Property of American AirlinesST. LOUIS MISSOURI · 2018-12-03 · 007 EC1033 EFI TPS switch 1 007...

AIRPORT SERVICES EQUIPMENT RESTORATION FACILITY

A DIVISION OF AMERICAN AIRLINES

ST. LOUIS MISSOURI · Prope

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Table of Contents

Introduction..................................... Section 1

Vendor List. ................................... u Section 2

Quick Parts Reference Guide. . . . . . . . . . . . . . . . Section 3

EFI Troubleshooting Guide . . . . . . . . . . . . . . ... Section 4

Wiring Information and Diagrams . ... ... . . Section 5

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . Section 6

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Vendor List

The following list is a compiled list of vendors whose products were used to build this tug. They are linked by number to the parts that were supplied in the quick reference parts section. It has been placed here to aid you when you need replacement parts for your tug.

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VENDOR CODES REFERANCE LIST

Vendor Name Address City State Zip

001 ACC Climate Controls 22428 Elkart E. Blvd Elkart IN 46514 002 AC Delco 6200 Grand Pionte Dr Grand Blanc MI 48439 003 Airtex 407 West Main St. Fairfield IL 62837 004 Allma-ETX 401 Terrance Dr. Mundelein IL 60060 005 Anchor 30775 Solon Industrial Cleveland OH 44139 006 ANCO I Federal Mogal 26555 Northwestern Hwy Southfield MI 48033 007 Borg Warner 37-18 Northern Blvd. Long Island City NY 11101 008 Bosch 2800 S 25th Ave. Broadview IL 60155 009 Cole Hersee 20 Old Colony Ave Boston MA 02127 010 Dorman/ Champ 3400 E. Walnut St. Colmar PA 18915 011 Exide Battery 13000 Deerfield Parkway Alpharetta GA 30004 012 Ford Motor Local Ford dealer 013 Four Seasons Radiator 1995 Thomas Rd Memphis TN 38134 014 Gates 1551 Wewatta St. Denver co 80202 015 General Driveshaft 133 W. Maple Ave. Monrovia CA. 91016 016 Grote 2600 Lanier Dr. Madison IN 47250 017 Holland Hitch P.O. Box 347 Denmark SC 018 HOOF - Pierce Co. 35 N. 8th St. Upland IN 46989 019 Horton Fan 2565 Walnut St. Roseville MN 55113 020 Ideal Clamps 3200 Parker Drive St. Augustine FL 32084 021 Imperial Supplies 789 Armed Forces Dr. Green Bay WI 54307 022 Jasper Engines P.O. Box 650 Jasper IN 47547 023 J.W. Speaker Corp. W185 N11315 Whitney Dr. Germantown WI 53022 024 McMaster Carr 600 N. County Line Dr. Elmhurst IL 60126 025 Morse Controls Atlanta GA. 026 Motorcraft P.O. Box 6248 Dearborn MI 48126 027 Nickson Industries 336 Woodford Ave Plainville CT 06062 028 Peterson Mfg. Co. 4200 Allgood Rd. Marietta GA 30062 029 Protectoseal 225 W. Foster Benson ville IL. 60106 030 Raybestos Products 4400 Prime Parkway McHenry IL. 60050 031 Rochester Gauges 11616 Harry Hines Blvd. Dallas TX 75229 032 Sage Parts 25 Dubon Court Farmingdale NY 11735 033 Shure Grip - Goodyear 1144 East Market St. Akron OH 44316 034 Stewart Warner P.O. Box 128 East Petersburg PA 17601 035 Truck-lite 310 E.Elmwood Ave. Falconer NY. 14733 036 Tug Technologies 815 Allgood Rd. Marietta GA 30062 037 Vehicle Safety Mfg. 408 Central Ave Newark NJ 07107 038 Walker Exhaust 1 International Dr. Monroe MI 48161 039 W exco Industries 3 Barnet Rd. Pine Brook NJ 07058 040 Affordable Fuel Injection 7575 N.Hollister Rd. Elsie MI. 48831

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041 Jeans Upholstery 401 Franklin Dr Euless TX. 76040 042 Harris Automotive 909 E. Pearce Blvd. Wentzville MO. 63385 043 Tiger Tractor Corp. P.O. Box 1340 Lee's Summit MO. 64063 044 TGI Direct 3212 S. Cravens Rd Ft. Worth TX 76119 045 Super Bright Led 4400 Earth City Expressway St. Louis MO 63045

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DEVOE HIGH PERFORANCE

COATINGS

PRIME COAT DEVRAN 220 Heavy Duty Epoxy Coating, A high performance, multi-purpose, two component chemically-cured epoxy semi-gloss coating. Product# DC220B2533 Gray Product # DC220C9003 Conve1ter 1 to 1 mix See data sheet for thinning, mixing, and application.

TOPCOAT DEVTHANE 379UV A Aliphatic Urethane Gloss Enamel. This product is also a high performance, two component chemically-cured aliphatic urethane gloss enamel.

Product# DC379B9502 Cobalt Blue (DC4752) Product# DC379C09IO Converter 4 to 1 mix See data sheet for thinning, mixing, and application.

Tinting formula for Cobalt Blue #DC4752 in 48ths Colorant oz. 48ths 96ths LB 1 1 PB 7Y 20 0 QV lY 32 0 TW 44 0

Product# DC379B9501 Machine Gray (DC6110) Product # DC379C0910 Converter 4 to 1 mix See data sheet for thinning, mixing, and application.

Tinting formula for Machine Gray# DC6110 in 48ths Colorant oz. 48ths 96ths LB 3Y O 0 YO lY 14 0 PG 20 0 TW lY 15 0

FOR ANY QUESTIONS ON YOUR COATINGS PLEASE CONTACT

Jim Donnelly Flanagan Paint, 1825 S. Broadway. St. Louis, MO, 63104 Phone: 314-421-0678 Cell: 636-399-3997 Email: jim@flanaganpaint.com

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Cobalt Blue Touch up Paint

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!lo!ot6x1cos mtflores en animales de labOra!orio :n.la.sposibilldadesdequelosweshumanos1es1men ifet:!os irrnanias de la MfC a bajas «mrenlraciones. ·ociadasc!e!puJveri.rador Lae..:poslci6nrepelldaaallas da/\ospermaneniesaiwetiroya1sistemal\8rvloso. bnsonmdl!'.K!onesdeQuelo!IWelesded"1solvente eradamenteelcontemdopurotserootivoolatal osyrnpaprn!ectora.mcJuyallOOdelantalyguan1es }nalosvapo1es.puede11reven11seas119ural'ldosedeque 1efresC-O.Unaparatoderesp1raCWn 1R1fificadordea11e unapara!oderesplraci6nl.lef)ll?SIOl1J>Ositivacon esclellabricantede!apara!Ode1e;piraci6nparaeluso 1asllrentesde1gnicion. Noluma1,Extioguiflodaslas !ll{l!Ort!se!6clnr:osyo!rasl11en!11Sdeignici6ndu1ante

IDS de seguridad de. m.ateriile~ oar~ oh!Anl\f

Customer Manufacturer

Job No.

!.Mante~...tsRESrQ(, \'MEOIAl COLLElt conaoJ Jrmatj

Japielsn ::~~, !i:~,

Brand Code: 15907 Main Layer

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OEM Code

Description 15907 Mixing Scheme OMNI AU (MAE) Price Code A Density 959.3667 g/L VOC Reg. 4.4473 lbs/gal (532.9031 gil) VOC Act. 4.4473 lbs/gal (532.9031 g/L)

'1·2),Xll .13-SfH' 1--1). ml lRMEAl !ldodeC

Variant PROPHET FORMULA Revision Date 7/1712009 1PGCana: JBRAMI OOR.F.C

briqu8, ~ULAl'a

MSDS Makes 1 U S. Quarts Notes PPG CONFIDENTIAL INFORMATION This color information 1s the propnetary property of PPG lndustnes. Inc and must be ma,nta,ned in strict confidence Access and use are restncted to rec1p1ent and its employees who have a need to know

4 MAE : MA Reducers

8 1 MAE . MH101/MH202 MR Reducers

[I] 3-4 cts.

Readca111ionsandemergencyinstruclions elsewhere on this label.

Ure IH mises: en garde el les Ulstructions en m d'11rgencaai!le11rssurcette&liquette.

Lealaspmaucionesylaslns!ruccionesde emergendaqueaparecenenotrolugardeesla ntiqueta.

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Quick Reference Parts Guide

The following section is a condensed version of the full tug parts manual. For the most part, you should be able to go here for any normal maintenance parts needed to support your new unit.

All new parts and changes in the tug have been reflected in this parts area and have been broken down into component groups in the order as follows:

Engine and Transmission assembly Water Pump and Related Radiator Exhaust System Fuel Tank Brake Lines Master Cylinder Firewall Shifter Steering Column Front Axle Rear Axle and Driveshaft Seat Frame and Hitch Engine Bay and Body Panels Electrical Cab Dash - Engine side

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If after a quick check for normal support parts the item is not found, refer to the enclosed Tug Incorporated Parts CD and order as needed as that part has not been upgraded and remains a standard Tug item.

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.::ngine / Transmission Parts List

Quick Reference list of needed components for engine transmission service

Vendor Code Vendor Part # Tug Part# Description Qty

022 524820 AA snec ford 300ci six 004 C6SBB2AA3YR C6 trans with Park brake 1 ul2 D2TZ-7007-A Separator plate 1 012 D5TZ-6375-AOEM Flex plate 1 005 2331Mount Motor mount RH 1 005 2332 Motor mount LH 1 019 T6-7002-132 T6-7002-132 16" 6 blade fan 1 003 AW4112AIR Water pump 1 012 EOTZ-8509-B Water Pump Pulley 1 014 33009S Thermostat 1 026 E7TZ-8592-B Thermostat Housing 1 007 WT332 Over temp sender 1 014 7400 Fan belts 2 014 *20537 Upper Hose 1 014 *20674 Lower hose 1 020 5728CLAMPS Hose clamps 4 007 GC408 Ground Stran 1 005 2448 Transmission mount 1 036 T6-6018-123 Trans cooler flex lines 4 008 SR7542N Starter 1 040 2342347 Upper alt bracket 1 032 2342347A Alt adjustment bracket 1 002 GM64912 Alternator 1 002 1944312 2 Groove alt pulley 1 003 60092 Mechanical fuel pump 1 007 10420820005 Oil pressure switch 1 007 PCV229 PCVValve 1 018 S372PE Hoof Governor 1 010 7998 Air Cleaner assembly 1 007 WT3000 EFI coolant sensor 1 007 EC1602 EFI Map sensor 1 007 OS120 EFI 02 sensor 1 007 EC1033 EFI TPS switch 1 007 7309V EFI IAC valve 1 002 10066605 Throttle body base gasket 1 007 £8094 EFI electric fuel pump 1 007 57023 Injector 1 007 7704 Press Regulator Diaphragm 1 Wix 33023 Fuel Filter 1

*Note* These hoses will need to be trimmed to proper length on assembly per Tug manual

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Vendor Code

013 013 012 014 003 026 014 014 014 020 007

Engine Water pump and related

Vendor part #

2915WS 195TS EOTZ-8509-B 7400 AW4112AIR E7TZ-8592-B 33009S *20537 C5JZ-8286-D 5728CLAMP WT332

Tug Part# Description Qty

Electric fan and shroud 1 Temp sensor for fan 1 Fan pulley 1 Belts 2

T6-4055-501 Water Pump 1 Thermostat housing 1 Thermostat 1

T6-6014-101 Upper Hose 1 Lower Hose 1 Hose Clamps 4

Water Temp sender for Thermostat Housing 1

*Note* These hoses must be trimmed as needed per Tug manual.

Vendor Code

013 014 010 036 013 013 009

Radiator build up kit

Vendor Part #

155360FS 31527CAPSAG 91663

2915WS 195SW 30A

Tug Part#

T6-4055-203 md-h04-107 T6-9011-330 T6-6018-123

Description

Radiator Radiator Cap Overflow Tank kit

Flex trans cooler line 2 Spal fan W/shroud 1 Temp on switch 1

~ampC/B I

l 0 ·2 2 a. £,Je., .m~~.;- . ,A)e(d Jo V ..:;> J dtt""ljC ~·,~

~!Z/ P~.L~P-K

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Vendor Code

038 038 027

Vendor Code

031 029

Vendor code

030 Local Local Local Local Local 036

Vendor Part#

17704 35408 75

Vendor Part#

GllO 1273A

Vendor Part #

MC36352CYL 3/16" X 20" 3/16 coupler 3/16" X 40" 3/16" X 30" 3/16"to 1/8 pipe

Exhaust System Parts

Tug Part#

T6-1005-105 T6-1005-119 T6-1005-115

Fuel Tank

Tug Part#

T6-6007-103 T6-6004101

Description

Muffler Clamps Hanger

Description Qty

Fuel Gauge 1 Safety Fuel Cap 1

Brake line and related

T6-6001-113 Master Cylinder 1 Brake line 2 coupler 2 Brake Line 1 Brake Line 1 Adapter 2

T6-6016-105 Flex line 2

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Master Cylinder Assembly

036 T6-8106-107 Brake Pedal 1 036 T6-80060105 Bronze Bushing 1 032 324045 T6-8007-101 Brake Booster 1 030 MC36352CYL T6-6001-113 Master Cylinder 1 009 8626 None Brake Light Pressure Switch 1

Firewall build up kit

036 T6-4004-103 Firewall 1 036 T6-5005-121 Upper Steering Brk. 1 036 T6-5005-I05 Column clamp 1 Local Scrap rubber isolator 1 025 2364588 T6-1002-151 Morse Shifter 1 036 T6-1003-103 Shifter Cover 1 036 T6-5003-101 Steering Wheel 1 036 T6-7012-107 Hom Button Kit 1 001 20057C003C T6-9004-103 Heater Assembly 1 032 A2780115 T6-7013-101 Hom 1

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Vendor code

036 036 036 025 036 025

Vendor code

036 036 036 036

Vendor Code

036 036 032 032 036 036 036

Shifter buildup

Vendor Part # Tug Part# Description Qty

T6-1021-103 Linkage Shift plate 1 T6-1004-119 Swivel end 1 T6-1021-107 Cable anchor 1

433cable T6- l 023-105 Shift cable 1 T6-1002-155 Cable clamps 2

2364588 T6-1002-151 Morse shifter 1

Steering Column Parts

Vendor Part #

*04440518AA *T6-3001-101AA

T6-5001-I01NEW T6-5003-101 T6-7012-I07 T6-5004-107LINK

Steering Column Steering Wheel Hom button kit Drag link

l I I 1

Front axle Parts

Tug Part#

T6-4039-I01 311BUSHING

U157RUBOLT T6-3002-201 T6-3000-I05

Description Qty

Leaf Spring 2 Leaf spring bushings 4

Briarton Front Axle I Rockwell Front Axle 1 U bolt Brierton axle 4 U bolt Rockwell axle 4

Clamping plate 2

• Note - Rockwell axles are a round center tube and use round "U" bolts

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Front Axle Continued

• Brierton axles are square center tube and use square "U" bolts • Parts for both Rockwell and Brierton axles can be found in the steer axle section of the Tug

manual

Rear axle / Drive shaft Parts

Vendor Code Vendor Part# Tug Part#

015 T6-2006-101 T6-2006-101 012 C6TZ-4A254-B T6-2006-105 012 382884S2 T6-2006-103 032 T6-2001-I01AA 036 T6-4020-115 036 T6-6016-105 032 632146

Seat and Frame Parts

Vendor code Vendor Part # Tug Part#

036 T6-401 l-101 036 T6-4513-10 I 036 T6-4513-I03 036 T6-4012-107

Frame and Hitch Parts

Vendor Code Vendor Part# Tug Part#

017 PHT60Sl 1240

Description

Driveshaft U joint straps Strap Bolts

Rebuilt Rear axle Axle Isolator mounts

Brake flex lines to axle Flex Lines to Calipers

Description

Seat Frame Seat bottom Seat back Rubber seat mounts

Description

Pintle Hitch

i 2 4 1 4 2

1 1 1 4

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036 036 036 036 036 036 036 036

Vendor Code

036 036 036 036 036 036 036

Vendor Code

Vendor Part #

Vendor Part#

032 T6-7011-1 OSAARF 035 81360-3 037 146844 011 2465BATTERY 034 150012 032 2805AA 007 CBE7MODULE 036 007 BC36X 007 BC30X

Frame Continued

T6-4017-108 T6-4017-107 T6-4017-104 T6-4017-104 T6-4016-131 T6-40160121 T6-4019-113 T6-4018-103s

Running Board RH 1 Running Board LH l Rear Fender RH 1 Rear Fender LH 1 Front Plate 1 Front Plate Rubber Bumper 1 Battery Level Plate 1 Battery Box 1

Engine body panels and related

T6-4006-l 03 LS engine side panel 1 T6-4006-104 RS engine side panel 1 T6-4005-119 Hood prop rod 1 T6-4005-121 Prop rod clip 1 T6-4005-120 Hood 1 T6-4005-109 Hood Handle 1 T6-4006-1 l lr Hood latches 2

Electrical Parts - Chassis

None Main Wire Loom and Dash 1 LED Headlights 2 Rubber headlight mounts 2

None Battery 1 T6-1300-257 Hour Meter 1

None Hour Meter Bracket 1 None Ignition Module 1

T6-1300-127S Engine Ignition wire Harness 1 T6-7016-119 Positive battery cable 1 T6-7016-I21 Negative battery cable 1

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':'ab Parts

Vendor Vendor Part# Tug Part# Description Qr; Code

032 531001 CMA-202 Roof Panel 1 036 T6-9003-159 Headliner 1 Local T6-9003-111M0D , Windshield 1 036 CMA-504 Windshield Rubber 1 u39 4R3-12-19S-R1 l0 T6-9003-I21 Wiper Motor 1 ul6 61031 T6-9003-197 Dome Light 1 007 S625 T6-9003-209A Dome light switch 1 036 T6-9003-163 Gas Gauge Window 1 036 T6-9003-165 Gas Gauge Window Gasket 1 024 8709K78 T6-9003-351 Foam Seal 1 037 4464LED T6-7006-101a Rear Tail / Stop light 2 037 4463W T6-7006-107a Back up light White 2 035 94926 None Pig Tail disconnect Brake/Tail light 2 028 43149 None Pig Tail Back up lights 2 035 40700 Rubber Mounting Grommets 4 Local T6-9003-109M0D Rear Window 1 032 111952 None Window Mounting Brackets 8 006 LE72I156 T6-9003-I23 Wiper Arm 1 006 BD72102014 T6-9003-I25 Wiper Blade 1 032 T6-7010-330AA Cab Wire Harness 1 036 T6-4027-115 Fuel Filler Neck Grommet 1 041 6236RD Canvas Door RH Blue 1 041 6237LH Canvas Door LH Blue l 032 111956 Radio mount bracket 1 032 111957 T-Link mount 2 pieces 1 010 7942 Cab fan6" 1

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Vendor Name

32 32 32 32

016 016 016 045 035 035 035 035 035

Vendor Code

044 044 044 044 044 044 044 044

Tires I Wheels

Vendor PIN

61506 W616GSE

W50IOGSE 05065010

Port Authority Options

28152 10623 48072

FL3-Red 30385Y 00801 93745

T6-4003-115 84-1006

Decals

Description Qty

LT225/75RI6 Radial 2 Rear Wheel 2

Front Rim (2 piece) 2 Front Tire 6.50 x 10 2

Round Flat Mirror 1 90" Mount Bracket 1

Turn Signal 1 Flasher 1

Signal Lights 2 Mounts 2

Plugs 2 Bracket 2

Flashers 1

Description Qty

GSE Approach Patern 1 Dashboard/Notice/Caution Decal 1 Tractor Roof AA Decal 1 Hood Number 2 Rear Cab Reflective Number l Battery Box Decal I Small Tractor / LIS Engine Panel l Gate Assignment Numbers

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009 009 009 009 009 009 009 008

70016 3013720 301 H61 30090-6 P-61

I 4RA003510

Description

Terminal Strip l Circuit 4 Circuit Breaker 2 Positive Jumper link 1 Circuit Breaker Mount l

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AFFORDABLE

INJECTION Parts list and troubleshooting guide

9415 W.Ridge Rd.

Else Ml 48831

248-941-3613 248-393-1621

989-862-4163

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GSE EQUIPMENT FORD 1-6 ENGINE

Ford 300 lnline 6 with 1 bbl. adapter & tach filter for Tiger 1100-49tch Baaaage Tractor "

Ford 300 lnline 6 with 1 bbl. adapter & tach filter for Tug Baggage 1100-49tug Tractor. Inc. Weatherproof enclosure and 8 Ft. wire harness.

Ford 300 lnline 6 with 1 bbl. adapter & tach filter for De,icing 1100-49ice machine. Includes weatherproof enclosure and 8 ft. wire harness.

Ford 300 lnline 6 with 1 bbl. adapter & tach filter for Trump 2000 and 2002 De-icing machines. Includes weatherproof enclosure

1100-49ice2k and 9 ft. wire harness.

COMPONENT PARTS

AFI# GM# Standard# Harness Baaaage Tractor 8315 - -Harness TUG Ba!:maae Tractor 8318 - -Harness De-lcina Machine 8318a - -ECM E8062 1228062 EM8062 Calibration Chip GSE6FFC - -Tach Filter 7813 - -ECT 7302 15326386 TX3 MAP 7300 12569240 AS5 02 7301 AF-12 SG12 TPS 7306 TH47 IAC 7309 AC15 Throttle body 7603 17088083 Injector 7650 17089098 TJ14 Flange Gasket 1192F 10066605 FJG119 Manifold base gasket -Fuel Pump GYIP52 - Bosch 0580254996 Relay 7311 - -CE Light 7312 - -Adapter Plate 7107 - -Fuse Link 7314 - -Throttle cable barrel! 100014 - Bowman 100-014 Throttle Ball stud Fuel Filter G7333 - Fram G7333 Fuel Tube Feed 801401 - PTC 801-401 Fuel Tube Return 801400 - PTC 801-400 Air Cleaner 2" adapter 11085 - -ECM Enclosure 4KP03 - Grainger 4KP03

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Troubleshooting your TBI Fuel Injection System Most of the problems encountered while installing your fuel injection system or after a time of operation are very simple. If your check engine light is on you more than likely have a hard fault meaning something is grounded out, unplugged, operating out of range or has gone bad. See below for,Jiow to determine what your fault may be and what the codes mean.

With the addition of Fuel Injection to your engine it is important to remember that the basics are still there, necessary and have not changed. Batteries must be fully charged, charging systems fully operational, the ignition system is fully operational and the integrity of the engine is intact. All of these items are common to an engine and need to be in full operational condition regardless of the fuel system that has been added to your engine.

The ALDL connector allows for full diagnostics of your unit. A scan tool can be used and set up for a GM TBI application to read the data, or to check for stored codes. Consult a service manual or see below for any check engine light cede definitions. You can use a late SO's or early 90's GM TBI definition. If you have access to a scan tool use a hook up for a 1990 350 cu. in. 5.7L Chevrolet truck. For some scan tools enter VIN 10th "L" 3rd "C" 8th "K".

If you have installed a Fuel Injection system in your vehicle and are having some initial issues here is a quick checklist to work from to get you started.

Pink Ignition wire MUST be connected to 12 volt switched ignition that receives ower durin crank and key on.

1. Check to make sure your check engine light is not on, or that it is on with the key on but the engine is not running.

2. Make sure that the red battery wire is connected to a battery source (It is highly recommended that this wire is connected directly to the battery) and the pink wire is connected to an ignition 1 source. If your ignition wire is not connected to an ignition 1 source your ECM will not be powered while cranking the engine.

3. Check that the ground wire is securely fastened to the block and that the interface between the block and the terminal are clean.

4. Ensure that there are t!Q..vacuum leaks. 5. Ensure that your MAP sensor is connected to a full manifold vacuum source and not a

ported source. 6. Set the ignition timing correctly making sure that you disconnect the set timing connector

to set it. In some cases you cannot set the timing with the connector disconnected and keep the engine running. If this happens set timing to 15 degrees, allow the engine to fully warm up, then disconnect the set timing connector to set the base timing to the correct specification.

7. Ensure that you have full manifold vacuum routed to your fuel pressure regulator (if equipped on MPFI systems) and there are no vacuum leaks with this connection.

8. Check your fuel pressure to ensure that you are providing the proper pressure to the system.

Fuel Pressure is critical for proper operation. Fuel tank must be -free from debris and fuel pressure needs to be constant and consistent. Some aftermarket high density fuel filters can cause a large drop in fuel pressure under load and are not recommended for use with your system. If you are using one of these types of filters insure that you have proper fuel pressure during all modes of operation.

99% of all issues are usually taken care of with one or more of these 8 steps of diagnosis.

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First and foremost the engine and fuel injection system must be free from vacuum leaks. Vacuum leaks are the leading cause of installation issues with your fuel injection system. Check all sources of potential vacuum leaks including components not related to the fuel injection system.

There are instances where the vacuum leak is coming from the adapter plate used to attach the throttle body to the manifold. If this is the case make sure that the seal is positive between the manifold and the adapter plate; also between the adapter plate and the throttle body. In some instances it is necessary to seal these with silicone to provide a positive seal.

Another common issue is a lack of good grounding. Many issues have been resolved simply by making sure that the ground path is secure and clean.

Fuel System Checks

Fuel Pressure is critical to the operation of a fuel injection system. Always check to insure that you have the proper fuel pressure. Fuel pressure should be a constant 10 - 15 PSI on a TBI fuel injection system and is typically around 12 - 13 psi. Higher pressure than 15 psi indicates that there is an issue with the installation. Many times this is due to kinked fuel lines, improper routing of the return line and/or fuel line restrictions. (See Part 3 of Troubleshooting guide #3) Many fuel tanks have fittings on them which are used for a fuel tank vent. These fittings are not suitable to use as a return line because they have an orifice in them and restrict the flow of fuel back to the tank. If you have installed your return line to a "vent" line you will need to route the return line in a different fashion.

Fuel pressure on a TBI unit should stay constant under all throttle conditions. There should be less than 1 psi of pressure difference from idle to WOT operation of the TBI unit. A pressure drop of more than 1 psi under these conditions indicates an issue with the fuel delivery system.

With retrofit fuel injection systems many times we are drawing fuel from gas tanks that are many years old; hence many years have passed where contamination can settle into the fuel tank. The electric fuel pump installed for a fuel injection system will draw considerable more volume of fuel from your tank than your old system did. If there are any contaminants in the tank this many times will plug up or greatly restrict the flow of fuel to the system causing many issues.

Step by Step Troubleshooting guide. Your fuel injection system has been pre calibrated to your particular vehicle. As long as the information about your engine was correctly stated, the system as received will provide many years of trouble free use. However from time to time problems are encountered with your fuel injection system. Here are a few commonly asked questions about fuel injection problems. Match the issue # with the chart below for an explanation of the issue and use the troubleshooting fault tree.

Use of this section may require a digital voltmeter, test light, fuel pressure gauge, timing light, tachometer and/or a diagnostic scan tool. If you are familiar with vehicles and how they are serviced you should be able to work through this section with no issues. In many instances you may want to have a professional automotive technician familiar with fuel injection repair to help you.

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1. My engine cranks but will not start. 2. My engine is running to lean, or is backfiring on acceleration. 3. My engine is running rich. 4. I do not seem to have as much power as I should. 5. I am getting a sag when I accelerate. 6. My engine takes longer to start than I think it should. 7. The fuel pump is not coming on when I first turn the key on. 8. The RPM on my engine does not come down when I come to an idle. 9. I am not getting as good of fuel economy as I think I should. 10. The engine is revving up and down when I come down to an idle. There is a

large "sucking" sound coming from the throttle body when it is warmed up. My engine stalls or almost stalls when I come down to an idle.

11. My fuel pump is real noisy. 12. My check engine light does not come on when I turn the key on. 13. My check engine light is flashing fast all the time. 14. My check engine light is on when the engine is running.

1. Engine cranks but will not start.

There is an assumption that the battery is at a full state of charge, the fuel tank has fuel in it and that all sensors are correctly connected and there are no trouble codes in the ECM.

1. Does the injector spray fuel when cranking the engine?

Yes - Go to step 2. No - Remove one of the injector connectors from an injector. With a voltmeter or test light measure the voltage or validate power to the pink wire of the connector with the key on.

Yes - Pink wire has voltage, go to step la. No - There is no power getting to the system. Check for proper connection to the

battery, fuses are good, relays have been connected and seated properly. Coriect the power issue; if there is still no fuel spray when cranking the engine after this has been corrected go to step la.

la. With the voltmeter or test light still connected crank the engine and verify voltage to the pink wire on the injector connector. Results:"O" volts or the light goes out when cranking the engine.

The primary (pink) ignition wire is incorrectly connected to the vehicle. This is to be an ignition 1 (INGl) source which is power in both the key run and crank position. Correct the connection of this wire and verify voltage to the pink wire on the injector connector. Test again for fuel spray during crank. If the engine still cranks, is spraying fuel, but will not start go to step 2.

"Low volts, < 8" This is an indication of either a battery in a state of very low charge, a bad battery or too much resistance In the system. -record the battery voltage while cranking at the battery. -record the voltage at the pink wire of the injector connector while

cranking the engine. -compare these two voltages, they should be within .2 (2/10) volts

of each other. If these voltages are greater than .2 there is a bad connection or too much resistance in the wire feeding the ECM.

-Correct the issue with low voltage. If cranking voltage is above 9 volts while cranking and there is still no fuel spraying the issue is in the fuel delivery system.

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"9 volts or higher" this is normal cranking voltage. If there is no fuel spraying while cranking the issue is in the fuel delivery system or ignition system Trouble shoot the fuel system for improper operation (See Fuel System checks at the beginning of this guide). Troubleshoot ignition system, go to lb.

lb. Your TBI fuel injection system fueling is "triggered" from the ignition system. It is assumed that the coil is operational, a 12 volt ignition 1 (IGNl) source is connected to the positive terminal of the coil for external coil applications or to the positive slot for coil in cap applications. Remove plug wire and check for spark while cranking.

No Spark - Repair ignition system. Has spark - Insure wire continuity between the ECM and the distributor or tach

Filter. If fuel is still not spraying go to fuel system troubleshooting before replacing any components. If all wires are in tact and routed correctly and all fuel system checks are correct, replace distributor module or tach filter.

2. Perform the fuel system checks found at the beginning of this troubleshooting Guide. If the fuel pressure and fuel system are operating as required Insure that the check engine light is on with the key on but the engine not running and there are no stored codes (except for code 42 if you have just set the ignition timing or code 12). If you have installed a new distributor, removed the distributor for any reason your ignition timing may be off too much to operate the engine properly. Disconnect the connector(s) from the injectors and set the ignition timing to its proper setting while cranking the engine. Assumption here also is that the timing mark on the balancer is lined up with TDC of #1 cylinder and that the distributor is seated properly and not 180 degrees off. If all of this checks OK go to step 3.

3. Measure the voltage on the throttle position sensor. If using a scan tool you can read TPS, if not measure the voltage. To measure the throttle position voltage check between the brown wire and the black/white striped wire on the TPS with the TPS still connected and the key on. DO NOT PUNCTURE THE WIRES to measure this voltage and only use a digital voltmeter. Voltage can be measured by back probing the TPS connector between these wires either with a thin paper clip or appropriate tool used for this type of measurement.

If you have gone through all of the above procedures and the engine still will not start you will need to call tech support. In many cases the specifications of the engine are different than what was originally discussed or assumed. When you call tech support you will need to have the following information available.

Fuel pressure at the inlet of the TBI unit. ____________ _ Return line fuel pressure ___________ _ Voltage measured at the battert while cranking ____ _ Voltage measured at the pink wire on the injector while cranking ____ _ Voltage measured at the TPS sensor key on engine off ________ _ Codes stored in the ECM Any information that you feel is important for diagnosing the issue at hand.

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2. My engine is running to lean, or is backfiring on acceleration.

Assumption here is that all plug wires are installed properly, the secondary ignition system (plug wires, coil, cap and rotor) is in good operating order and the engine is in good order. ~

Perform fuel system checks found at the beginning of this guide.

Check initial ignition timing again.

If the timing is OK check to insure that the timing is advancing as it should with throttle lever actuation.

If the fuel system checks performed are OK and the initial ignition timing is OK we may not have been given the proper information to build your system and you will need to call tech support.

If you have gone through all of the above procedures and the engine is still running lean or is backfiring on acceleration you will need to call tech support. In many cases the specifications of the engine are different than what was originally discussed or assumed. When you call tech support you will need to have the following information available.

Fuel pressure at idle, ____________ _ Fuel pressure while briefly accelerating the engine to WOT ____ _ Return line fuel pressure __________ _ Voltage measured at the battery while running ____ _ Engine operational temperature. ________ _ Initial ignition timing, _______ _ Timing at 2000 RPM _______ _ Any information that you feel is important for diagnosing the issue at hand.

3. Engine runs too rich.

Check for vacuum leaks and insure that all vacuum leaks are corrected and sealed. If the engine is also running at a higher than expected idle this is a good indication of a vacuum leak as well.

1. Is the vacuum line to the MAP sensor securely fastened to both the MAP sensor port and the port on the throttle body?

Yes, If engine is still running rich go to step 2. No - Repair leak, kink or routing, is engine still running rich? If yes go to step 2.

2. Is the MAP sensor connected to a full manifold vacuum port? For 2 bbl. units this will be the port on the back of the throttle body between the two fuel lines or the far left port on the front side of the throttle body as you are looking at the front of the throttle body. On a 1 bbl. unit this is the one of the far left ports.

Yes - If engine is still running rich go to step 3. No - Correct the vacuum source issue, if the engine is still running rich go to step 3.

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3. Is the fuel pressure measured at 12 psi"+" or"·" 1 psi while running?

Yes - If the engine is still running rich go to step 4. No - Is the return line connected to an unrestricted return port on the fuel tank?

Many fuel tanks have a port on the fuel tank that is for a fuel vent. These ports are not adequate for a fuel return. There is an orifice in these ports that will restrict the flow of fuel. Check that you have not used a vent port for the fuel return line.

No - Go to step 3a. Yes - Fuel is being returned to a vent line. Re-route fuel return line to a non orificed port or fabricate a free flowing return line port to the fuel tank or fuel return. If still running rich go to step 3a.

3a. Measure return line fuel pressure. This pressure should be less than 3 psi, if not there is a restriction in the return fuel line. If return fuel line pressure is less than 3 psi and the engine is still running rich go to step 4. If return line pressure is not less than 3 psi there is a restriction in the fuel line Find and repair the restriction until the fuel pressure on the return line is less than 3psi. In some cases this requires a larger diameter fuel return line. Go to step 3b to help determine root cause of increased return line pressure.

3b. Remove the fuel return line and attach a length of rubber hose of sufficient length to run into an approved gasoline container. Run engine and recheck fuel pressure on both the feed side and the return side. If both sides are within the above ranges there is a restriction in the fuel delivery system that needs to be repaired.

4. Does the engine have a fully operational thermostat?

Yes - insure that the engine will reach 180 deg. in a reasonable time, go to step 5. No - Install new thermostat, proper size thermostat will be 180 or higher. 160 degree in many cases is OK but the preference is 180 or higher. If still running rich go to step 5.

5. Is the coolant sensor installed in a portion of the engine or the cylinder block which provides a constant flow of coolant over the tip of the sensor?

Yes -Go to step 6. No - Reinstall the coolant sensor in a different location to insure constant flow of coolant over the sensor. If still running rich go to step 6.

6. Is the charging system operating properly and is the voltage measured at the battery and the injector 13 volts or higher with the engine running?

Yes - Go to step 7. No - Repair charging system. Note the discussion about older style AC Delco single wire alternators. If still running rich after reparing go to step 7.

7. If you have gone through all of the above procedures and the engine is still running rich you will need to call tech support. In many cases the specifications of the engine are different than what was originally discussed or assumed. When you call tech support you will need to have the following information available.

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Fuel pressure at idle. ____________ _ Return line fuel pressure __________ _ Voltage measured at the battery while running ___ _ Voltage measured at the pink wire on the injector while cranking. Engine RPM at start up idle on a cold start~----------Engine RPM at idle with stabilized temperature ________ _ Engine operational temperature ________ _ Initial ignition timing _______ _ Any information that you feel is important for diagnosing the issue at hand.

4. I do not seem to have as much power as I should.

Verify that you have set your timing properly by disconnecting the set timing connector, setting the timing to the specified value, reconnecting the connector and shutting the engine off and starting it back up before proceeding. For tach filter applications insure that the timing is set to factory specifications and that both the mechanical and vacuum advance units are operating properly. In some instances you can advance your timing an additional 4 - 5 degrees and evaluate. If you do not have any spark knock this setting may be OK for your application. Evaluate for spark knock and return the ignition timing back to its base at any time you may encounter spark knock. •

Ensure that your plug wires are properly connected with the correct firing order.

Your fuel pressure may be insufficient; see fuel system checks at the beginning of this guide.

Verify that there are no vacuum leaks and that the MAP sensor is properly connected.

5. I am getting a sag when I accelerate.

Timing is a critical issue with sags. Verify that your timing is correctly set by disconnecting the set timing connector and properly setting the timing; see #4 also.

Fuel pressure is not adequate for proper operation, make sure that there is no contamination in the tank or your fuel filter is plugged. (See Fuel System check above). A plugged fuel filter may be an indication of a contaminated tank.

Bad ground to the block, insure that the surface that you are making the connection to on the block is clean and making a positive connection.

Your 02 sensor may be contaminated, bad or not properly installed in the exhaust.

You may have left out some of the important specifications for the proper calibration chip to be made.

If you have gone through all of the above procedures and the engine is still sagging on acceleration you will need to call tech support. In many cases the specifications of the engine are different than what was originally discussed or assumed. When you call tech support you will need to have the following information available.

Fuel pressure at idle ____________ _ Fuel pressure when throttle is blipped to WOT ________ _

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Return line fuel pressure ___________ _ Voltage measured at the battery while running ____ _ Voltage measured at the pink wire on the injector while cranking. Engine RPM at start up idle on a cold start. __________ _ Engine RPM at idle with stabilized temperature _________ _ Engine operational temperature _________ _ Initial ignition timing ________ _ Any information that you feel is important for diagnosing the issue at hand.

6. My engine takes longer to start than I think it should.

Check for vacuum leaks, this is the most common cause.

Make sure that your timing ls set correctly; see Troubleshooting point #4. Fuel pressure is not adequate for proper operation. See Fuel System Checks at the beginning of this guide.

Fuel pump relay is not coming on or is faulty.

On a TBI system verify that the crank wire is connected to the crank side of the ignition switch or the crank side of the starter solenoid.

Check that the MAP sensor is properly connected to a full manifold vacuum source. Ensure that the vacuum source to your MAP sensor is free from restrictions and has a secure connection.

Throttle plates are not adjusted properly not allowing an adequate amount of air for starting the engine. Go to Troubleshooting guide # 10 and verify the adjustment.

Throttle position sensor is out of adjustment or faulty. Throttle position voltage with throttle fully closed with the key on should be .5 volts+,- .2 volts.

If you have gone through all of the above procedures and the engine is still sagging on acceleration you will need to call tech support. In many cases the specifications of the engine are different than what was originally discussed or assumed. When you call tech support you will need to have the following information available.

Fuel pressure at idle. ____________ _ Voltage measured at the battery while running ____ _ Voltage measured at the pink wire on the injector while cranking ____ _ Voltage measured between the black wire and brown wire on the TPS with the key on engine not running ______ _ Engine RPM at start up idle on a cold start. __________ _ Engine RPM at idle with stabilized temperature ________ _ Engine RPM at idle with IAC fully seated or blocked off. ______ _ IAC counts at stabilized idle in drive if using a scan tool _______ _ Engine operational temperature _________ _ Initial ignition timing ________ _ Any information that you feel is important for diagnosing the issue at hand.

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7. The fuel pump is not coming on when I first turn the key on.

Is the check engine light on with the key on engine off? (Assumes check engine light is connected properly, see installation instructions to verify check engine light installation)

Yes - Go to step 1. No - Check for proper installation of check engine light.

a. Check fuses to insure that they are not blown. If fuses are OK go to b. b. Check voltage at check engine light, if 12 volt are not present the check engine

light is not connected properly. If 12 volts are present either the ECM is not powered properly or is defective.

1. Insure that the IGNl wire is not connected to a battery feed. a. Check pink wire to the power relay and/or the pink wire powering up the injector(s)

to insure there is no voltage with the key off. If voltage is present with the key off the pink wire is not properly connected or the power relay is bad.

a. Check fuel pump relay for proper operation. • Turn ignition off for at least 15 seconds. • Connect voltmeter or test light to the blue wire at the fuel pump relay. • Turn ignition on, voltage should be present at this wire for the first 2 or

3 seconds after turning on the ignition switch. • If voltage is not present either the ECM is not powered or grounded

properly or the ECM is faulty. • If voltage is present check for voltage at the fuel pump with the same

type of operation. • If voltage is not present at the fuel pump check the wiring, if wires

appear to be OK replace the fuel pump relay. • If voltage is present verify the ground for the fuel pump is sufficient and

securely fastened. If fuel pump ground is OK the fuel pump is defective.

If you have gone through all of the above procedures and the fuel pump is still not coming on when you turn the key on you will need to call tech support. When you call tech support you will need to have the following information available.

Voltage measured at the check engine light with key on engine off ___ _ Voltage measured at the pink wire on the injector while cranking ____ _ Voltage measured at the pink wire on the injector with the key off ____ _ Voltage measured at the blue wire at the fuel pump relay at first 3 seconds of the key on ____ _

Voltage measured at the pink wire to the fuel pump at the first 3 seconds of the key on ____ _

Voltage measured with voltmeter between the black wire and pink wire on the fuel pump for the first 3 seconds of the key on. ____ _ Any information that you feel is important for diagnosing the issue at hand.

8. The RPM on my engine does not come down when I come to an idle.

• More than likely you have a large vacuum leak, verify that your system is free from vacuum leaks.

• Check that all non used vacuum ports are plugged.

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• Verify that the bolts holding down your throttle body are not protruding through the bottom of the adapter plate causing the plate to lift off its base.

• Your ignition wire is connected to a battery source and not an ignition 1 source.

• The engine has not come to full operating temperature as of yet. • Your thermostat is inoperable or opens at too low of a temperature. You

should be using at least a 180° stat. • Throttle cable or throttle on the throttle body is not coming to a complete

close. Throttle plate is binding in the throttle bores. • The throttle plates are adjusted too far out, see procedure #10 for proper

adjustment sequence. • IAC is not working, either faulty or there is a wiring issue.

If you have gone through all of the above procedures and the engine is still idling too high you will need to call tech support. When you call tech support you will need to have the following information available.

Voltage measured between the black wire and brown wire on the TPS with the key on engine not running, ______ _ Engine RPM at start up idle on a cold start __________ _ Engine RPM at idle with stabilized temperature _________ _ Engine RPM at idle with IAC fully seated or blocked off. _______ _ IAC counts at stabilized idle in drive if using a scan tool _______ _ Engine operational temperature ________ _ Initial ignition timing _______ _ Any information that you feel is important for diagnosing the issue at hand.

9. I am not getting as good of fuel economy as I think I should.

If all is set up properly with the installation of your fuel injection system you are probably getting as good of fuel economy as you are going to get.

1. Insure that your timing is set properly 2. Your thermostat is in good working order 3. Your fuel pressure is at the specified pressure (see fuel system check at the

beginning of this guide. 4. You may have other factors such as tires, brake drag or other external issue from the

fuel injection system that is not working properly. 5. Re-evaluate your driving habits and insure that you are driving in a fashion that will

provide you optimum fuel economy. If you are trying to race everyone from the light chances are you will not get the fuel economy that you expect.

If you have gone through all of the above procedures and you still feel that you should be getting better fuel economy you will need to call tech support. In many cases the specifications of the engine are different than what was originally discussed or assumed. When you call tech support you will need to have the following information available.

What is the Fuel Economy that you are getting ____________ _ What is the Fuel Economy that you are expecting ____________ _ Voltage measured at the battery while running ___ _

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Voltage measured between the black wire and brown wire on the TPS with the key on engine not running, ______ _ Engine RPM at idle with stabilized temperature. ________ _ Engine operational temperature ________ _ Initial ignition timing _______ _ Trouble Codes from the ECM (see #14) _____ _ Any information that you feel is important for diagnosing the issue at hand.

10. The engine is revving up and down when I come down to an idle. There is a large "sucking" sound coming from the throttle body when it is warmed up. My engine stalls or almost stalls when I come down to an idle.

This is usually an indication of a vacuum leak; again make sure that you have no vacuum leaks.

This could also be an indication of the wrong base ignition timing. Verify that you have set your ignition timing correctly (see #4).

Your engine may also require more air going through the throttle plates at idle than it is currently set for. Here is a procedure to check this setting.

a. Make sure your engine temperature is at full operating temperature. b. Jumper Pins A & B of the ALDL connector (I use a paper clip) with the key on but the engine off. This is the same thing you do when checking for engine codes and your check engine light will flash off and on. c. Wait about 45 seconds or until any trouble codes present have flashed through; code 12 is normal (see #14) After this then unplug your IAC valve which is on the throttle body but do not turn off the key. d. Remove the jumper from the ALDL, turn the key off, wait 15 seconds and start the engine. It may start hard and you may have to depress the throttle pedal a little bit to start the engine. e. If you have a fast idle this did not work or you have a vacuum leak that is not repaired, or the throttle plates are already too far open. You may have to tape over the fresh air hole that the IAC receives its air from. f. If you do not have a fast idle then it is OK and you can proceed to adjust the throttle plates. Let the engine idle for a little bit and then check you idle speed. The speed should be about 575 - 600 at idle in drive or about 50 rpm less than you requested for your chip. If it is lower than this you can raise the idle up or if it is above this determine if you should bring the speed down. More than likely it will always be lower. g. There is a little cap on the side of the throttle body by your throttle lever that has an adjustment screw under it (if not already removed). h. Remove this cap and use the screw under there to adjust your base idle speed without the IAC operational. Base idle is to be set in drive for an automatic transmission. i. If you have done all of this and you still have an issue we may not have received all of the proper information to build your chip and you will need to call tech support.

If you have gone through all of the above procedures and the engine is still idling too high you will need to call tech support. When you call tech support you will need to have the following information available.

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Voltage measured between the black wire and brown wire on the TPS with the key on engine not running ______ _

Engine RPM at start up idle on a cold start~----------Engine RPM at idle with stabilized temperature. ________ _ Engine RPM at idle with IAC fully seated or blocked off. _______ _ IAC counts at stabilized idle in drive if using a scan tool _______ _ Engine operational temperature ________ _ Initial ignition timing _______ _ Any information that you feel is important for diagnosing the issue at hand.

11. My fuel pump is real noisy.

If your fuel pump is real noisy you may not have isolated it from the body or the frame real well. Isolation brackets were provided with your fuel pump. If these are properly installed it should isolate any radiated noise from the pump. If this is insufficient you may need to isolate it more with some rubber grommets.

We have also diagnosed noisy fuel pumps with fuel return lines being too small. By stepping up the size of the return line you may eliminate fuel pump noise after the other items have been addressed. Fuel pump noise also can radiate through the fuel lines to the frame or body of the vehicle. Insure that the fuel lines are isolated as well if need be to eliminate the noise.

A noisy fuel pump can also be an indication that it is starving for fuel. Insure that all filters are in good order and that the fuel tank sock is clean. Prolonged fuel starvation will damage the fuel pump and not allow proper flow; it may also radiate a lot of noise.

12. My check engine light does not come on when I turn the key on.

Your check engine light should illuminate when you turn the key to the on position for a bulb check. Check for proper installation of check engine light.

a. Check fuses to insure that they are not blown. If fuses are OK go to b. b. Check voltage at check engine light, if 12 volt are not present the check engine

light is not connected properly. If 12 volts are present either the ECM is not powered properly or is defective.

c. If the fuse is OK insure that you are receiving 12 volts to the ECM where indicated (see wiring diagram provided) If you are not receiving 12 volts to the ECM something in the vehicle's power circuit is not connected properly.

d. If 12 volts is available at the proper cavities of the ECM please check that you have a proper ground circuit to the engine block.

If you have gone through all of the above procedures and the fuel pump is still not coming on when you turn the key on you will need to call tech support. When you call tech support you will need to have the following information available.

Voltage measured at the check engine light with key on engine off ___ _ Voltage measured at the pink wire on the injector while cranking ____ _ Voltage measured at the pink wire on the injector with the key off ____ _ Any information that you feel is important for diagnosing the issue at hand.

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13. My check engine light is flashing fast all the time.

A constant rapid flashing check engine light indicates that you have a fault in the ECM and it is operating in back up or limp home mode. Make sure that the calibration chip is in the ECM and there are no bent pins on the chip. If the chip is properly installed and there are no bent pins the ECM or the chip is faulty and needs to be replaced or repaired.

14. My check engine light is on when the engine is running.

A check engine light indicates a hard fault with your fuel injection system.

Insure that all of your sensors are connected, you have a good ground and that no wires are pinched.

Also insure no vacuum leaks and that your MAP sensor is connected to a full manifold vacuum source.

If all of these steps indicate a proper installation and no issues you will need to read the codes from the memory area of the ECM and follow the diagnostic procedures for that particular code.

If you have a scan tool this is very easy. If you do not have a scan tool you can use your check engine light to output the fault codes. Below you will find this procedure along with a definition of all the different fault codes that can be output.

THE CONNECTOR --------tab------------1 F E D C B A ! lMLK JI HI

To Display Trouble Codes Run a wire (I use a paper clip that is in a "U") from Pin A to Pin B with the ignition on but the engine not running. The "Check Engine" light will flash in the following sequence: flash, pause, flash-flash, long pause flash, pause, flash-flash, long pause flash, pause, flash-flash, long pause. This is a code "12" which will always be there. After this series of flashes and pauses any stored trouble codes will now flash. If you do not see the "12" flash three times, your diagnostic circuit is defective.

Vehicles will display stored trouble codes, then "12" again, followed by energizing "most system controlled relays." The fuel pump relay will not energize. The idle air control valve will fully extend to enable checking minimum idle speed.

CLEARING THE TROUBLE CODES Turn the keyswitch to the off position. To clear any trouble codes, disconnect the battery for 30 seconds or unplug the connectors to the ECM. If this is done at the battery, and your car stereo is equipped and programmed with a four digit pin code, you may have to re-enter that as well to use your stereo again. A better place to remove power is at the fuse.

TROUBLE CODES

12. No reference pulses to Electronic Control Module (ECM). The code is always flashed when checking codes and only indicates that the engine is not running.

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13. Oxygen sensor signal stays lean during warm engine cruise, your 02 sensor could be unplugged.

Qode 13 (02 open)

Veri Sensor is not un lu ed

With an ohmmeter veri continuit from round to Pin D-6

-Sensor is not unplugged -Si nal and round wire both have continuit

-Clear code and verify that the code still sets before moving on with diagnostics

-With engine fully warmed up Place the engine into Service diagnostic mode **

Flashes Closed Loo

Problem is Intermittent Check for chaffed or loose wires 02 sensor ma be bad

Check engine light went out for at least 15 seconds

Fault connector or sensor

Flashes Open Loo

-Diagnostic terminal still rounded

-Unplug 02 sensor and ground connector terminal

-Start engine and immediately note check engine light

Check for opens in the circuits just as above. If no opens exist then you have a faulty ECM connector or ECM

** Service diagnostic mode is entered the same as Engine Off Self Test. Ground out Pin A and B on the ALDL connector with the engine running. Rapid flashing (approx 1/2 - 1 sec interval) is open loop. Flashing at a slower rate indicates closed loop.

14. High temperature indicated at engine coolant temp. sensor. Sensor could be unplugged

Code 14 (Coolant Sensor Low

Verif Sensor is not un lu ed

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I With a ohmmeter verify continuity between Pin C-10 and the ECT Sensor I

-Sensor is not unpluaaed I -Clear code and verify that the code still sets before I moving on with diagnostics if any actions were I taken

-With engine fully warmed up unplug ECT sensor and check voltage between ECT connector (yellow wire) and around

I Over4 volts I Below 4 volts

I Check resistance across If all wiring checks out OK

I sensor, resistance should be above the problem is the ECM more than 100 ohms or ECM connector i

If resistance is above 100 I Resistance is below 100 ohms, repiace I ohms the problem is sensor I intermittent. Verify that all wiring is OK and not chaffed or grounding out.

Disconnect ECM connector and insure yellow wire to Pin C-10 is not grounded out to the chassis or another wire.

15. Low temperature indicated at engine coolant temp. sensor

Code 15 (Coolant Sensor High)

I Verify Sensor is not unplugqed I

I With a ohmmeter verify continuity between Pin C-10 and the ECT Sensor I

I -Sensor is not unplugqed

-Clear code and verify that the code still sets before moving on with diagnostics if any actions were taken

I Engine off Clear codes. Disconnect Coolant sensor and jumper harness terminals together. Start engine and run until check engine light comes on. Gound diagnostic connector and note code.

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Code 15

Probe coolant sensor harness (yellow wire) with a voltmeter to ground. Should measure 4 - 6 volts

4 - 6 volts

Ignition off, disconnect ECM connector C-D. Check yellow wire (C-10) for open circuit. If no open circuit it is faulty ECM or ECM connector.

Code 14

Faulty coolant sensor or connection.

Below 4 volts

Ignition off, disconnect ECM connector C-D. Check yellow wire (C-10) for open circuit. If no open circuit it is faulty ECM or ECM connector.

21 H" h . 19 vo tage att h rott e pos1ton sensor. s ensorcou Id b d e unp ugge •

Code 21 (TPS High) I Verify Sensor is not unplugged I

With an ohmmeter verify continuity between Pin C-13 and Pin B (flat TPS) or I Pin C (round TPS) on the TP Sensor I

-Sensor is not unpluaaed

-Clear code and verify that the code still sets before I moving on with diagnostics if any actions were taken I

Engine off Clear codes. Start engine and run until check engine light comes on. Gound diagnostic connector and note code.

I Code 21 No Code set,

problem is intermittent

Clear codes I Disconnect TP Sensor

Key on, engine off. Backprobe with voltmeter between Start engine and idle till CE light Pin B (flat TPS) or Pin C (round TPS) and ground.

Manually move throttle slowly from closed to WOT. comes on. Insure that voltmeter increases in voltage and does not Note the code that is set "glitch" open or closed during the process. If there are

any disruptions, replace sensor. If OK, check Code 22 connections and connector.

Code 21

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Probe TPS Harness pin A (flat TPS) or Pin B (round TPS) with test light to 12 volts Check Pin

I for short t I I Check for

Light "ON\ (round TP

B (flat TPS) or Pin C (round TPS) o other voltage. short to pin C (flat TPS) or Pin A S) If all OK, ECM could be at fault

! Light "Off' I

Faulty TPS Repair open in Blk/wht wire, connection or Pin A (flat TPS) Pin B (round Sensor TPS)

22. Low voltage at throttle position sensor

Code 22 (TPS Low) I Verify Sensor is not unplugged I

With an ohmmeter verify continuity between Pin C-13 and Pin 8 (flat TPS) or Pin C (round TPS) on the TP Sensor

-Sensor is not unpluaaed

Engine off Clear codes. Start engine and run until check engine light comes on. Gound diaanostic connector and note code.

Clear codes I Disconnect TP Sensor and

Key on, engine off. Backprobe with jumper pin C to 8 (flat TPS) or Pin A to C (round TPS) voltmeter between Pin 8 (flat TPS) or Pin C

Start engine and idle till CE (round TPS) and ground. Manually move

light throttle slowly from closed to WOT. Insure that voltmeter increases in voltage and does

comes on. not "glitch" open or closed during the Note the code that is set process. If there are any disruptions, replace

sensor. If OK, check connections and Code 22 connector.

Code 21

I Remove Jumper from pins. Check voltage between Pin C Replace TPS

and A (flat TPS) or Pin A and B {round TPS)

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4 - 6 volts I Below 4 volts I I I

Disconnect ECM connector Disconnect ECM connector and and check for open or short to check for open or short to ground in TPS signal brown ground in Sv signal orange wire. wire. If OK it is faulty ECM If OK it is faulty ECM connector connector terminal or ECM. terminal or ECM.

33. High voltage Clow vacuum) at MAP sensor, sensor could be unplugged.

Code 33 (MAP High) I Verifv Sensor is not unpluaaed I

If vehicle is equipped with a governor insure proper operation of the governor before using this chart.

If engine idle is rough, unstable, or incorrect, correct any issues before using this chart.

-Sensor is not unoluaaed -Clear code and verify that the code still sets before moving on with diagnostics if any actions were taken

Clear codes ! Disconnect sensor and run

Key on, engine off. Backprobe with voltmeter between engine for 1 minute or until CE light comes on. Pin B and Pin A. With no vacuum applied voltage should

be over 4 volts. Apply 25 " of vacuum with a hand held or Note the code that is set similar vacuum pump. Voltage should be approx. 1 - 1.5

volts. If these voltages are correct system is working as it Code 33 should. Look for loose or chaffed wires, terminals or

connectors. See first note on idle conditions.

Check for short to voltage on Brown Code 34 I wire Pin B I

Check for Plugged or leaking I If circuit is OK Replace ECM Sensor vacuum hose. I

If vacuum hose is OK, check for / open ground circuit in blk/wht wire

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pin A.

If ground circuit is OK, Replace sensor

34. Low voltage (hiah vacuum) at MAP sensor.

Code 34 (MAP Low) I Verify Sensor is not unpluaaed I

-Sensor is not unplugged

Clear codes I

Disconnect sensor and Key on, engine off. Backprobe with voltmeter between jumper harness terminal "B" Pin B and Pin A. With no vacuum applied voltage should to "C" and run engine for 1 be over 4 volts. Apply 25 " of vacuum with a hand held or minute or until CE light comes similar vacuum pump. Voltage should be approx. 1 - 1.5 on. volts. If these voltages are correct system is working as it Note the code that is set should. Look for loose or chaffed wires, terminals or

connectors. See first note on idle conditions. Check TPS Code 34 adjustment.

Code 33 I Remove jumper "B" to C". I Check voltage between Replace Sensor

harness terminal "A" and "C" with voltmeter

Below 4 - 6 volts I 4 -6 Volts

Check for open or short to ground on connector Pin C,

Check for open or short to orani:ie wire.

ground on connector Pin B, brown wire. Circuit OK, Faulty ECM

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I connector or ECM

Circuit OK, Faulty ECM connector or ECM

44. Oxygen sensor lean ,-----------------~ Code 44 (02 Lean)

Codes 33 and 34 can cause a code 44. If either of these codes are present repair them first before proceeding.

-Sensor is not unplugged -Ground diagnostic terminal (field service mode)**

-Run warmed up engine for approximately 1 minute between 1200 and 1800 RPM, note "Check En ine" Li ht

Flashin Closed Loo

Trouble Is intermittent

Light staying off more than on or flashing "O en Loo " at either RPM

-Ignition off diagnostic terminal grounded

....---------------J -Disconnect 02 sensor -Start en ine and note "Check En

"Check Engine" light off for at least 15 seconds

Check Purple wire from ECM Pin D-7 for o en or short to round

If circuit and wire OK, Faulty ECM or ECM connector

Check the following: Sensors Bad or lean

injectors Contaminated fuel EGR valve (if equipped) Low fuel pressure Vacuum leaks or exhausts stem leaks

If all check OK re lace 02 sensor

** Service diagnostic mode is entered the same as Engine Off Self Test. Ground out Pin A and B on the ALDL connector with the engine running. Rapid flashing (approx 1/2 - 1 sec interval) is open loop. Flashing at a slower rate indicates closed loop.

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45. Oxygen sensor rich

Code 45 (02 Rich) I Verify 02 Sensor is not unplucicied I

Codes 33 and 34 can cause a code 45. If either of these codes are present repair them first before proceedinci.

-Sensor is not unplugged -Ground diagnostic terminal (field service mode)**

-Run warmed up engine for approximately 1 minute between 1200 ·and 1800 RPM, note "Check Engine" Light.

I Flashinq Closed Loop Light staying on more than off or flashing

"Open Loop"

Trouble is intermittent, perform fuel I system check, contaminated 02 sensor -Ignition off diagnostic terminal grounded or other forms of non metered fuel. -Disconnect 02 sensor and ground harness

end of connector

-Start enqine and note "Check Engine Light" "Check Engine" light off for I at least 30 seconds Steady Liqht

I System is Rich Faulty ECM

Check the following:

Sensors Bad or leaking injectors Contaminated

fuel EGR valve (if equipped) High fuel

pressure Performfuel system check out

** Service diagnostic mode is entered the same as Engine Off Self Test. Ground out Pin A and Bon the ALDL connector with the engine running. Rapid flashing (approx 1/2 - 1 sec interval) is open loop. Flashing at a slower rate indicates closed loop.

51. PROM error 52. Calpak Missing

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54. Low voltage at fuel pump OR Low voltage at Fuel pump relay 55. Problem at Electronic Control Module (ECM) - ECM failure OR Serial bus

Code 51 (Eprom Problem)

Check that all pins are fully inserted in the socket. If OK, replace PROM, clear memory and recheck. If code 51 reappears replace ECM

Code 52 (Fuel CALPAK missing)

Install missing or faulty CALPAK

Code 54

Fuel Pump Relay or relay wirin

Code 55

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FUEL INJECTION T.B.I. WIREPINOUT

A-1 BLUE FUEL PUMP RELAY "85" A-5 ORANGE CHECK ENGINE UTE A-6 PINK IGN I RUN TO PIN A ON INJECTORS A-8 BLUE ALDL CON. PIN "E" A-9 BROWN ALDL CON. PIN "B" A-I I BLACK/WHITE MAP RETURN GREEN CON. A A-12 BLACK TO BLOCK GROUND TO CONNECT WD-1, D-6

B- I BAT RED FUSED CONNECTS \VITH C-16 B-2 ORANGE FUEL PUMP REL\ Y PIN"87" r:·•. B-3 BLACK/WHITE PIN D IGN GROUND.· . B-5 GRAYTACHFTLTER

C-3 GR!·E:\ !AC PJN D C-4 BLUE !AC Pl:-J C C-5 GREFN lAC Pr\ A C-6 BLUE !AC PIN B C-9 TAN CRANK INPUT TO STARTER STUD or !GNlTION SWITCH C-10 YELLOW ECT C-11 BROWN MAP INPUT P[N BON GREEN CON. C-13 BRO\VN TPS PINC C-14 ORANGE {5V REF) GOES TO MAP PINC & TPS PIN A C-16 RED 12 VOLT CONNECTS IN WITH B-1

D-1 BLACK BLOCK GROUND CONNECT W/ D-6, A-12 D-2 BLACK/WHITE ECT & TPS RETURN ON TPS PIN B D-6 BLACK/WHITE 0/2 GROUND GOES TO BLOCK GROUND CONNECT W/D-1,A-12 D-7 PURPLE 0/2 D-14 or D-I6 GREEN or PURPLL. l"\H:C !OR Pl:-; B

PINK WIRE TO IGN. I PIN A FROM INJECTORS FROM A 6

PIN A, ON ALDL TO BLOCK GROUND

RELAY 85 FROM IGN. SWITCH 86GROUND 30 I2V. 87 IGN. OUT/ FUEL PUMP

87 86 Pro

Airline

AFI Service Bulletin 2009-001 EFI MAP Sensors Jan. 8, 2009

3. Thermostat/engine operational temperature. A bad thermostat and/or an improperly sized thermostat can cause operational issues. These issues result in running richer than normal, fouling or partially fouling spark plugs and causing a roughness at idle or misfires. These conditions can cause a DTC code for a MAP sensor and possibly a replacement for a part that is not bad. A thermostat must be installed in an engine, installed properly and fully operational at the proper opening temperature for proper eniine operation. It is recommended that a 190 deg. Thermostat be used for all GSE equipment utilizing the AFI fuel injection system. A 180 degree thermostat can be used but the 190 degree is recommended. Any thermostat with an opening temperature lower than this can cause operational issues. This is especially true in colder weather operation and colder climates. Generation II fuel iniection units require a 190 degree thermostat due to exhaust emission compliance. It is recommended to verify the operational temperature of the engine at least on an annual basis and whenever any service of the fuel injection system is being performed. It is very easy to verify the engine temperature and proper operation of the thermostat using a scan tool.

4. False DTC codes: This would be a DTC being set with no issues with the sensor itself. If there are other issues with an engine such as a dead cylinder, faulty ignition, high or low fuel pressure, bad ECT sensor running rich or bad 02 sensor and the engine running rich, bad or improperly sized thermostat, all can cause MAP sensor codes. These items need to be repaired before the MAP sensor is replaced to insure proper engine operation.

5. No DTC code: In some instances a MAP sensor can be faulty and not set a code. This will almost always show up as a rich running condition. in this case check the output voltage of the MAP sensor with a scan tool or voltmeter and a hand held vacuum pump. The foilowing table shows the approximate output of the MAP sensor vs. the vacuum applied.

20" 1.lv 15" 2.2v 10" 3.3v

If the voltage is not close to these values with the vacuum applied change the sensor.

Just because a DTC is set does not necessarily mean that the sensor is faulty. Always look for additional codes and diagnose these issues first before automatically changing a MAP sensor for a code.

Example: A vehicle comes in and has a code 22 and code 34. These codes indicate a TPS sensor low and MAP sensor low. Both share a common 5 volt source. With a scan tool or voltmeter look at the output voltage of each sensor. If both are reading low or zero volts check for 5 volts on the orange wire feeding the sensor. Disconnect one sensor at a time and verify the voltage and operation of the other sensor.

If a TPS sensor is bad, when you disconnect the TPS, 5 volts will now come back to the MAP sensor and the MAP sensor will read properly. The reverse is also true of the MAP sensor and the TPS voltage.

Two other sensors share 5 volts as well that can cause the same issue. The coolant sensor and the tach filter. The tach filter is the primary cause of the 5 volt reference not operating properly on both sensors. With this example the engine will not be running and the TPS and MAP sensor and possibly ECT sensor codes will be set.

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Code 33: This code is set when the ECM sees a high voltage from the MAP sensor. A code 33 does not always mean a bad MAP sensor. Vacuum leaks, improper engine operation from other faulty sensors etc. can cause a code 33. Always insure that all engine operational issues are repaired if this code exists and replacement of the sensor does not fix the issue.

Code 34: This code is set when the ECM sees a low or no voltage from the MAP sensor. If the only code set is a code 34, and the 5 volt reference is present at the connector, it is almost always a sensor issue and needs to be replaced.

Engine Calibration

AFI has a revised engine calibration which results in a less rich running condition for a failed MAP sensor or ECT sensor. This upgraded calibration can be procured on an exchange basis at no charge.

Exchange process: Contact Bob Russ {248-941-3613 or email bob@affordable-fuel-iniection.com) or Kevin Witte (989-862-4163 or email keviQ.@affordable-fuel-iniection.com) for the exchange.

Based on the# of units that you desire to update, AFI will send you a new ECM(s) with the updated calibration. The new ECM is to be installed and the removed ECM shipped back to AFI. When the returned ECM(s) are returned, AFI will ship out more updated units for exchange.

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Code 33 (MAP High)

Verify Sensor is not un lu ed

If vehicle is equipped with a governor insure proper operation of_the governor before using this chart.

Engine off Clear codes. Start engine and run until check engine light comes on. Ground dia nostic connector and note code.

Code 33

Clear codes

Disconnect sensor and run engine for 1 minute or until CE light comes on. Note the code that is set

Code 33

Check for short to voltage on Brown wire Pin B

If circuit is OK Re lace ECM

No Code set, problem is intermittent

Key on, engine off. Back probe with voltmeter between Pin B and Pin A. With no vacuum applied voltage should be over 4 volts. Apply 20 " of vacuum with a hand held or similar vacuum pump. Voltage should be approx. 1 - 1.5 volts. If these voltages are correct system is working as it should. Look for loose or chaffed wires, terminals or connectors. See first note on idle conditions.

Code 34

Check for Plugged or leaking Sensor vacuum hose.

I I 1t vacuum hose is OK, check for

open ground circuit in blk/wht wire pin A.

If ground circuit is OK, Replace sensor

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Code 34 (MAP Low)

Verif Sensor is not un lu ed

I Engine off Clear codes. Start engine and run until check engine light comes on. Ground diaqnostic connector and note code.

I I Code 34 I No Code set, I

I Clear codes Disconnect sensor and jumper harness terminal "B" to "C" and run engine for 1 minute or until CE light comes on. Note the code that is set

Code 34 I

Remove jumper "B" to C".

Check voltage between harness terminal "A" and "C" with voltmeter

4- 6 Volts I

Check for open or short to ground on connector Pin B, brown wire.

Circuit OK, Faulty ECM connector or ECM

I I Key on, engine off. Backprobe wit h voltmeter between

applied voltage should um with a hand held or

Pin B and Pin A. With no vacuum be over 4 volts. Apply 25 " of vacu similar vacuum pump. Voltage sh volts. If these voltages are correct should. Look for loose or chaffed connectors. See first note on idle adjustment.

I Code 33 I I

I Replace Sensor

I I Below 4 - 6 volts I

I I Check for open or short to

ground on connector Pin C, I

orange wire.

I I Circuit OK, Faulty ECM I

connector or ECM

ould be approx. 1 - 1.5 system is working as it wires, terminals or conditions. Check TPS

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Diagnostic Tools Price List

DIA5001 X-RAY 5000 $614.00

Fuel Pressure Tester

Hand Held Vacuum Pump

Voltmeter

Diagnostic Cable

DIA5001S X-RAY 5000 Spanish v,ersion $684.00

Voltmeter

Diagnostic Cable

D1A5002 X-RAY 5000 $480.00

Diagnostic Cable

DIA5002S X-RAY 5000 Spanish version $543.00

Diagnostic Cable

DIA3001 X-RAY 3000 $514.00

Voltmeter

Diagnostic Cable

D1A3002 X-RAY 3000 $373.00

Diagnostic Cable

D1A5000 X-RAY 5000 $325.00

D1A5000S X-RAY 5000 Spanish version $395.00

D1A3000 X-RAY 3000 $225.00

D1A6000 Fuel Pressure Tester $63.00

D1A6001 Hand Held Vacuum Pump $62.00

D1A6002 Voltmeter $79.00

D1A6003 Diagnostic Cable $85.00

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Wiring Information

This section includes a wiring diagram and information on the electronic of this tug.

For wiring information on the Electronic Fuel Injection, please refer to the back of the EFI section.

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11 ---ii..----------------------1""""---RI G HT TURN

7 C STARTER

ALTERNATOR

RIGHT HEADLIGHT I (:,J.~,

WATER TEMP SWITCH

I II"'-. I I

I \.It LEFT HEADLIGHT

LEFT TURN

FORD!GNBOX

HORNRELAY

?~ 13 21

PONY KIT

HORN BUTTON

WIRING DIAGRAM REVISION: 2 DRAWN BY: MICHEL LANDRY

RIGHT BACKUP

LEFT BACKUP

TAJLLIGHT

SAGE PART NUMBER· OF: CE3 CUSTOM ELECTRONICS INTEGRATORS · FOR: SAGE GSE SERVICES

T6701110SAARF DATE:JUL Y 27, 2009 Prope

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RIGHTTURN

RlGHT HEADLIGHT

LEFT HEADLIGHT

ALTERNATOR

WATER TEMP SWITCH

STARTER 1 c

BORN 21

I.S,6 CDRELAY

._ ____________________ ...... ~ ... ~ u

con. REDANDPINK JS

WBITB 8

FORDIGNBOX

2'I:IJ 2'o::::::::iJ ~

_ ....... ~ ~ ia:::c:::1]32

J<C£:::i:] 23

CIRaJIT BREAKER 30 20

16.24.25

PONY KIT

HOR.~ BUTTON

- ----!II

RlGBT BACKUP

LEFT BACKUP

LEFT TAILI.IOHT

W!RING DIAGRAM REVISION: 2 ORA WN BY: MICHEL LANDRY

SAGE PART 1''UMBER: T6701110SAARF

OF· CID CUSTOM ELECTRONICS INTF.GRATORS FOR: SAGE GSE SERVICES DAT6.:JULY 27, 2009

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Wire Table for Tug Tractor

This list is oriented as if the mechanic were looking at the dash plate from the engine side.

Wire # Component

1 CD Relay Left Side Large Terminal to 30 Amp CB Battery post 2 CD Relay Right Side Large terminal to #1 20 amp CB post 3 Ign on Ign to Left Side small terminal on CD Relay 4 Batt on Ign to Aux terminal on 30 amp CB 5 CD Relay Left Side Large Terminal to Starter 6 CD Relay Left Side Large Terminal to Alternator 7 Starter to White Wire on Shifter 8 ST on Ign to White Wire on Ford Harness 9 ST on Ign to Green Wire on Shifter 10 #1 TS bottom to Backup Lights 11 Daisy Chain to Battery terminal on LED's to #3 20 amp CB Aux 12 Pwr on Htr Switch to #3 20 amp CB Aux 13 Horn Relay #87 and 30 (front and rear) to #3 20 amp CB aux 14 #3 20 amp CB aux to the Red and Blue Wire on Shifter 15 #1 20 amp CB Aux to Red and Pink wire on Ford Engine Harness 16 #2 20 amp CB Aux to Brake Pressure Switch 17 Signal on Heater Toggle to Heater Blower Motor 18 Left Side LED to Water Temp Switch 19 Right Side LED to Oil Press Switch - NC 20 #86 Horn Relay (left) to Horn Button 21 #85 (right) on Horn Relay to Hom 22 #2 Terminal Strip Bottom to Brake Pressure Switch 23 #1 Terminal strip Top to Black wire on Shifter 24 #2 CB Aux to Reverse But to Left and Right Headlights

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25 #2 CB Aux to Left and Right Taillights 26 #3 Terminal Strip Bottom to Right Hand Rear Blinker 27 #4 Terminal Strip Bottom to left Rear Blinker 28 #5 Terminal Strip Bottom to Left Front Blinker 29 36 Terminal Strip Bottom to Right Hand Front Blinker 30 NO on Oil Pressure Switch to Hour Meter 31 Power feed From CB to Hour Meter 32 GND Right Side Small Terminal on CD Relay to GND 33 GND Common Terminal on Oil Pressure Switch to GND The top CB is a 20 amp Aux breaker for any station specific needs. ***Do not cut into any other wires for accessory power***

The extra 30 amp CB off to the side of the breaker block is just for the cooling fan as it draws 21amps

* *Do not add anything to this Circuit breaker**

Wiring for the fan is as follows:

Yell ow - Battery power from circuit breaker to relay Orange - Ign power from ign side of circuit breaker to relay Grey - from relay to sending unit Red - Power from relay to fan

Brown Wire Yellow Wire

Pony Flasher

#2 Terminal Strip Top Slip Terminal to Yellow (L) wire from Turn Signal Harness Slip Terminal to Blue (P) wire from Turn Signal Harness

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Tum Signal Switch Wiring

From tum signal switch: 1. Yellow wire connects to Yellow wire on flasher base. 2. Blue wire connects to Blue wire on flasher base. 3. Light Green or Black with Grey wire connects to Brown wire #32 on terminal. 4. Black wire connects to Green wire #26 on terminal strip for R. Rear tum. 5. Red wire connects to Green wire #29 on terminal strip for R. Front tum. 6. Dark Green wire connects to Yellow wire #28 on terminal strip for L. Front turn. 7. Grey wire connects to Yellow wire #27 on terminal strip for L. Rear turn. 8. White - Ground 9. Brown wire from flasher base to 2ed c/b down from top on ign side power to flasher.

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If Turn Signal switch is not used, a jumper must be installed to make Brake Lights function. On terminal strip jump wires #32,#26 and #27.

Note: All LED Lights are polarity sensitive. All dash LED's positive post will be the right side terminal

The Cab wiring consists of a positive feed wire from the #2 CB Aux Terminal to a junction at the upper right side of the cab. This feeds the Wiper and the Dome light. Two additional positive leads are included for the addition of station specific accessories. A separate ground is included for positive grounding of the cab to the chassis.

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Wan·anty Information

This section includes warranty information and contact numbers for the warranty on your engine, transmission and radiator.

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~SPEL.-D 'f MENGINES&TRANSMISSIDNS ~ Be Car Care Aware·

Seller Limited Nationwide Transferable

Warranty JASPER warrants components against defects in our workmanship and material in accordance with the schedules and limitations outlined

below. Repairs or replacement will be made at the JASPER factory within a reasonable time after notice and upon receipt of the goods deemed to be defective per the schedules and limitations of our written warranty. A warranty case number must be assigned and repair instructions provided prior to repair or replacement of goods.

GASOLINE ENGINES: Short Blocks Completes and Special Completes

for Cars and Trucks Industrial/Non-Automotive

PERFORMANCE ENGINES: Class I, Cars and Trucks - Short Blocks Class I, Cars and Trucks - Completes Class II, Cars and Trucks - Short Blocks

(Except Racing and Abuse) Class II, Cars and Trucks - Completes

(Except Racing and Abuse)

Class Ill

Time or Mileage, whichever occurs first. A Maximum labor on Short Blocks not to exceed purchase price of unit.

6 Months or 8,000 Miles

3 Years or 100,000 Miles 6 Months

6 Months or 8,000 Miles 3 Years or 100,000 Miles

6 Months or 8,000 Miles

6 Months or 8,000 Miles 1 Year or 16,000 Miles Including racing applications

- Motor Homes: Maximum of 25 hours for Completes; Maximum of 20 hours for Special Completes. t Ambulance, automotive off-highway use, package delivery, police, snow removal, taxi, tow truck,

or any vehicle over 1 ton, 18 Months or 100,000 Miles, whichever occurs first.

MARINE STOCK NUMBERS: Short Block Engines

Complete Engines Class II Performance Marine

Stern Drives Outboard Lower Units Outboard Powerheads

90 Days 6 Months 18 Months 6 Months 1 Year 2Years 2 Years 1 Year

Parts + LaborA

Parts+ Labor-t Parts

Parts + LaborA Parts+ Labor-t

Parts+ LaborParts No Warranty

Parts + Labor* Parts Parts + Labor* Parts + Labor' Parts Parts + Labor* Parts + Labor Parts + Labor*

* Marine Labor - Maximum labor on Short Blocks not to exceed purchase price of unit; Maximum hours for Completes 16.5; Maximum hours for Outboard Powerheads 10. Because of design limitations, Mercruiser Alpha stern drives installed on applications with more than 300 hp are not warranted.

DIESEL ENGINES: Short Blocks**

School Bus Class 5-6-7 Truck (33,000 lbs. or less) Class 8 Truck (33,001 lbs. or more) Industrial/Non-Automotive Transit/Bus

Completes** School Bus Class 5-6-7 Truck (33,000 lbs. or less) Class 8 Truck (33,001 lbs. or more) Industrial/Non-Automotive• Transit/Bus

Running Completes**+

6 Months 6 Months 6 Months 6 Months 6 Months

1 Year 1 Year 6 Months 6 Months 6 Months

Parts Parts Parts Parts Parts

Parts + Labor Parts + Labor • Parts Parts + Labor Parts

School Bus 2 Years Parts + Labor Class 5-6-7 Truck+ (33,000 lbs. or less) 2 Years Parts+ Labor• Class 8 Truck (33,001 lbs. or more) 1 Year Parts Industrial/Non-Automotive• 1 Year Parts + Labor Transit/Bus 1 Year Parts

NOTE: Fuel injectors, fuel pumps, water pumps, hydraulic high pressure pumps, sensors, sending units, turbochargers, belts, hoses and other accessories installed have a one year warranty, after which time they are considered maintenance items and are not covered by parts or labor. Parts included in installation kits are covered for the time stated by the manufacturer.

** Does not include problems related to fuel components and accessories not installed by JASPER. + Detroit 8.2 & 8.2T engines and the Isuzu 4BD2T engine, 1 Year Parts & Labor. • Two Year Warranty on Cummins 4 & 6 cylinder B Series (3.9 & 5.9) and C Series (8.3) Running Complete engines and

One Year Warranty for Complete engines for non-automotive applications. Maximum 18 hours R & R. • Motor Homes: Maximum of 30 hours for Completes; Maximum of 25 hours for Running Completes. 6.86.13F27 9/8/08

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See Additional Warranty Information On Reverse Side.

TRANSMISSIONS/TRANSFER CASES: Cars and Trucks Allison Transmissions

Industrial/Non-Automotive

PERFORMANCE TRANSMISSIONS: Class I, Cars and Trucks Class II, Cars and Trucks The Monster Box

Time or Mileage, whichever occurs first.

3 Years or 100,000 Miles 1 Year 2 Years 6 Months

3 Years or 100,000 Miles 6 Months or 8,000 Miles 18 Months - unlimited mileage

t Ambulance, automotive off-highway use, package delivery, police, snow removal, taxi, tow truck, or any vehicle over 1 ton, 18 Months or 100,000 Miles, whichever occurs first. ZF transmissions over 1 ton, 2 years/unlimited mileage.

DIFFERENTIALS: Cars and Trucks Industrial/Non-Automotive

Time or Mileage, whichever occurs first.

3 Years or 100,000 Miles 6 Months

t Ambulance, automotive off-highway use, package delivery, police, snow removal, taxi, tow truck, or any vehicle over 1 ton, 18 Months or 100,000 Miles, whichever occurs first.

Lubricant must be used in applications for which it is provided for warranty to apply.

Parts + Labort Parts+ Labor Parts Parts

Parts + Labort Parts Parts + Labor

Parts + Labort Parts

All labor expense for field repairs, removal and reinstallation shall be determined from hours listed in the current ALL DATA/MOTORS time guide or pre-approved time at the factory approved rate.

Buyer specifically acknowledges that the components purchased will require additional accessories/components and must be properly installed or the warranty may be void. The limited warranty will be void and not apply to defects or failures caused by (1) overrevving (2) accident, abuse or an operation for which it was not designed, or alteration, either drive train or suspension, from the original manufacturer's specifications (3) damaged or inefficient parts, components or accessories not included in the sale (4) dirty or improper installation (5) overheating and/or freeze cracks to blocks, heads or drive cases (6) burned or melted pistons (7) lack of lubricants or fluids (8) extensive corrosion damage to stern drive (9) detonation or preignition (10) burned thrust bearings caused by rear pressure (11) rust, corrosion or damage caused by electrolysis.

Buyer specifically acknowledges that proper maintenance procedures which include, but are not limited to, changing or calibrating as applicable, the filter, lubricant, harmonic balancer, fan hub, water pump, fuel injectors, fuel pumps, hoses, belts, etc., must

e performed as recommended by the original manufacturer or the warranty will be void. Camshaft timing belts must be replaced in accordance with O.E.M. recommendations. JASPER will not assume any responsibility for the cost of this routine maintenance. Failure to change this belt may lead to internal engine damage that will not be covered by the JASPER Seller Limited Warranty. BELTS, HOSES AND OTHER ACCESSORY PARTS SUPPLIED BY JASPER AS PART OF THE ASSEMBLED PRODUCT, ARE COVERED FOR THE FIRST YEAR OF THE WARRANTY ONLY.

Proper installation procedures must be followed to avoid accident or injury. JASPER's limited warranty will end after the expiration of time or mileage from the date of the original invoice. Any repairs or replacement

will not extend the warranty. The buyer shall be responsible for all defects, thereafter, regardless of cause. JASPER's limited warranty is in lieu of all other warranties expressed or implied and JASPER MAKES NO WARRANTY OF

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The buyer must notify JASPER of any warranty claim prior to repair for assignment of an authorization number. The work will be

performed either at JASPER's factory or by another selected vendor. It is the sole responsibility of the buyer to pay for such work and, in writing, submit a claim with the alleged defective parts shipped prepaid to JASPER for its review and sole determination.

Buyer agrees that JASPER will not be responsible for (1) incidental or consequential damages (2) lost profits, sales or income (3) injury to person or property (4) oil, antifreeze, fluids or other substances (5) towing charges (6) lift, dock or storage fees (7) telephone calls (8) freight (9) substitute transportation, lodging, etc. (1 O) unauthorized repairs (11) labor on a gasket kit, oil pump and lifters purchased with a short block engine or gasket kit supplied with a complete engine.

Buyer and seller agree the seller's price is based upon this limited warranty. Buyer and seller also agree the buyer's sole and exclusive remedy against seller on account of breach of contract, warranty or performance shall be for the repair or replacement at JASPER's factory in Jasper, Indiana, of defects in JASPER'S factory workmanship or material within the periods of this warranty. The buyer will be responsible for shipment and subject to the limitations and conditions of this warranty.

No benefits or remedies are available under this limited warranty while the invoice for the unit or related services remains outstanding.

~SPEL~D i"MtNGINES &TRANSMISSIONS

815 Wernsing Road • P.O. Box 650 • Jasper, IN 47547-0650 Phone (812) 482-1041 •Toll Free 1-800-827-7455 • Fax (812) 634-1820

www.jasperengines.com Warranty Department: 1-800-827-7450

Specifications subject to change without notice.

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ALMAPRODUCTS COMPANY NATIONAL LIMITED WARRANTY

36 Mons,ooo MILES FOR INDUSTRIAL 2 & 3 SPEED C6 NON LOCKUP TRANSMISSIONS

Alma Products Company warrants that it will replace, repair, or refund at its sole option, any remanufactured transmission or part supplied by Alma Products Company, which is defective in material or workmanship, for 36 months or 75,000 miles whichever comes first on Industrial 2 & 3 Speed C6 Non· lockup transmissions. This warranty is limited to the first retail purchaser of the remanufactured transmission ("the Purchaser"). This warranty covers remanufactured transmissions installed in airport ground support vehicles, including lightweight trucks. This warranty is limited to defects in workmanship and material furnished by Alma Products Company and is not an unconditional guarantee against all hazards or failures (see Exclusions and Limitations to Limited Warranty).

If it is determined that a remanufactured transmission or part furnished by Alma Products Company is defective in workmanship or material. Alma Products Company will allow a labor allowance (some restrictions apply, see Warranty Labor Allowance). The labor allowance shall be credited to Purchaser only upon a determination that a remanufactured transmission or a part supplied by Alma Products Company is defective in material or workmanship. The limited warranty period begins on the original date of sale to the retail Purchaser. In the event a replacement-remanufactured transmission is provided to the Purchaser, the warranty period does not start over on the date the Purchaser is supplied with the replacement. The warranty period runs from the original date of sale to the Purchaser and is not extended by supply of a replacement.

There are no warranties that extend beyond the description herein. All other warranties express or implied, including but not limited to, all warranties of merchantability and fitness for a particular purpose are hereby disclaimed and excluded by Alma Products Company. Alma Products Company transfers only such title or rights as it has on the goods it selfs. No statement or undertaking whether a condition, warranty or otherwise, is given by Alma Products Company that the goods do not comprise or include patented, and registered or protected designs inventions or equipment or trademark or copyright material. The above limited warranty is void and will not apply in the event the Purchaser does not follow the vehicle manufacturer's instruction or in any way abuses the vehicle. The above warranty does not apply to goods supplied to vehicles used for racing or any type of vehicular competition.

In the event that any provision of this warranty should be or become invalid or unenforceable because of any laws or court action, the remaining terms and conditions hereof shall remain in full force and effect.

EXCLUSIONS AND LIMITATIONS TO LIMITED WARRANTY This Limited Warranty does not warrant against and does not cover damage or loss due to the following:

t. MISUSE, MAINTENANCE NEGLECT. ABUSE, VANDALISM, ABNORMAL OPERATION, COMMERCIAL SNOW REMOVAL OR ACCIDENTS.

2. DEFECTIVE OR IMPROPER INSTALLATION. 3. ENVIRONMENTAL CONDITIONS, OVERHEATING OR FREEZE CRACKS. 4. LACK OF LUBRICANTS OR FLUIDS. 5. IMPROPER COOLING SYSTEM FLUSHING. 6. FAILURES TO COMPONENTS OR PARTS NOT FURNISHED BY ALMA PRODUCTS

COMPANY OR OTHERWISE APPROVED BY ALMA PRODUCTS COMPANY FOR INSTALLATION, OR COMPONENTS OR PARTS UNSUITABLE FOR USE WITH A WAR.RANTED REMANUFACTURED TRANSMISSION OR PART.

7. ABNORMAL WEAR AND TEAR OR USE OF A REMANUFACTURED TRANSMISSION OR PART FROM WHICH IT WAS ORIGINALLY INTENDED OR A CHANGE FROM ORIGINAL APPLICATION.

&. INTERNAL MODIFICATION WITH AFrERMARKET PERFORMANCE PARTS

0671-002AA Revised. 2/26/09

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This Limited Warranty does not cover or provide credit for the following: Replacement fluids or other substances; towing charges, vehicle rental, or other substitute transportation; diagnostic time, Jabor (except as set forth herein) or service call; gaskets or other parts or items associated with but not included with this limited warranty; transportation charges or lodging; loss of time, income, sales or profits; toss of the use of vehicle; telephone calls or communication expense; lift, truck or storage fees; tune-ups or replacement of hoses or maintenance items; routine or regularly required maintenance; iajury or death to persons or damage or destruction of property; or, consequential, incidental or punitive damages.

CONDITIONS TO COVERAGE This Limited Warranty is subject to the conditions set forth below. Failure to comply with these conditions will void this Limited Warranty.

L The Purchaser must follow the claims procedure described when making a claim or this warranty will be void and of no force and effect.

2. A remanufactured transmission or part that is furnished as a replacement under this Limited Warranty for a rernanufactured transmission or part found to be defective is warranted only for the unexpired warranty period remaining on the original defective remanufactured transmission or part.

3. Warranty Registration Card must be completed and returned within 15 days of the receipt of the remanufactured transmission.

4. This warranty is limited to one replacement transmission during the warranty period.

This Limited Warranty is of no force or effect while any payments for remanufactured transmission or parts remain outstanding. Claims for transmission parts must be made at the initial delivery to the Purchaser of the remanufactured transmission.

WARRANTY UNIT LABOR ALLOWANCE A labor allowance may be issued upon request at Alma Products Company discretion. A labor allowance may only be issued in the first year of the applicable warranty period. In the second year of an applicable warranty period. Alma Products Company will supply the Purchaser with a replacement, remanufactured transmission. In order to receive a labor allowance, the Purchaser must have followed the claim procedure and spoke with the Technical Department. The Purchaser must receive a claim reference number for the transmission. Aima Products Company must have been contacted "prior" to the removal of the transmission that is allegedly defective. Upon receiving the allegedly defective transmission, Alma Products Company will thoroughly inspect, analyze and determine the reason for failure. Valid reasons for an allowance to be issued include remanufacturing error, part failure, and torque converter failure. Installer, vehicle, wrong application or other (no problem found) claims will not receive labor aUowance. In addition, Alma Products Company reserves the right to bill the purchaser for any installation damage, abuse and damage due to improper cooling system flushing. Labor allowance credits will be given pursuant to the following schedule:

AUTOMATIC TRANSMISSION LABOR ALLOWANCE The labor allowance credit shall be provided by Alma Products Company at $50 per hour pursuant to the Mitchell Warranty Book Time for the work to be conducted. Only labor charges paid to a professional installer will qualify as refundable, provided, however, no more than $350.00 shall be credited as a labor allowance hereunder.

No other labor allowance credit shall be provided by Alma Products Company other than as specified above.

0671~002AA Revised. 2126/09

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CORE CREDIT REQUIREMENTS A core charge is required. To receive full credit the core must be complete and useable or the following charges will be assessed.

• Torque converter is not returned -$50 • Case damaged or cracked -$150 • E-Brake • $200 • Yoke-$75 • Missing tail housing section • $75 • Dipstick and tube • $50 • Returnable Dunnage not returned -$100 • If core does not match the transmission and converter sold. NO CREDIT will be given

If you have questions, please call our ETX technical support line, 1-800-428-7726 Sales Department press 1, or Tech Department press 2,

Business hours M-Th 8:00am to 6:00pm Friday 8:00am to 5:30pm (Hours subject to change)

WARRANTY CLAIM PROCEDURE In the event your Alma Products Company transmission doesn ~t initially perform properly, the following procedure MUST be followed: This statement doesn't automatically assume there is a transmission problem, just a performance issue.

• Make certain you have completed and mailed or faxed us your Warranty Registration Card. • Next call our ETX Technical Hotline at 1·800-428-7726 (option 2) and ask to speak with one of

our technicians. He or she will walk you through several important checks. Most problems are easily handled during this process.

• If our technician is unable to resolve the problem, you may request that a Warranty Claim be initiated.

• Our technician will issue you a Returned Material Authorization (RMA) Number for tracking purposes. Issuing this RMA Number does not in any way imply liability.

• Any unit that is returned to Alma Products Company without an RMA number by a customer. intact and that is the same type of unit, may receive CORE CREDIT ONLY, unless the unit is broken and then they will receive NO CREDIT.

• At this time, you may order a replacement transmission with a P.O. issued to Alma Products (either email or fax). When the failed unit is returned and analyzed, the failure mode will be identified. If the unit failed due to remanufacturing workmanship, you will be credited for the cost of the original unit

• Drain ALL transmission fluid from the unit. and install the torque converter retaining brackets and other protective plugs and caps provided with your remanufactured transmission.

• Following our Core Return Procedure, carefully repackage the transmission as it was originally shipped to you. If it was shipped to you in a plastic POD, carefully place the transmission in the POD and tighten the internal straps to hold the transmission in place. If it was shipped to you on a wooden pallet, place the transmission in the plastic bag, place the bagged transmission on the pallet and secure the transmission to the pallet

• Call our technical hotline, and arrangements will be made to pick up your transmission.

Failure to follow this procedure may void your warranty.

0671-002AA Revised. 2/26/09

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ALMA PRODUCTS COMPANY HANDLING WARRANTY CLAIMS

Procedure: Whenever a warranty situation arises, it is essential that the customer contact our ETX Technical Service department at 1-800-428·7726. The Technical representative will analyze the problem and determine the next steps. The customer will need to provide us with the serial number of the transmission in question along with the mileage of the vehicle and the original date of sale so that we may access the transmission history (i.e. test -0ata/lnvoice & vehicle information). In many cases, our technical support personnel will be able to analyze the problem and recommend adjustments that will eliminate the need for a replacement transmission. If a warranty unit ls required, the technical department will issue an AMA number for the unit It is essential that an AMA number be obtained In order for any labor credit to be allowed or approved. The customer may place an order for a replacement unit at this time. In rare situations of repeated failure or inconsistent problem definition, the technical department may choose to issue what we call a "LIVE GREEN TAG" (Definition: Pick up customer's unit to rebuild, whether it be a defect or "new"). In these situations, Atma Products Company will request to pick up the defective transmission for analysis, This is done to protect all parties involved as we determine the failure and remedy the problem.

" i:..n returning a defective transmission to Alma Products Company, the AMA number, along .vith the serial number, must be provided on the packing slip for proper identification. In addition, the dP8£..Ctive transmission should be fully assembled and include the torque converter and in-line fa•. , • .. upplied) tor full credit to be issued. If a "defective" or "installed" transmission is returned , Alma P•oducts Company for a cancelled sale, lt will be at Alma Products Company' sole

di!':"'' · ;.;n to issue credit for the transmission and charge a $50.00 restocking fee.

Invoicing: Warranty transmissions wlll be invoiced at the standard price. Upon receiving and inspecting the defective transmission, a "warranty' credit will be issued for the value of the transmission therefr"" •ffsetting the charge. Credit will be issued provided the serial number returned is sti!I

.,,,,1ranty (time and I or miles} and it is a defect in remanufacturing.

Customer Repair Labor Credits: Alma Products Company offers technical support whenever necessary. It is our goal to educate our customers by walking them through the test procedures and processes used for on-sight repair, In cases where the cu.stomer is requesting labor reimbursement, Alma Products Company has Instituted a Purchase Order system to track the credits. We have also defined the repairs for which we will issue labor crecfrt and have setup a standard rate defining the amounts. In order to qualify for these credits, the customer must contact our technical support staff and obtained a P.O. number. When parts are found to be the reason for failure, the old parts must be tagged and returned to Alma Products Company for inspection in order for credit to be issued.

0671·002AA Revised. 2/26/09

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ALMA PRODUCTS COMPANY REMANUFACTURED TRANSMISSION

Installation Instructions

Read the Warranty Policy included with this remanufactured transmission. Failure to comply with installation instructions provided with this transmission and available from the vehicle manufacturer's installation instructions may cause improper installation or unit failure.

MAY VOID YOUR WARRANTY. I.) Before unpacking the remanufactured transmission, make certain it is the correct unit for the vehicle. Verify the

placement of the shift lever, bolt holes on the torque converter housing that mate to the engine, and location of the shift position sensor.

2.) Refer to an approved service manual or aftermarket workshop manual for correct removal and installation instructions.

3.) Install the remanufactured transmission directly from its shipping container. Never place the transmission on the ground on its oil pan. To do so may damage internal components.

4.) Remove all shipping caps before installing the transmission in the vehicle. Install the removed caps onto your core.

5.) Be sure both dowel pins are in place between the engine and transmission. Missing dowel pins will cause misalignment and rapid wear.

6.) Take care when installing the torque converter to the engine tlywheel. Do not allow any undue pressure or binding on the flywheel or the torque converter.

7.) Check the converter to flywheel clearance and shim to meet installation specifications. 8.) The case electrical connection requires the original seal must be in place. Confirm that the seal is included when

you connect the purchased transmission. 9.) You must fill the remanufactured transmission with factory approved Automatic Transmission Fluid using the

drain stand-pipe to determine the correct level. Refer to an approved workshop manual for proper filling instructions.

10.) The vehicle's transmission oil cooling system must be thoroughly flushed with the means of a flushing system. This is critical, as there may be residual debris from the failed transmission in the cooling system. If not properly tlushed, the transmission may faH immediately, suffer a slow failure, or exhibit reduced performance. Flush the system before installing the cooling lines to the transmission. Always check for any in line or canister type transmission filters that may have been installed and replace them before the new transmission is installed. If you return the unit under warranty, and this debris is present, your warranty will be void.

11.) After installation and correctly topping off the automatic transmission fluid level take these steps. Check the PRNDL alignment. Perform a test drive of the vehicle to assure correct performance. Run EEC (self test) codes. Correct all hard fault codes. Inspect for leakage and correct as required.

12.) Problems with installation? Please call our

ETX Help Line at 1-800-428-7726. Press 2 for Technical Department

Business hours M-Th 8:00am to 6:00pm Friday 8:00am to 5:30pm (Hours subject to change)

13.) See the National Limited Warranty for additional infonnation before repairing or removing an alleged defective transmission.

14.) Any transmissions returned at no fault of manufacturer must have all accessories and packaging included or a $50 charge will be accessed.

15.) Shipping charges may be issued for misdiagnosed returns to manufacturer.

In addition to the above guidelines you must follow the vehicle manufacturer's instructions for removing and installing your transmission. For Technical help please contact a representative from the point of purchase.

Nosotros hablamos Espanol 0671-015 2/20/09

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Core Return Instructions

Core value will vary, based on the condition of the core. Therefore, it is very important that your core be returned in the ;iackaging provided, with all the components attached that were included on the remanufactured transmission you purchased.

If the core being returned has one or more of the following conditions, deductions will be made from the invoiced core charge. o Torque converter is not returned - $50 o Case damaged or cracked - $150 o Returnable Dunnage not returned - $ I 00 o If core does not match the transmission and converter sold, no credit will be given.

Please include the following steps in preparing your core for return. Your adherence to them will help protect your core and avoid oil spills.

I. Use all plugs from purchased transmission 2. Place core in bag that protected purchased transmission 3. Secure core to pallet or use the pod if your transmission was shipped in a pod. 4. Attach Core Return Label to bag or pod with correct address and core type.

****URGENT**** TECHNICAL INSTALLATION

INFORMATION C-3, C-4, C-5, C-6

FORD REAR WHEEL DRIVE

WARNING: FAILURE TO FOLLOW THE PROCEDURES ON THESE SHEETS WILL CAUSE IMMEDIATE TRANSMISSION FAILURE AND VOID

WARRANTY ..

• COOLER AND COOLER LINES MUST BE THOROUGHLY FLUSHED, CHECKED FOR LEAKS, AND CHECKED FOR PROPER FLOW. COOLER FLOW VOLUME MUST BE A MINIMUM OF 1 QUART IN 20 SECONDS.

• An engine to body, or engine to frame ground strap must be installed, contact areas must be clean to aHow for a good ground connection. Clean all electrical terminals on transmission and vehicle before installation!

• Two (2) engine to transmission dowel pins must be used for correct alignment. Many units returned still have the dowel pins stuck into the bell housing. If the dowels are not replaced, the second unit will quickly damage the front bushing and cause front seal leaks. Note: if your original unit has a worn converter hub, the replacement will do the same!

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• Torque Converter to flywheel clearance is very critical, and must equal l/8 of an inch; measurement is made with the converter pushed fully'back into the transmission prior to bolting the converter to the flywheel. A. If the clearance is greater than l/8 of an inch, equal sized shims must be installed between the

converter mounting pads and the flywheel. until 1/8 of an inch clearance is achieved. B. If the clearance is less than 1 /8 of an inch, the converter is not installed onto the transmission

correctly. if the engine is started, damage WILL occur.

All Ford transmissions are very susceptible to governor hang-ups by metal returning from the cooler. AH coolers must be flushed. We strongly recommend replacement of your radiator. Or installing an aftermarket cooler and completely bypassing the factory system.

• M0DULATORVACUUMMUSTBEAMINIMUM0Fl4" ATANIDLE,ANDRAPIDLY DROP TO 0° AT THE WIDE OPEN THROTTLE. THIS TEST MUST BE MADE AT THE MODULATOR WITH A GAUGE!

Suecial instructions for diesel engines used with C.,6 transmissions: • All diesel engines use a vacuum pump and regulator to simulate a gas engine vacuum. The C-6

transmission relies on a vacuum for proper line pressure and shift timing. A vacuum gauge must be installed in the vacuum supply line at the modulator. A vacuum supply must be steady and drop rapidly at the wide-open throttle and then recover immediately after the throttle is released. Due to several different pumps and regulators we recommend using the vehicle specific manual for proper adjustment and testing. Incorrect vacuum supply may cause firm late shifts or soft early shifts and slippage. Failure to correct will cause transmission failure.

Due to numerous variations ... Linkage levers are the installer's responsibility! To ensure proper replacement, follow the steps and precautions illustrated below:

• Remove the oil pan and larger 3/8" head valve body bolts. Keep track of the various lengths. • Before removing the valve body, notice how the detent lever (l) is spring-loaded and the manual

valve (3) is aligned into the control lever. • Loosen the large retaining nut (2) on the manual lever and pull out the linkage arm. Notice the flats on

the linkage arm and whether the lever was up or down. Be sure to tighten the linkage arm nut. • Re~assemble. Note, the detent lever (1) and manual lever (3) must be properly located before the valve

body is tightened to 80 inch-lbs.

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Outer Manual Lever & Shatt

Oetenl Spring

Oetent Spring Attaching Screw

SEPEAATOR Pt.ATE

Bell housing installation for all C4, CS, with case mounted fill tube (Part No. C-4C, c .. sc)

• All units are delivered without the bell housing due to bell housing variations. • "Precautions" must be followed to prevent dropping the two selective washers and/or damaging the

seal rings. This has been a frequent occurrence, and wm happen to your transmission if the following steps are not taken!

• It is best to install the bell housing with the transmission standing vertical with the pump facing up. • Install a long bolt with the head cut off or an alignment pin into an open pump bolt hole. This will

prevent the gasket between the pump and the bell housing from moving. • While firmly holding the pump into the transmission case, remove the four pump retaining bolts

supplied. Do not allow the pump to lift or the internal parts may come out of alignment. • Align your bell housing and carefully slide it over the alignment pin. • Install the beH bolts hand tight. Then torque in a cross pattern to 28 ft-lbs.

In addition to the abov~ g~idelines you must follow the vehicle manufacturer's instructions for removing and instalUng your transnussmn. For Technical help please contact a representative from the point of purchase.

Nosotros hablamos Espanol 0671-015

2/20/09

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ro: ALMA PRODUCTS COMPANY (Warranty Department) 2000 MICHIGAN AVENUE ALMA, MICHIGAN 48801

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WARRANTY REGISTRATION CARD

NNER1S NAME: __________ _

· OWNER'S STREET ADDRESS:. ________________ _

OWNER'S CITY, STATE & ZIP: ________________ _

OWNER1S PHONE#: _________ _

DATE OF INSTALLATION: ________ _

MAKE: _______ MODEl: ______ YEAR:. _____ _

ENGINE: ________ MILEAGE ON VEHICLE:. _______ _

TRANSMISSION SERIAL#: _________ _

COMMENTS: ____________________ _

WARRANTY REGISTRATION CARD MUST BE FILLED OUT AND RETURNED WITHIN 15 DAYS OF INSTAL(ATION OR WARRANTY IS VOID. ,71-017 REVISED 11-05-08

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Four Seasons Racing Products http://www.fsrproducts.com/contact.htrnl

Contact Us

FSR Racing Products 1995 Thomas Road

Memphis, TN. 38134

1-877-385-1900 Phone 1-877-385-1901 Fax

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0) f /1~ ,i lf/lll I) fl

JlwJ / Z.Ll L/Q c-Plv1

- '3cJ ( 020 Lf o/ -

1131 SE Oraialm, Road Ankeny, IA 50021

Pllnm,: (800) 345·0327 {800) 654· 7725

Ernai!: lnlo@spalusa.cmn Web: www.spsiHsa.com

t1amess to enable the of our fans. It is ~rn~"~"~'" with a!I vehicles and can be installed on

When electric Mount the fan as up on the core core of U1e radiator where there is a metal

of the without """"'rn,

1-'1~•::1.::A call for fan shroud

in the

Yellow:

" Note: On rnediurn

the Thermostat Switch:

vehicles with no modifications.

to cover much surface area as ,.,u,,.,,cm:;_ Attach the fan to the smali area around the

1/4" to 3/8". This will allow

away from heat sources. Once this is

with blue connector, fuse holder and yellow crimp connectors

is in run position. (Hook to constant the ignition switch is off).

with the kit is an OE

terminal or fans use a 15 amp fuse

connect the wires

is suitable. The 195FH <:Pnr1,,nn unit comes on at 195 The modules will work on the

can be found at most automotive or tape on the sensor it can cause poor electrical contact and

on reverse page

connect Yellow a1r conclitiormig positive

(12 Volts activated ON"J

To Ground

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General Information: If the vehicle has there can be many causes. one is to determine what the overt1eat The chart below several cause and solutions to Please contact at with any additional

Problem overheats at idle and low

En ine overheats continuously

Fan Wiring

radiator

Poor ventilation

Insufficient radiator

timing too advanced Poor radiator I engine combinatio Defective or stuck thermostat

install electric fan or duct air into

Install SPAL fan and make sure

Have the core cleaned or with an appropriate size.

ch idle circuit.

iator. tat.

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p formjQA71

PB Global, Inc. PB Global Action Type: PO Box 217 Main Street

Farmingdale, NewYork 11735 Part Specification ~

PB Global Ground Support Equipment Parts Specification This form is used to document Sample, First Article, and Production part specifications.

Date:9/10/09 PB Global Part Number: GM64912

Part Specification

Part Number 20-104-1

Description Alternator, 12v, 72A, Neg, with Internal regulator

Terminals/ Application 1,2,3 or L,S,R SI Series, Delco type 116

Test Results

Maximum Alternator output Amps 73

Max Output Power Watts 936@12.SV Output

Voltage Set point Volts 14.5

Leakage Current mAmps 0.35

Ripple Current Amps 23

Alternator Turn on Speed RPM 975

Regulator Activiation Speed RPM 855

Secondary Regulation Volts 11.1

Tach Frequency HZ 293

Stator Voltage Volts 6.4

Output Amps

0 1000 2000 3000 4000 5000 5000

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Property of American AirlinesST. LOUIS MISSOURI · 2018-12-03 · 007 EC1033 EFI TPS switch 1 007...

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