An LPG 2.2L that cranks but won't catch, or throws a code halfway through a shift, rarely explains itself; the 299-page Utilev Mazda 2.2L LPG Fuel System Parts and Service Manual PDF (OEM ID 76001979, 2012) covers that LPG fuel system from regulator to ECM. Engine wiring schematics for both LPG and gasoline versions show the harness routing, and the diagnostic scan tool chapter walks you through live testing before anything comes apart. DTC coverage runs from crank and cam sensor codes such as DTC 16 through throttle position, injector driver, oil pressure and adaptive learn faults up to DTC 2126, and the fuel system chapter ends with ECM and Electronic Pressure Regulator replacement. Confirm primary fuel pressure at 2.0 to 4.0 psi, then torque the EPR to its bracket at 14 to 18 ft. lbs. A regulator swap stalls when nobody knows the inlet line torque. Bookmarked and text-searchable, your copy travels wherever the truck sits.
What's Inside This Utilev Mazda 2.2L LPG Fuel System Parts Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 5-8 | Servicing Your Emissions Certified Engine, Fuel System Cautions |
| Maintenance | 9-17 | Engine Belts, Engine Electrical System Maintenance |
| LPG Fuel System | 18-26 | Description and Operation of the Fuel Systems |
| LPG Fuel System Diagnosis | 27-34 | Fuel System Description |
| LPG Symptom Diagnostics | 35-49 | Intermittent, No Start, Hard Start |
| Electrical Section | 50-89 | Diagnostic Scan Tool (Using the DST for Testing and Trouble Shooting), Engine Wiring Schematics (Both LPG and Gasoline) |
| Engine and Camshaft Sensor Diagnostics | 90-106 | DTC 16-Never Crank Synced at Start, DTC 107-Map Low Voltage, DTC 108-Map High Pressure, DTC 112-Iat Low Voltage, DTC 113-Iat Voltage High, DTC 117-Ect Low Voltage, DTC 118-Ect Voltage High |
| Throttle Position Sensor Diagnostics | 107-141 | DTC 121-Tps 1 Lower Than TPS 2, DTC 122-Tps 1 Signal Voltage Low, DTC 123-Tps 1 Signal Voltage High, DTC 129-Bp Low Pressure, DTC 134-Ego 1 Pre Cat Open/Lazy, DTC 154-Ego Open/Lazy Post Cat 1, DTC 187-Ft Voltage Low, DTC 188-Ft Voltage High |
| Fuel Injector and Driver Diagnostics | 142-165 | DTC 261-Injector Driver 1 Open, DTC 262-Injector 1 Coil Shorted, DTC 264-Injector Driver 2 Open, DTC 265-Injector 2 Coil Shorted, DTC 267-Injector Driver 3 Open, DTC 268-Injector 3 Coil Shorted, DTC 270-Injector Driver 4 Open, DTC 271-Injector 4 Coil Shorted |
| Crankshaft and Camshaft Synchronization Diagnostics | 166-175 | DTC 336-Crank Sync Noise, DTC 337-Crank Loss, DTC 341-Cam Sync Noise, DTC 342-Camshaft Sensor Loss |
| Oil Pressure and System Voltage Diagnostics | 176-194 | DTC 522-Oil Pressure Sender Low Voltage, DTC 523-Oil Pressure Sender High Voltage, DTC 562-System Voltage Low, DTC 563-System Voltage High, DTC 642-External 5 Volt Reference Low, DTC 643-External 5 Volt Reference High |
| Microprocessor and Communication Diagnostics | 195-250 | DTC 650 MIL (Malfunction Indicator Lamp) Open, DTC 685-Relay Coil Open, DTC 686-Relay Control Ground Short, DTC 687-Relay Coil Short to Power, DTC 1111-Fuel Rev Limit, DTC 1112-Spark Rev Limit, DTC 1612-Rti 1 Loss, DTC 1613-Rti 2 Loss |
| Auxiliary, Fuel Control, and Adaptive Learn Diagnostics | 251-279 | DTC 1637-Aux PWM4 Open/Ground Short, DTC 1638-Aux PWM4 Short to Power, DTC 2111-Unable to Reach Lower TPS, DTC 2112-Unable to Reach Higher TPS, DTC 2121-Fpp 1 Lower Than FPP 2, DTC 2122-Fpp 1 High Voltage, DTC 2123-Fpp 1 Low Voltage, DTC 2126-Fpp 1 Higher Than FPP 2 |
| Servicing the Fuel System | 280-294 | Engine Control Module, Electronic Pressure Regulator (EPR) |
| Definitions | 295-299 | Definitions of Phrases and Acronyms Used Throughout This Service Manual |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| EPR primary diaphragm pressure | 10.34 kpa (3.5 psi) | p. 21 |
| Primary fuel pressure | 2.0 – 4.0 PSI | p. 31 |
| Spark plug wire resistance | 30,000 ohms | p. 47 |
| EPR to Mounting Bracket torque | 19.0-24.4 N·m (14-18 ft. lbs.) | p. 284 |
| Mixer to Adapter torque | 9 N·m (80 in. lb.) | p. 284 |
| Adapter to Throttle Body torque | 12 N·m (106 in. lbs.) | p. 289 |
| Adapter Cover torque | 6.5 N·m (4.8 ft. lbs.) | p. 288 |
| V-belt tension depression limit | 13mm (1/2 inch) | p. 10 |
| LPG fuel tank safety valve setting | 25.8 bar (375 psi) | p. 20 |
| EPR secondary stage pressure | negative 38.1 mm (1.5 inches of water column) | p. 28 |
| ECM mounting bracket screw torque | 7.5 N·m (5.5 ft. lbs.) | p. 292 |
| Mixer to Adapter screw torque | 9 N·m (80 in. lb.) | p. 284 |
Utilev Mazda 2.2L LPG Fuel System Common Problems This Manual Covers
Utilev 2.2L Mazda LPG engine cranks but will not start, primary fuel pressure low at the EPR
Verify the tank is at least 1/4 full, the manual shut-off valve is open, the high-flow valve has not tripped, the quick disconnect is fully engaged, and the LPG fuel filter is clean, per page 30. Then connect a 0-5 PSI gauge to the EPR primary test port, key ON, crank, and look for 2.0 to 4.0 PSI (page 31). Keep open flames and lighted tobacco away from all fuel components (page 7).
Manual Section: LPG Fuel System Diagnosis p. 30No primary fuel pressure at EPR test port while cranking with the tank valve open
Verify the manual shut-off valve is ON, then disconnect the lock-off valve electrical connector and apply 12V to its terminals while watching the primary gauge (page 32). Above 1.0 PSI, the lock-off is opening and the chart calls for replacing the ECM. No pressure means replace the lock-off valve (page 33). Relieve LPG fuel system pressure before removing fuel components (page 283).
Manual Section: LPG Fuel System Diagnosis p. 32EPR secondary pressure on the gauge does not match the DST Faults Screen reading
Fit the secondary pressure test adapter in the LPG temp sensor port, run to operating temperature, and compare a 0-10 inch WC gauge to the DST Faults Screen. Allow +/-0.75 inch WC (page 32). Outside that, unplug the EPR connector at idle: -1.0 to -2.0 inch WC means repair or replace the EPR; any other reading means replace the mixer. Relieve LPG pressure before EPR service (page 283).
Manual Section: LPG Fuel System Diagnosis p. 32Mixer air valve shows no movement while cranking with the air induction hose removed
Check air valve movement: close the manual shut-off valve, run the engine until it dies, key OFF, remove the air induction hose, and watch the air valve while cranking (page 32). Movement is minimal at cranking speed, but none means replace the mixer assembly. Never disassemble the mixer (page 33). Relieve LPG pressure first (page 283) and torque mixer to adapter screws to 9 N·m (80 in. lb.) per page 284.
Manual Section: LPG Fuel System Diagnosis p. 32Heavy-end deposits built up inside the low-pressure LPG fuel supply hose at the EPR
Remove the LPG temperature sensor from the EPR after closing the manual valve and running the engine until it dies, but do not disconnect its electrical connector (page 31). If the hose shows deposits, inspect, clean or repair the EPR and check the mixer diaphragm through the air inlet without disassembling the mixer (page 33). Relieve LPG system pressure before servicing fuel components (page 283).
Manual Section: LPG Fuel System Diagnosis p. 31Adaptive 1 fuel correction reads above +15% at idle or under hydraulic load
Check the intake manifold, every throttle body and mixer gasket or o-ring, and all vacuum hoses and fittings for leaks, since page 34 reads this as a lean condition. Inspect the exhaust for leaks too; they dilute the HEGO and can mask the real problem. Verify HEGO 1 switching, then rerun the load test and confirm -15% to +15% (page 33).
Manual Section: LPG Fuel System Diagnosis p. 34Frequently Asked Questions
How do I reset the diagnostic trouble codes on the UTILEV Mazda 2.2L LPG Fuel System?
Diagnostic trouble codes can be cleared from memory using a laptop computer with the Diagnostic Scan Tool (DST) or by turning the ignition key to the OFF position and removing the ECM power fuse or battery cable for at least 15 seconds. p. 81
What is the replacement interval for the LPG fuel filter element?
The in-line replaceable fuel filter element should be replaced annually, or bi-annually if the equipment is operated in dusty environments. p. 17
What is the correct belt tension for the V-belt system on the Utilev Mazda 2.2L LPG Fuel System?
Check the belt tension by pressing down on the midway point of the longest stretch between two pulleys. The belt should not depress beyond 13mm (1/2 inch). p. 10
What is the torque spec for the EPR mounting bracket nuts on the Utilev Mazda 2.2L LPG Fuel System?
When mounting the Electronic Pressure Regulator (EPR) to the EPR mounting bracket, the nuts should be torqued to 19.0-24.4 N•m (14-18 ft. lbs.). p. 284
How tight should the mixer-to-adapter screws be on the Utilev Mazda 2.2L LPG Fuel System?
When installing the mixer to the adapter, the four retaining screws should be torqued to 9 N•m (80 in. lb.). p. 284
What format is this Utilev Mazda 2.2L LPG Fuel System manual in?
This is a 299-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Can I print just the pages I need from this Utilev Mazda 2.2L LPG Fuel System manual?
Yes. Print the pages or sections you need for your own shop use. Any standard printer works.
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