necessary to identify the stroke (or cycle) of the engine to properly activate the fuel injection system and ignition
(for coil-on-plug engines) for precise engine control.
For a cam synchronized engine, the ECU must see a valid camshaft position signal while running. If no signal is
present, the signal amplitude is too high (due to improper air gap with respect to trigger wheel), or an irregular cam
pattern is detected causing the ECU to resynchronize this fault will set. Irregular cam patterns can be detected by the
ECU and can be caused by: electrical noise, poor machining of trigger wheel, or trigger wheel run out and/or gear
lash. In some instances this fault can cause rough engine operation and can cause the engine to stall or die if attached
with coil-on-plug ignition engines.
Ensure cam circuit used with VR/magnetic pick-up sensors are properly twisted.
9Y1200311EUS0113US0
1-S95
DTC 341-Camshaft Input Signal Noise
9Y1200311EUS0114US0
1-S96
(2) MAP (Manifold Absolute Pressure Sensor) (DTC 237, 238)
DTC 237-Intake Manifold Pressure Voltage Low

• Hardware: Manifold Absolute Pressure Sensor
• Enabling Conditions: Key on or Engine running
• Set Conditions: MAP sensor voltage less than 0.1V for longer than 1 second
• Corrective Action(s): Illuminate MIL and O2 feedback adaptive learn stop. Speed limit is 2500 min-1 (rpm). Throttle
limit is 30%. Simulate Intake Manifold Pressure from Engine Speed and Throttle Position.
• Possible Causes: Sensor or Wiring harness open, short or damage
Sensor malfunction
9Y1200311EUS0115US0
DTC 238-Intake Manifold Pressure Voltage High
• Hardware: Manifold Absolute Pressure Sensor
• Enabling Conditions: Key on or Engine running
• Set Conditions: Intake manifold pressure sensor voltage is upper than 4.9V for longer than 1 second
• Corrective Action(s): Illuminate MIL and O2 feedback adaptive learn stop. Speed limit is 2500 min-1 (rpm). Throttle
limit is 30%. Simulate Intake Manifold Pressure from Engine Speed and Throttle Position.
• Possible Causes: Sensor or wiring harness short to power
Sensor malfunction
9Y1200311EUS0116US0
The Manifold Absolute Pressure sensor is a pressure transducer connected to the intake manifold. It is used to
measure the pressure of air in the manifold prior to induction into the engine. The pressure reading is used in
conjunction with other inputs to determine the rate of airflow to the engine. The rate of airflow into the engine is used
to determine the required fuel flow rate.
When these fault are active, the ECU simulate intake manifold pressure from engine speed and throttle position.
9Y1200311EUS0117US0
1-S97
DTC 237-Intake Manifold Pressure Voltage Low
9Y1200311EUS0118US0
1-S98
DTC 238-Intake Manifold Pressure Voltage High
9Y1200311EUS0119US0
1-S99
(3) IAT (Intake Air Temperature Sensor) (DTC 111, 112, 113, 127)
DTC 111-IAT Exceeds Stage 1

• Hardware: Intake Air Temperature Sensor
• Enabling Conditions: Key on or Engine running. Intake Manifold Temperature Sensor is normal.
• Set Conditions: Depend on OEM
• Corrective Action(s): Depend on OEM
• Non-emissions related fault
• Possible Causes: Damaged inlet air system allowing hotter than normal air into engine intake system
"Depend on OEM": When the DTC occurred, you can check the detail at diagnostic tool monitor.
9Y1200311EUS0120US0
DTC 112-IAT Low Voltage
• Enabling Conditions: Key on or engine running
• Set Conditions: IAT sensor voltage less than 0.1 V for longer than 1 second
• Corrective Action(s): Illuminate MIL, simulate intake manifold temperature at 30.0 °C (86.0 °F), O2 feedback
adaptive learn stop, and throttle limit is 30%
• Possible Causes: Sensor or Wiring harness open, short or damage, sensor malfunction
Sensor malfunction
9Y1200311EUS0121US0
DTC 113-IAT High Voltage
• Set Conditions: IAT sensor voltage greater than 4.6 V for longer than 1 second
• Corrective Action(s): Simulate intake manifold temperature at 30.0 °C (86.0 °F), O2 feedback adaptive learn stop,
and throttle limit is 30%
• Possible Causes: Sensor or Wiring harness short to power, sensor malfunction
Sensor malfunction
9Y1200311EUS0122US0
1-S100
DTC 127-IAT Exceed Stage 2
• Hardware: Intake Air Temperature
• Possible Causes: Damaged inlet air system allowing hotter than normal air into engine intake system
9Y1200311EUS0123US0
The Intake Air Temperature sensor is a thermistor (temperature sensitive resistor) located in the intake manifold
of the engine. It is used to monitor incoming air and the output, in conjunction with other sensors, is used to determine
the airflow to the engine. The ECU provides a voltage divider circuit so that when the air is cool, the signal reads higher
voltage, and lower when warm.
The Manifold Air Temperature is a calculated value based mainly on the IAT sensor at high airflow and influenced
more by the ECT/CHT at low airflow. It is used to monitor incoming air and the output, in conjunction with other
sensors, is used to determine the airflow to the engine, and ignition timing.
9Y1200311EUS0124US0
DTC 111-IAT Higher Than Expected Stage 1
Diagnostic Aids
• This fault will set when inlet air is hotter than normal. The most common cause of high inlet air temperature is a
result of a problem with routing of the inlet air. Ensure inlet plumbing sources are external, is cool, and is not too
close to the exhaust at any point.
• Inspect the inlet air system for cracks or breaks that may allow unwanted underhood air to enter the engine.
• If no problem is found, replace the IAT sensor with a known good part and retest.
9Y1200311EUS0125US0
1-S101
DTC 112-IAT Low Voltage
9Y1200311EUS0126US0
1-S102
DTC 113-IAT High Voltage
9Y1200311EUS0127US0
DTC 127-IAT Higher Than Expected Stage 2
Diagnostic Aids
• This fault will set when inlet air is hotter than normal. The most common cause of high inlet air temperature is a
result of a problem with routing of the inlet air. Ensure inlet plumbing sources are external, is cool, and is not too
close to the exhaust at any point.
• Inspect the inlet air system for cracks or breaks that may allow unwanted underhood air to enter the engine.
• If no problem is found, replace the IAT sensor with a known good part and retest.
9Y1200311EUS0128US0
1-S103
(4) ECT (Engine Coolant Temperature) (DTC 116, 117, 118, 217)
DTC 116-ECT Exceed Stage 1

• Hardware: Engine Coolant Temperature Sensor
• Enabling Conditions: Engine running, Engine coolant sensor is normal
• Possible Causes: Overheating engine, sensor out of calibration, signal wire partially shorted to ground or faulty
ECU
9Y1200311EUS0129US0
DTC 117-ECT Voltage Low
• Set Conditions: ECT sensor voltage less than 0.10 V for longer than 1 second
• Corrective Action(s): Illuminate MIL, simulate engine coolant temperature at 70.0 °C (158.0 °F), O2 feedback
• Possible Causes: Faulty ECU (no voltage on signal wire), signal wire shorted to ground or sensor internally
shorted, Sensor malfunction
9Y1200311EUS0130US0
DTC 118-ECT Voltage High
• Set Condition: ECT sensor voltage greater than 4.9 V for longer than 1 second
• Corrective Action(s): Turn on MIL, simulate engine coolant temperature at 70.0 °C (158.0 °F), O2 feedback
• Possible Causes: Signal wire shorted to power, signal wire open, sensor open internally or open sensor ground,
Sensor malfunction
9Y1200311EUS0131US0
1-S104
DTC 217-ECT Higher Than Expected Stage 2
• Enabling Conditions: Engine running, Engine coolant sensor is normal
Engine coolant temperature is normal
• Possible Causes: Overheating engine, sensor out of calibration, signal wire partially shorted to ground or faulty
ECU
9Y1200311EUS0132US0
The Engine Coolant Temperature sensor is a thermistor (temperature sensitive resistor) located in the engine
coolant. The ECT is used for engine fuel calculation (cold engine), ignition timing control, to enable certain features,
and for engine protection (overheats). The ECU provides a voltage divider circuit so when the sensor reading is cool
the sensor reads higher voltage, and lower when warm.
The fault of DTC 116 and DTC 217 will help protect the engine in the event of over temperature.
The ECU will use a default value for the ECT sensor in the event of the faults of DTC 117 or DTC 118.
9Y1200311EUS0133US0
Diagnostic Aids
• If the "ECT High Voltage" fault is also present, follow the troubleshooting procedures for that fault as it may have
caused "ECT Higher Than Expected 1".
• If the cooling system utilizes an air-to-water heat exchanger (radiator) and fan:
– Check that the radiator has a proper amount of ethylene glycol/water and that the radiator is not leaking
– Ensure that there is no trapped air in the cooling path
– Inspect the cooling system (radiator and hoses) for cracks and ensure connections are leak free
– Check that the fan is operating properly
– Check that the thermostat is not stuck closed
• If the cooling system utilizes a water-to-water heat exchanger:
– Check that the heat exchanger has a proper amount of ethylene glycol/water and that the heat exchanger is
not leaking
– Check that the raw water pickup is not blocked/restricted by debris and that the hose is tightly connected
– Check that the raw water pump/impeller is tact and that it is not restricted
9Y1200311EUS0134US0
1-S105
DTC 117-ECT Voltage Low
9Y1200311EUS0135US0
1-S106
DTC 118-ECT Voltage High
9Y1200311EUS0136US0
Diagnostic Aids
• If the "ECT High Voltage" fault is also present, follow the troubleshooting procedures for that fault as it may have
caused "ECT Higher Than Expected 2".
• If the cooling system utilizes an air-to-water heat exchanger (radiator) and fan:
– Check that the radiator has a proper amount of ethylene glycol/water and that the radiator is not leaking
– Check that the fan is operating properly
• If the cooling system utilizes a water-to-water heat exchanger:
– Check that the heat exchanger has a proper amount of ethylene glycol/water and that the heat exchanger is
not leaking
– Check that the raw water pickup is not blocked/restricted by debris and that the hose is tightly connected
– Check that the raw water pump/impeller is tact and that it is not
9Y1200311EUS0137US0
1-S107
(5) TPS (Throttle Position Sensor) (DTC 122, 123, 222, 223, 1618, 1619, 2135)
DTC 122-TPS1 Signal Voltage Low

• Hardware: Throttle Body-Throttle Position Sensor 1
Motor power supply is normal or TPS power supply is normal
• Set Conditions: TPS1 sensor voltage lower than 0.20 V for longer than 0.5 seconds
• Possible Causes: Loss of 5.00 V reference feed, open or shorted to ground signal circuit, open or shorted to
ground TPS in throttle body, bad ECU
9Y1200311EUS0138US0
DTC 123-TPS1 Signal Voltage High
• Hardware: Throttle Body-Throttle Position Sensor 1
• Set Conditions: TPS1 sensor voltage higher than 4.8 V for longer than 0.5 seconds
• Possible Causes: 5.00 V reference feed (TPS POWER) shorted to voltage, Open sensor ground (TPS GND)
circuit, signal wire shorted to voltage or bad TPS in throttle body
9Y1200311EUS0139US0
1-S108
• Hardware: Throttle Body-Throttle Position Sensor 2 (electronic throttle body only)
• Enabling Condition: Key on or engine running
• Set Condition: TPS2 sensor voltage lower 0.20 V for longer than 0.5 seconds
• Possible Causes: Loss of 5.0 V reference feed, open or shorted to ground signal circuit, open or shorted to ground
TPS in throttle body, bad ECU
9Y1200311EUS0140US0
• Hardware: Throttle Body-Throttle Position Sensor 2 (electronic throttle body only)
• Set Conditions: TPS2 sensor voltage higher than 4.8 V for longer than 0.5 seconds
• Corrective Action(s): Illuminate MIL, engine stop
• Possible Causes: 5.0 V reference feed (TPS POWER) shorted to voltage, Open sensor ground (TPS GND)
circuit, signal wire shorted to voltage or bad TPS in throttle body
9Y1200311EUS0141US0
The throttle controls the airflow through the engine, directly affecting the power output of the engine. When the
throttle is electronically controlled in an Electronic Throttle Body it can be used to control the idle stability and limit
engine speed based on operating conditions.
Each Throttle Position Sensor uses a variable resistor and voltage divider circuit to determine throttle plate
position, and is located within the throttle body. The output of the TPS is linear with angular position. The TPS input(s)
provide angular position feedback of the throttle plate. In an Electronic Throttle Body multiple position feedback
sensors (usually two counteracting potentiometers) are used to perform speed governing with improved safety and
redundancy.
9Y1200311EUS0142US0
DTC 1618-TPS Main I/F Circuit Error
• Hardware: Throttle Body
• Enabling Condition: Key on or engine running, Motor power supply is normal or TPS power supply is normal,
TPS1 is normal, TPS2 is normal
• Set Conditions: Partial pressure terminal of TPS >= 4.8 V or partial pressure terminal of TPS <= 0.2 V for longer
than 0.45 seconds
• Possible Causes: TPS malfunction
9Y1200311EUS0143US0
DTC 1619-TPS Power Supply Error
• Hardware: Throttle Body
• Enabling Condition: Key on or engine running, Motor power supply is normal
• Set Conditions: TPS power supply voltage <= 4.1 V for longer than 0.5 seconds
9Y1200311EUS0144US0
DTC 2135-TPS Correlation Error
• Hardware: Electronic throttle body
• Enabling Conditions: Key on or engine running, Motor power supply is normal or TPS power supply is normal,
TPS1 is normal, TPS2 is normal, TPS main I/F circuit is normal
• Set Condition: TPS1 Voltage + TPS2 Voltage <= 4.1 V or TPS1 Voltage + TPS2 Voltage >= 5.5V for longer than
0.9 seconds
9Y1200311EUS0145US0
1-S109
The throttle is an air valve used to control the amount of air available to the engine for combustion and thereby
the engine's power output. An electronic throttle simply means that a motor is controlled electronically through an
electronic control system to actuate the throttle valve. Electronic throttle control is advantageous because it tends to
offer improved starting, improved idle governing, improved maximum speed governing, excellent load acceptance
and steady-state speed governing, permits engine synchronization, and offers flexibility to protect the engine during
certain fault conditions.
This fault is generated when both feedback sensors in the ETB (TPS1 and TPS2) simultaneously produce
out-of-range faults. This fault indicates that there is no feedback of the throttle valve and as a result throttle control
cannot take place.
9Y1200311EUS0146US0
1-S110
9Y1200311EUS0147US0
1-S111
9Y1200311EUS0148US0
1-S112
9Y1200311EUS0149US0
1-S113
9Y1200311EUS0150US0
1-S114
DTC 2135-TPS Correlation Error
9Y1200311EUS0151US0
1-S115
(6) EGO Sensors ((Exhaust Gas Oxygen) Sensors) (DTC 130, 134, 135, 140,
141)
DTC 130-Pre O2 Sensor Stay at One Side

• Hardware: Heated O2 Sensor
• Enabling Conditions: Depend on OEM
• Set Conditions: Judgment continue rich or lean, judgment period is depended on OEM
• Corrective Action(s): Illuminate MIL, O2 feedback stop
• Possible Causes: Exhaust leaks upstream or near the O2 sensor, Fuel pressure is abnormally, An injector that is
stuck closed, Wiring harness open or short, sensor malfunction
9Y1200311EUS0152US0
DTC 134-Pre O2 Sensor Non Activity
• Hardware: Heated O2 Sensor (Pre-Catalyst)
• Set Conditions: O2 sensor is non active, judgment period is depended on OEM
• Corrective Action(s): Illuminate MIL
• Possible Causes: Open feed circuit to O2 heater, Open heater ground circuit, Open or shorted to ground O2 signal
wire, open sensor ground (SENSOR GROUND), inoperative sensor
9Y1200311EUS0153US0
1-S116
The heated O2 sensor is a switching-type sensor about stoichiometry that measures the oxygen content present
in the exhaust to determine if the fuel flow to the engine is correct. If there is a deviation between the expected reading
and the actual reading, fuel flow is precisely adjusted using the Closed Loop multiplier and then "learned" with the
Adaptive multiplier. The multipliers only update when the system is in "CL Active" control mode.
Cold or non-responsive is defined as the actual impedance of the sensor heater not reaching the target
impedance.
9Y1200311EUS0154US0
DTC 135-Pre O2 Heater Error
• Set Conditions: O2 heater running current above 10.5 A or less than 170 mA, O2 heater stop, Voltage less than
3.0 V for longer 1 second
• Corrective Action(s): Illuminate MIL, O2 feedback adaptive learn stop
• Possible Causes: Wiring harness open, short, or damaged, O2 heater malfunction
9Y1200311EUS0155US0
DTC 140-Post O2 Sensor Non Activity
• Hardware: Heated O2 Sensor (Pre-Catalyst)
• Set Conditions: O2 sensor is non active, judgment period is depended on OEM
• Possible Causes: Open feed circuit to O2 heater, Open heater ground circuit, Open or shorted to ground O2 signal
wire, open sensor ground (SENSOR GROUND), inoperative sensor
9Y1200311EUS0221US0
The heated O2 sensor is a switching-type sensor about stoichiometry that measures the oxygen content present
in the exhaust to determine if the fuel flow to the engine is correct. If there is a deviation between the expected reading
and the actual reading, fuel flow is precisely adjusted using the Closed Loop multiplier and then "learned" with the
Adaptive multiplier. The multipliers only update when the system is in "CL Active" control mode.
Cold or non-responsive is defined as the actual impedance of the sensor heater not reaching the target
impedance.
9Y1200311EUS0154US0
DTC 141-Post O2 Heater Error
• Set Conditions: O2 heater running current above 10.5 A or less than 170 mA, O2 heater stop, Voltage less than
3.0 V for longer 1 second
• Possible Causes: Wiring harness open, short, or damaged, O2 heater malfunction
9Y1200311EUS0222US0
1-S117
DTC 134-Pre O2 Sensor Non Activity
9Y1200311EUS0156US0
1-S118
(7) Engine Speed (DTC 219)
DTC 219-Engine Speed Exceeds Threshold Engine Speed

• Hardware: Max Govern Speed Override- Crankshaft Position Sensor
• Fault Condition-Engine speed greater 4300 min-1 (rpm) for 20 times within in 10 seconds
• Corrective Action(s): Illuminate MIL, Depend on OEM
• Possible Causes: Engine over speed condition, stuck throttle, large vacuum leak into intake manifold after throttle
blade
9Y1200311EUS0157US0
DTC 219-Engine Speed Exceeds Threshold Engine Speed
Diagnostic Aids
NOTE
• If any other DTCs are present, diagnose those first.
• Ensure that no programmed governor speeds exceed the limit set in the diagnostic calibration for Max Govern
Override Speed
• Check mechanical operation of the throttle
• Check the engine intake for large air leaks downstream of the throttle body
9Y1200311EUS0158US0
1-S119
(8) Injectors (DTC 201, 202, 203)
DTC 201-Injector 1 Error

• Hardware: Each Injector (each cylinder in the block order)
• Enabling Conditions: Engine running, Battery voltage is normal
• Set Conditions: No serge detection over 20 times
• Emissions-related fault
• Possible Causes: Loss of 12.0 V feed to injector, open injector coil, open or shorted to ground injector driver circuit
in engine harness, bad ECU, injector malfunction
9Y1200311EUS0159US0
The fuel injector is an electronically controlled valve and nozzle that is controlled to deliver a precise quantity of
fuel to a cylinder. Each fuel injector is supplied 12.0 V from the power relay and is operated by the ECU through a low
side driver (LSD) circuit that is monitored for the correct voltage for the current state of the injector (on or off).
9Y1200311EUS0160US0
1-S120
9Y1200311EUS0161US0
1-S121
(9) Oil Pressure Switch (DTC 524, 1609)
DTC 524-Oil Pressure Low

• Hardware: Engine Oil Pressure Switch
• Enabling Conditions: Engine running speed is higher than 800 min-1 (rpm), Oil switch is normal
• Possible Causes: Oil pressure problem with engine, oil pressure switch failure, oil pressure switch circuit shorted
to ground, faulty ECU
9Y1200311EUS0162US0
The ECU can be configured to monitor oil pressure through a switch. Oil pressure monitoring is important to
prevent engine damage due to low oil pressure resulting in higher friction and lack of lubrication. In addition, high oil
pressure can be undesirable because it can cause oil to leak past seals and rings, can be a result of a restriction in
the oil flow path, or can be a sign of a malfunctioning oiling system.
If the switch is normally open, the fault will set if the circuit becomes grounded. Go to the Faults page in KGST to
determine how the input is configured. ("Open=OK" is normally open). The engine will should be configured to derate
or force idle in the event of this fault to help prevent possible damage.
9Y1200311EUS0163US0
DTC 1609-Oil Switch Error
• Hardware: Engine Oil Pressure Switch
• Enabling Conditions: Key on
• Set Conditions: Oil pressure SW open for longer than 8.0 seconds
• Possible causes: Sensor malfunction
9Y1200311EUS0164US0
1-S122
DTC 524-Oil Pressure Low
9Y1200311EUS0165US0
1-S123
(10) Battery Voltage (DTC 562, 563)
DTC 562-Battery Voltage Low

• Hardware: System voltage to ECU
• Enabling Conditions: Engine running
• Set Conditions: Battery voltage to ECU is less than 8.0 V for longer than 5 seconds
• Corrective Action(s): Illuminate MIL, Throttle limit is 20 %, Speed limit is 2500 min-1 (rpm), O2 feedback adaptive
learning stop
• Possible Causes: Low charging system output, low voltage input into ECU, faulty battery
9Y1200311EUS0166US0
DTC 563-Battery Voltage High
• Hardware: System voltage to ECU
• Set Conditions: Battery voltage to ECU is greater than 16.0 V for longer than 5 seconds
• Corrective Action(s): Illuminate MIL, Throttle limit is 20 %, Speed limit is 2500 min-1 (rpm), O2 feedback adaptive
learning stop
• Possible Causes: Charging system overcharging
9Y1200311EUS0167US0
The battery voltage powers the ECU and must be within limits to correctly operate injector drivers, ignition coils,
throttle, power supplies, and other powered devices that the ECU controls.
The fault of DTC 562 will set if the ECU detects system voltage less than 8.0 V while the engine is operating as
defined in the diagnostic calibration as the alternator should be charging the system. The adaptive learn is disabled
to avoid improper adaptive learning due to the inability to correctly time injector firings.
The fault of DTC 563 will set if the ECU detects system voltage greater than 16.0 V for longer than 5 seconds
while the engine is running. The adaptive learn is disabled to avoid improper adaptive learning.
9Y1200311EUS0168US0
1-S124
DTC 562-Battery Voltage Low
9Y1200311EUS0169US0
1-S125
DTC 563-Battery Voltage High
9Y1200311EUS0170US0
1-S126
(11) Internal Processor Diagnostics (DTC 601, 604, 605, 606, 1616, 1621)
DTC 601-ROM Error

• Hardware: Engine Control Unit-Flash Memory
• Set Conditions: Internal microprocessor error
• Corrective Action(s): Illuminate MIL, Engine stop (fuel cut)
• Possible Causes: Faulty ECU
9Y1200311EUS0171US0
The ECU has checks that must be satisfied each time an instruction is executed. Several different things can
happen within the microprocessor that will cause this fault.
If this fault sets, the ECU will reset itself and log the code. A fault of flash memory can occur for any calibration
variable set and thus could cause undesirable operation.
9Y1200311EUS0172US0
DTC 604-RAM Error
• Hardware: Engine Control Unit-Random Access Memory
• Set Conditions: Internal ECU microprocessor error
9Y1200311EUS0173US0
Random Access Memory is located within the microprocessor and can be read from or written to at any time. Data
stored in RAM include DTCs (when fault configuration is set to "Battery Power Retained"), adaptive fuel learn tables,
octane adaptation table, misfire adaptaion tables, and closed loop fuel multipliers. The ECU has checks that must be
satisfied each time an instruction is executed.
This fault will set if the ECU detects a problem accessing or writing information to RAM. If this fault sets, the ECU
will reset itself and log the code. This fault should be erased by a technician after diagnostics are performed.
9Y1200311EUS0174US0
DTC 605-EEPROM Error
• Hardware: Electrically Erasable Programmable Read-Only Memory
• Enable Conditions: Key on or engine running
• Set Conditions: Unique ID is incorrect
9Y1200311EUS0175US0
1-S127
DTC 606-Microprocessor Failure-COP
• Hardware: Engine Control Unit
• Set Conditions: Internal microprocessor error
9Y1200311EUS0176US0
happen within the microprocessor that will cause this fault.
If this fault sets, the ECU will reset itself and log the code.
9Y1200311EUS0177US0
DTC 1616-A/D Converter Error
• Set Conditions: Microprocessor Error
• Possible Causes: A/D Converter malfunction
9Y1200311EUS0178US0
DTC 1621-Mutual surveillance Error (System LSI)
• Set Conditions: System LSI error
• Possible causes: System LSI malfunction
9Y1200311EUS0179US0
happen within the microprocessor that will cause this fault. The ECU will reset itself in the event this fault is set, and
the MIL will be on until the code is cleared. This fault should be erased after diagnosis using a scan tool. It will not
self-erase.
9Y1200311EUS0180US0
1-S128
DTC 601-ROM Error
9Y1200311EUS0181US0
1-S129
DTC 604-RAM Error
9Y1200311EUS0182US0
1-S130
DTC 606-Microprocessor Failure-COP
9Y1200311EUS0183US0
1-S131
DTC 1616-A/D Converter Error
9Y1200311EUS0184US0
1-S132
(12) Fuel Pump (DTC 627)
DTC 627-Fuel Pump Error

• Hardware: Fuel Pump
• Enabling Conditions: Key on, Un-driving
• Set Conditions: Fuel pump voltage is low for longer 1 second
• Possible Causes: Wire harness open, short or damage
9Y1200311EUS0185US0
The ECU has auxiliary low-side drivers that can turn on warning devices or ground electromagnetic relay coils to
control power to devices connected to the engine.
The fault of DTC 627 sets if the output for the fuel pump relay is detected as an open circuit. If this fault is active
the fuel pump will not receive power and the engine will not run on gasoline.
9Y1200311EUS0186US0
1-S133
DTC 627-Fuel Pump Error
9Y1200311EUS0187US0
1-S134
(13) 5 V External (DTC 642)
DTC 642-Sensor Power Source Error

• Hardware: Sensor Power Source
• Set Conditions: Sensor power source is less than 4.1 V for longer 1 second
• Corrective Action(s)- Illuminate MIL, Throttle limit is 30%, O2 feedback adaptive learn stop
• Possible Causes: Internal short to ground in any sensor fed by SENSOR POWER supply, SENSOR POWER
shorted to ground in wire harness, faulty ECU (no 5 V output on SENSOR POWER)
9Y1200311EUS0188US0
The external 5-volt supply powers sensors and other components in the engine control system. The accuracy of
this supply is critical to the accuracy of the sensors' feedback, therefore, it is supplied from a precision regulator
whose output is internally monitored by the ECU. The ECU monitors the 5-volt supply to ratio metrically correct sensor
feedback and determine if the circuit is overloaded, shorted, or otherwise out of specification.
The fault of DTC 642 will set if the internally measured voltage feedback of the regulator output is lower than the
low voltage limit as defined in the diagnostic calibration anytime the engine is running or stopped at key-on (if
applicable).
9Y1200311EUS0189US0
1-S135
DTC 642-Sensor Power Source Error
9Y1200311EUS0190US0
1-S136
(14) Power Relay (DTC 687)
DTC 687-Power Relay Error

• Hardware: Power Relay Pull in Coil
• Enabling Conditions: Key off
• Set Conditions: ECU is alive for longer 30 seconds after key off
• Possible Causes: Fault ECU (Power relay malfunction)
9Y1200311EUS0191US0
The fault of DTC 687 sets if the output for the power relay is detected as shorted to power.
9Y1200311EUS0192US0
1-S137
DTC 687-Power Relay Error
9Y1200311EUS0193US0
1-S138
(15) ETV (Electronic Throttle Valve) (P1601 to P1608)

DTC 1601-F/B Error1
• Hardware: Electronic Throttle Valve
• Enabling Conditions: Key on or engine running, Battery voltage is normal, TPS is normal
• Set Conditions: The difference of target TPS and actual TPS >= 0.6V and Target TPS< 1.5V or the difference of
target TPS and actual TPS >= 1.0V for longer than 1.3 seconds
• Possible causes: ETV malfunction
9Y1200311EUS0194US0
DTC 1602-F/B Error2 (Valve Open)
• Hardware: Electronic Throttle valve
• Enabling Conditions: Key on or engine running, Battery voltage is normal, TPS is normal
• Set Conditions: The difference of actual TPS and target TPS >= 0.5 V for longer than 0.5 seconds
9Y1200311EUS0195US0
DTC 1603-F/B Error2 (ISC Close)
• Enabling Conditions: Key on or engine running, Battery voltage is normal, TPS adaptive completed
• Set Conditions: The difference of actual TPS and target TPS >= 0.05 V for longer than 10 seconds
9Y1200311EUS0196US0
DTC 1604-Motor Error
• Enabling Conditions: Key on or engine running, ETV power supply voltage is normal
• Set Conditions: Short to power, Short to ground, Temperature is abnormally for longer than 0.3 seconds
9Y1200311EUS0197US0
DTC 1605-F/B Error3
• Enabling Conditions: Key on or engine running, Battery voltage is normal, Motor drive circuit is normal
• Set Conditions: ETV drive duty >= 100 % for longer than 0.7 seconds
9Y1200311EUS0198US0
DTC 1606-Motor Current Open Error
• Enabling Conditions: Key on or engine running, Battery voltage is normal
• Set Conditions: Motor power supply voltage <= 6.0 V for longer than 0.35 seconds
9Y1200311EUS0199US0
DTC 1607-Return Spring Breakage
• Set Conditions: Middle valve adaptive value >= 3.8 V immediately
• Corrective Action(s): Illuminate MIL, speed limit is 1600 min-1 (rpm)
9Y1200311EUS0200US0
1-S139
DTC 1608-DBW Open Stuck
• Enabling Conditions: TPS is abnormality (except power supply error)
• Set Conditions: Filling-up efficiency >= 50 %, Engine speed is over 4000 min-1 (rpm) for longer than 0.35 seconds
9Y1200311EUS0201US0
1-S140
(16) Fuel System (DTC 1617)

DTC 1617-Fuel System Error
• Hardware: Fuel System
• Set Conditions: Compensation value of O2 feedback and adaptive value of O2 feedback > 35 %, Compensation
value of O2 feedback and adaptive value of O2 feedback < −35 % immediately
• Corrective Action(s): Illuminate MIL, Throttle limit is 30 %, Speed limit is 2500 min-1 (rpm), O2 feedback stop, O2
feedback adaptive learning stop
• Possible causes: Exhaust leaks upstream or near the O2 sensor, Fuel pressure is abnormality, An injector that is
stuck closed, Wiring harness open, short or damage, O2 sensor malfunction
9Y1200311EUS0202US0
DTC 1629-LPG Fuel System Error
• Hardware: Fuel System
• Set Conditions: Gaseous Solenoid > 98%, Gaseous Solenoid < 2%
• Corrective Action(s): Illuminate MIL, Depend on OEM
• Possible causes: Exhaust leaks upstream or near the HEGO sensor, Fuel pressure abnormality, Fuel property
abnormality, Mixier malfunction, Vaporizer malfunction, Wiring harness open, short or damage, O2 sensor
malfunction
9Y1200311EUS0203US0
1-S141
(17) Lock Off Valve Fuel Shutoff Solenoid (DTC 1624)

DTC 1624-LPG Fuel System Error
• Hardware: Lock Off Valve
• Set Conditions: Engine Keeps Running after Key Off (Error Keeps 3 Key Cycle), Judgment period is depended
on OEM
• Corrective Action(s): Engine Stop(Spark Cut)
• Possible causes: Wiring harness short to power, Both lock off valve and fuel shutoff solenoid malfunction
9Y1200311EUS0204US0
9Y1200311EUS0205US0
1-S142
(18) Solenoid Valve (DTC 1628)

DTC 1628-Solenoid Valve Error
• Hardware: Solenoid Valve
• Enabling Conditions: Key On or engine running
• Set Conditions: Solenoid Valve Voltage is Low for longer than 1 second
• Corrective Action(s): O2 feedback Stop, O2 feedback Adaptive Learn Stop
• Wiring harness open, short or damage, Solenoid valve malfunction
9Y1200311EUS0206US0
9Y1200311EUS0207US0
1-S143
(19) APS (Accelerator Position Sensor) (DTC 2122, 2123, 2127, 2128, 2138)
DTC 2122-APS1 Signal Voltage Low

• Hardware: Accelerator Position Sensor
• Set Conditions: APS1 voltage <= 0.1 V for longer than 1 second
• Corrective Action(s): Illuminate MIL, Forced idle
• Possible Causes: Wiring harness open, short or damage, APS malfunction
9Y1200311EUS0208US0
• Set Conditions: APS2 voltage <= 0.1 V for longer than 1 second
9Y1200311EUS0209US0
DTC 2123-APS1 Signal Voltage High
• Set Conditions: APS1 voltage >= 4.9 V for longer than 1 second
9Y1200311EUS0210US0
• Set Conditions: APS2 voltage >= 4.9 V for longer than 1 second
9Y1200311EUS0211US0
1-S144
DTC 2138-APS Correlation Error
• Enabling Condition: Key on or engine running, APS1 is normal, APS2 is normal
• Set Conditions: The difference of APS1 and APS2 > 20 % for longer than 1.5 seconds
• Possible Causes: APS malfunction
9Y1200311EUS0212US0
The APS is an electronic device that is coupled to a mechanically driven input as commanded by the
vehicle/engine operator. The APS output is proportional to the commanded input. The ECU uses the APS input to
control the throttle and adjust the engine's load in order to achieve the requested power. Since the APS inputs directly
affect the engine's power output, redundant sensors are generally used to ensure safe, reliable operation. In
electronic throttle control systems the foot pedal position/throttle control position sensor is used by the
engine/equipment operator or system to command either throttle position or a governor speed target proportional to
the input in order to achieve desired system behavior.
9Y1200311EUS0213US0
1-S145
9Y1200311EUS0214US0
1-S146
9Y1200311EUS0215US0
1-S147
9Y1200311EUS0216US0
1-S148
9Y1200311EUS0217US0
1-S149
(20) Ignition Coil (DTC 351, 352, 353)
DTC 351-Ignition Coil 1 Error

• Hardware: Ignition Coil
• Enabling Conditions: Key On or engine running
• Set Conditions: System LSI detects open or short to power for longer 1 second
• Possible Causes: A short to ground or open circuit in the harness or an open internal to the primary coil
9Y1200311EUS0218US0
Each ignition coil #1, #2 and #3 fires the corresponding cylinder, the 1st, 2nd and 3rd cylinder each in the block
order.
9Y1200311EUS0219US0
1-S150
9Y1200311EUS0220US0
1-S151
Editor : Engine Service Department
Address : 64, Ishizu-Kitamachi, Sakai-Ku, Sakai-City, Osaka, 590-0823, Japan
Phone : +81- 72-241-1531
Fax : +81- 72-245-2928
E-mail : kbt_g.estg-pub@kubota.com
Printed in Japan 2021. 09, S, EI, EI, engusa Code No.9Y110-03113

KUBOTA Corporation 2015. 07, S, EI, EI, engusa

Kubota WG972 Diagnose Manual

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DIAGNOSIS MANUAL

KiSC issued 09, 2021 A

KiSC issued 09, 2021 A

KiSC issued 09, 2021 A

1. SAFETY FIRST .............................................................................................................................. I-1

KiSC issued 09, 2021 A

PREVENT ACID BURNS

DISPOSE OF FLUIDS PROPERLY

PREPARE FOR EMERGENCIES

KiSC issued 09, 2021 A

KiSC issued 09, 2021 A

KiSC issued 09, 2021 A

The question chart can aid the service person in diagnosing,

Trouble Check Sheet for WG Engines

Condition when problem occurs (Duplicated answers can be possible)

a. Starting b. Just after starting

3. SYMPTOM CHARTS BY COMPONENTS

Cuts Out, Misses

Lack of Power, Sluggishness, or Sponginess

Poor Fuel Economy

Rough, Unstable or Incorrect Idle or Stalling

[2] GASEOUS SYMPTOM CHARTS

Cuts Out, Misses

Hesitation, Sag, Stumble

Lack of Power, Sluggishness, or Sponginess

Poor Fuel Economy

Rough, Unstable, or Incorrect Idle, Stalling

4. SET UP AND PROCEDURE DIAGNOSIS TOOL

[2] DIAGNOSTIC TOOL CONNECTION PROCEDURE

[3] SET UP AND PROCEDURE

(2) Recommended PC Hardware/Software Environment

Table2: PC software environment

(3) How to Install the Software and Interface Driver

[4] HOW TO USE DIAGNOSIS SOFTWARE

(2) User Authentication

(3) Description of Monitor Command

(a) Load and save file and end operation.

(4) Model Screen

 Histogram button (d)

(5) Faults Screen

(a) Displays historic faults (DM2). EU012US

(a) Displays the fault code (PCode) and basic text.

(6) Tests Screen

You perform function tests from the Tests screen.

5. BASIC SYSTEM INFORMATION

Gasoline ECU Input and Outputs

LPG/NG ECU Input and Outputs

Electronic Throttle Body (ETB)

[2] ELECTRICAL SYSTEM

PIN DISCRIPTION PIN DISCRIPTION PIN DISCRIPTION

(2) Connector Views

Pin Number Description Wire Color

Pin Number Description Wire Color

Pin Number Description Wire Color

Pin Number Description Wire Color

Pin Number Description Wire Color

Pin Number Description Wire Color

Pin Number Description Wire Color