A 2.2L that cranks on LPG but won't catch, or stumbles on gasoline with a code stored, is the job on your bench, and this 369-page Utilev Mazda 2.2L Bi-Fuel System Parts & Service Manual PDF (OEM ID 76001982) answers it, covering the industrial engine's fuel and engine control systems. Diagnostic trouble codes are laid out one by one, each tied to its application, a circuit schematic and code-specific checks, while separate LPG and gasoline symptom diagnostics cover intermittent, no start and hard start conditions. Engine wiring schematics trace both fuel versions, and the Diagnostic Scan Tool chapter walks you through DST testing. To clear faults without the scan tool, pull the ECM power fuse for at least 15 seconds; regulator mounting bolts go back at 17 N·m (12.5 ft. lbs.). Misread one code and you buy a regulator you never needed. Bookmarked and text-searchable, the PDF helps you pin down the failed component so you order the right part number the first time.
What's Inside This Utilev Mazda 2.2L Bi-Fuel System Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 5-9 | Introduction, Fuel Quality, Fuel Line Connections, Air Filtration Requirements, Fuel System Cautions |
| Maintenance | 10-16 | Engine Belts, Engine Electrical System Maintenance |
| LPG Fuel System | 17-25 | LPG Fuel Tank, Regulator, Throttle Control Device |
| LPG Fuel System Diagnosis | 26-33 | Fuel System Description, Diagnostic Aids, Pressure Gauges, LPG Fuel System Diagnostics |
| LPG Symptom Diagnostics | 34-48 | Intermittent, No Start, Hard Start |
| Gasoline Fuel System | 49-54 | Gasoline Multiport Fuel Injection System |
| Gasoline System Diagnosis | 55-61 | Fuel System Description, Diagnostic Aids |
| Gasoline Symptom Diagnostics | 62-75 | Poor Fuel Economy, Incorrect Idle, Stalling, Surges/Chuggles |
| Diagnostic Scan Tool | 76-111 | Using the DST for Testing and Trouble Shooting |
| Engine Wiring Schematics | 112-114 | Engine Wiring Schematics for Both LPG and Gasoline |
| Engine Wire Harness Repair | 115-118 | Repairing a Wire Harnesses on a Vehicle |
| Diagnostic Trouble Codes (DTCs) | 119-119 | Application, Schematic and DTC Specific Code Information |
| DTC 16-Never Crank Synced at Start | 120-170 | DTC 107-Map Low Voltage, DTC 121-Tps 1 Lower Than TPS 2, DTC 134-Ego 1 Pre Cat Open/Lazy |
| DTC 261-Injector Driver 1 Open | 171-218 | DTC 262-Injector 1 Coil Shorted, DTC 283-Injector 8 Coil Shorted |
| DTC 336-Crank Sync Noise | 219-237 | DTC 342-Camshaft Sensor Loss, DTC 522-Oil Pressure Sender Low Voltage, DTC 562-System Voltage Low |
| DTC 601-Flash Checksum Invalid | 238-255 | DTC 604-Ram Failure, DTC 642-External 5 Volt Reference Low, DTC 685-Relay Coil Open |
| DTC 1111-Fuel Rev Limit | 256-276 | DTC 1112-Spark Rev Limit, DTC 1151-Closed Loop High LPG, DTC 1162-Adaptive Learn Low LPG |
| DTC 1612-Rti 1 Loss | 277-303 | DTC 1626-CAN Tx Failure, DTC 1635-PWM9 Open/Ground Short |
| DTC 2111-Unable to Reach Lower TPS | 304-346 | DTC 2121-Fpp 1 Lower Than FPP 2, DTC 2229-Bp High Pressure, DTC 3001 Secondary FP High Voltage, DTC 3005-Gaseous FT Voltage High |
| Servicing the Fuel System | 347-364 | Engine Control Module, Throttle Body, Regulator, Fuel Filter Element (High Pressure), Lock-Off Solenoid and Cartridge, LPG Fuel Pressure Relief |
| Definitions | 365-369 | Definitions of Phrases and Acronyms Used Throughout This Service Manual |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Method to clear DTCs | Select the “Clear All Faults” function on the Diagnostic Scan Tool (DST) or turn the ignition key to the OFF position and remove the ECM power fuse or battery cable for at least 15 seconds | p. 110 |
| ECM mounting bracket screw torque | 7.5 N·m (5.5 ft. lbs.) | p. 348 |
| Regulator mounting bolt torque | 12.5 ft.lbs. (17 Nm) | p. 352 |
| Fuel outlet fitting screw torque | 2 to 3 N·m (17.7 to 26.55 in. lb.) | p. 353 |
| Fuel inlet fitting torque | 18 to 20 N·m (13.3 to 14.75 ft.lbs.) | p. 354 |
| Fuel temperature and pressure sensor torque | 10 Nm +/- 1.0 Nm (7-9 ft.lbs.) | p. 349 |
| Maximum recommended air filtration restriction | 4” W.C. @ 75 cfm | p. 7 |
| LPG tank pressure relief valve setting | 25.8 bar (375 psi) | p. 19 |
| Regulator outlet fuel pressure | 88 kPa (12.6 psi) | p. 20 |
| Gasoline fuel pressure (Ignition ON) | 296-310 kPa (43-45 psi) | p. 56 |
| ECM Mounting Bracket torque | 7.5 N·m (5.5 ft. lbs.) | p. 348 |
| Throttle Body mounting screws torque | 12 N·m (106 in. lbs.) | p. 348 |
Utilev Mazda 2.2L Bi-Fuel System Common Problems This Manual Covers
Utilev Mazda 2.2L LPG engine cranks but will not start, no liquid fuel reaching the regulator
Check that the LPG tank is at least ¼ full, the manual shut-off valve is fully open, and the excess flow valve has not tripped, following page 29. Confirm the tank is mounted and rotated to the correct position, the quick disconnect is fully engaged, supply hoses have no kinks, and the LPG fuel filter is clean. Keep all flame and lighted tobacco away from fuel components (page 7).
Manual Section: LPG Fuel System Diagnosis p. 29LPG regulator primary fuel pressure low, high or missing at the test port while cranking
Connect a calibrated 0-5 PSI gauge to the Regulator primary test port, open the manual shut-off valve, key ON and crank. You want 2.0 to 4.0 PSI (page 30). If it reads low or high, repair or replace the Shut Off Valve. If there is no pressure, apply 12V to the lock-off terminals. Above 1.0 PSI means replace the ECM; otherwise replace the Shut Off Valve. Relieve LPG pressure before servicing fuel components (page 358).
Manual Section: LPG Fuel System Diagnosis p. 30Engine cranks with correct regulator primary pressure but still will not start on LPG
Test ignition secondary voltage output with J 26792 or equivalent, because LPG needs higher secondary voltage than gasoline (page 30). Pull the spark plugs and check for the correct LPG plug type, oil-fouled wet electrodes, cracks, wear, improper gap, burned electrodes and heavy deposits. If ignition checks clean, run a cylinder leak-down test. Every cylinder must show under 10% leakage, or the engine needs repair.
Manual Section: LPG Fuel System Diagnosis p. 30DST shows LPG Adaptive 1 fuel correction below minus 15 percent, engine running rich
Check the ignition system first by repeating the spark plug and secondary voltage checks from page 30. Inspect the air cleaner and all intake ducting for airflow obstructions. Maximum air filtration restriction is 4 in. W.C. at 75 cfm (page 7). Check the exhaust for flow obstructions and verify HEGO switching. Then rerun the Adaptive 1 test, which must hold within -15% to +15% (page 33).
Manual Section: LPG Fuel System Diagnosis p. 33DST shows LPG Adaptive 1 fuel correction above plus 15 percent, engine running lean
Inspect the intake manifold, every throttle body gasket and o-ring, and all vacuum hoses and fittings for leaks, following page 33. Check the exhaust system for leaks as well. An exhaust leak lets excess O2 dilute the HEGO sensor, so the engine can look rich while Adaptive 1 shows a large positive correction. Verify HEGO switching, then retest for -15% to +15%.
Manual Section: LPG Fuel System Diagnosis p. 33Intermittent engine fault that may not light the MIL or store a DTC
Check the suspect circuit for faulty fuses, poorly mated connectors, backed-out terminals and weak terminal tension. Skip the DTC tables here, because page 36 warns they can lead you to replace good parts. Run the engine with the DST connected and wiggle test the harness while watching the Faults Screen (page 32). Do not bend or spread terminals (page 111), and do not probe Weather-Pack seals with oversized probes (page 116).
Manual Section: LPG Symptom Diagnostics p. 36Frequently Asked Questions
How do I retrieve or clear fault codes on the Utilev Mazda 2.2L bi-fuel system?
Diagnostic Trouble Codes (DTCs) can be read using a laptop computer with the Diagnostic Scan Tool (DST) software. To clear codes, use the DST to select the 'Clear All Faults' function, or turn the ignition key to the OFF position and remove the ECM power fuse or battery cable for at least 15 seconds. p. 110
What causes a Utilev Mazda 2.2L bi-fuel engine to crank but not start?
A 'No Start' condition can be caused by a closed LPG manual fuel shut-off valve, air intake system leakage around the throttle body, or issues with the fuel control solenoids. Additionally, check for proper communication with the ECM, system fuses, and ensure the cam angle sensor is providing an RPM signal. p. 37
How does the DST Clear All Faults function work on the Spectrum fuel system?
You can clear active codes using the Diagnostic Scan Tool (DST) by selecting the 'Clear All Faults' function. Alternatively, you can clear codes by turning the ignition key to the OFF position and removing the ECM power fuse or battery cable for at least 15 seconds. p. 110
What is the correct torque specification for the ECM mounting bracket screws on the Utilev Mazda 2.2L Bi-Fuel System?
When mounting the ECM controller into its bracket, the four screws should be torqued to 7.5 N•m (5.5 ft. lbs.). p. 348
What is the required engine oil and oil filter change interval for the Utilev Mazda 2.2L Bi-Fuel System?
The engine oil and oil filter should be changed every 250 hours or 6 months of operation, whichever occurs first. p. 16
How is this Utilev Mazda 2.2L Bi-Fuel System Parts & Service Manual delivered?
Immediate download of the complete 369-page searchable Service Manual. Access it on any device, from a laptop at your desk to a phone in the field.
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