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Engine 4JA1 - 4JH1-TC PDF
Engine 4JA1 - 4JH1-TC PDF
TF SERIES
ENGINE
4JA1/4JH1-TC
SECTION 6
TROUBLESHOOTING 6 – 1
SECTION 6
TROUBLESHOOTING
TABLE OF CONTENTS
PAGE PAGE
BASIC INSPECTION PROCEDURE ... 6– 2 11. ROTATING PART WEAR OF
TURBOCHARGER ............................. 6– 14
1. HARD STARTING ........................... 6– 3
12. OIL LEAKAGE FROM
1-1.Starter Motor Inoperative ......... 6– 3
TURBOCHRGER ............................... 6– 15
1-2. Starter Motor Operates But
13. INSUFFICIENT ACCELERATION
Engine Does Not Turn Over .......... 6– 3
AND/OR LACK OF POWER DUE
1-3. Engine Turns Over But Does TO TURBOCHARGER ....................... 6– 15
Not Start Engine ............................. 6– 4
14. BATTERY CHARGING AND
2. UNSTABLE IDLING ........................ 6– 5 NOISE PROBLEM.............................. 6– 16
3. INSUFFICIENT POWER ................. 6– 6 14-1. Battery No Charging .............. 6– 16
4. EXCESSIVE FUEL 14-2. Battery Overcharging ............ 6– 16
CONSUMPTION................................. 6– 7
14-3. Battery Under Charging......... 6– 17
5. EXCESSIVE OIL CONSUMPTION.. 6– 8
14-4. Battery Unstable Charging
6. OVERHEATING............................... 6– 9 Current ............................................ 6– 17
7. WHITE EXHAUST SMOKE ............. 6– 9 14-5. Charging System Noise......... 6– 18
8. DARK EXHAUST SMOKE .............. 6– 10 15. STARTER MOTOR PROBLEM..... 6– 19
9. OIL PRESSURE DOES NOT RISE . 6– 11 15-1. Starter Motor Pinion Engages
10. ABNORMAL ENGINE NOISE ....... 6– 12 to Ring Gear But Engine Does
Not Turn Over ................................. 6– 19
10-1. Engine Knocking.................... 6– 12
15-2. Incorrect Pinion And Ring
10-2. Gas Leakage Noise ................ 6– 12 Gear Engagement .......................... 6– 19
10-3. Continuous Noise .................. 6– 13 15-3. Starter Motor Continues To
10-4. Slapping Noise ....................... 6– 13 Run After The Starter Switch Is
Turned Off....................................... 6– 20
10-5. Excessive Turbocharger
Noise ............................................... 6– 14 15-4. Excessive Commutator
Sparking.......................................... 6– 20
6 – 2 TROUBLESHOOTING
1. Hard Starting
Inspect the following items before diagnosis.
1. The battery conditions.
The terminal connection condition.
The battery charge condition or battery power weakness.
2. The fan belt loosen or broken.
3. The main fuse condition (open or not).
4. Fuel quantity level.
1–1 Starter motor inoperative
Step Action Value(s) Yes No
1 Check the starter switch. — Repair or
Does the starter switch work? replace the
Go to Step 2 starter switch
2 Check the starter relay. — Repair or
Does the starter relay work? replace the
Go to Step 3 starter relay
3 Check the magnetic switch. — Repair or
Does the magnetic switch work? replace the
magnetic
Go to Step 4 switch
4 Check the pinion gear condition on the starter motor. — Replace the
Was the condition normal? Go to Step 5 pinion gear
5 Check the brush wear or brush spring weakness. — Repair or
Was the condition normal? Replace the replace the
starter motor brush or brush
assembly spring
1-2 Starter motor operates but engine does not turn over
Step Action Value(s) Yes No
1 Check the engine internal seizure. — Check other
Was the engine seized? Repair or DTC by Tech
replace seized 2 and go to
parts indicated DTC
6 – 4 TROUBLESHOOTING
2. Unstable Idling
Step Action Value(s) Yes No
1 Was the fuel line air bled completely? — Go to Step 3 Bleed the air
2 Was the fuel line leakage or blockage found? — Repair or
replace relation
parts. Go to Step 4
3 Was the water contained in the fuel? — Replace the
fuel Go to Step 5
4 Was the fuel filter element clogged? — Replace the
fuel filter
element Go to Step 6
5 Was the injection starting pressure or the injection (See below)
spray condition OK? Replace the
Go to Step 7 injection nozzle
6 Was the injection nozzle sticking? See Step 6 Replace the
injection nozzle Go to Step 8
7 Check the throttle valve condition. — Repair or
Was the idling port clogged in the throttle valve? replace the
throttle valve Go to Step 9
8 Was the valve clearance improper adjusted? 0.4 mm
(0.016 in)
both intake
and exhaust Adjust the
valves valve clearance Go to Step 10
9 Was the compression pressure OK? 3,040 kPa Readjust the
2
(31 kg/cm , valve clearance
441 psi) at or replace the
200rpm cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
Go to Step 11 and valve seat
10 Are any DTC stored? — Go to indicated
DTC Solved
3. Insufficient Power
Step Action Value(s) Yes No
1 Was the air cleaner element condition OK? (Clogged — Clean or
or not) replace the air
cleaner
Go to Step 2 element.
2 Was the intake air leakage found from intake — Repair or
system? replace the
intake air
system. Go to Step 3
3 Was the fuel filter element condition OK? (Clogged — Clean or
or not) replace the fuel
Go to Step 4 filter element.
4 Check the fuel injection pipes. — Repair or
Does the injection pipes have obstruction or any replace the fuel
damage? injection pipes. Go to Step 5
5 Was the water contained in the fuel? — Replace the
fuel Go to Step 6
6 Was the injection nozzle pressure or spray pattern — Readjust the
normal? injection nozzle
pressure or
replace the
Go to Step 7 nozzle.
7 Was the compression pressure OK? 3.0 MPa Readjust the
2
(31.0 kg/cm , valve clearance
441 psi) at or replace the
200 rpm cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
Go to Step 8 and valve seat
8 Was the exhaust pipe clogged? — Repair or
replace the
exhaust pipe. Go to Step 9
9 Was the exhaust gas leakage found from exhaust — Repair or
system? replace the
exhaust
system. Go to Step 10
10 Was the waste gate control actuator hose broken or — Replace the
cracked? hose. Go to Step 11
11 Was the waste gate working completely? — Replace the
turbocharger
Go to Step 12 assembly.
12 Was turbocharger working completely? — Replace the
turbocharger
Go to Step 13 assembly.
13 Are any DTC stored? — Go to indicated
DTC Solved
TROUBLESHOOTING 6 – 7
Replace the
Go to Step 7 injection nozzle
7 Are any DTC stored? — Go to indicated
DTC Solved
6 – 8 TROUBLESHOOTING
6. Overheating
Step Action Value(s) Yes No
1 Was the engine coolant level OK? — Replenish the
Go to Step 2 coolant
2 Was the water leakage or the radiator restriction — Repair or
found? (Include radiator cap) replace the
leakage part. Go to Step 3
3 Was the fan belt slippage found? — Tension or
replace the fan
belt. Go to Step 4
4 Was the fan clutch working completely? — Replace the
fan clutch
Go to Step 5 assembly.
5 Was the oil leakage found from fan clutch? — Replace the
fan clutch
assembly Go to Step 6
6 Was the thermostat working normally? — Replace the
Go to Step 7 thermostat.
7 Was the water pump working OK? — Replace the
water pump
Go to Step 8 assembly.
8 Was the restriction by the foreign materials in the — Clean or
cooling system found? For example, clog the water replace the
hose between the cylinder body and radiator etc.. clog part. Go to Step 9
9 Was the water leakage found from the sealing cap — Replace the
on the cylinder body? sealing cap or
replace the
cylinder body. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC. Solved
Replace the
Go to Step 4 injection nozzle
4 Was the oil leakage found from the turbocharger oil — Replace the oil
seal? seal Go to Step 5
5 Was the oil drain pipe of the turbocharger restricted? — Repair or
replace the oil
drain pipe Go to Step 6
6 Was restricted the oil drain passage in the — Clean the
turbocharger center housing restricted? center housing Go to Step 7
7 Does turbine wheel has any impact damage? — Replace the
turbocharger Go to Step 8
8 Does PCV (Positive Crankcase Ventilation) Valve — Repair or
has problem? replace the
relation parts Go to Step 9
9 Are any DTC stored? — Go to indicated
DTC Solved
TROUBLESHOOTING 6 – 11
Replace the
Go to Step 2 injection nozzle
2 Was the compression pressure OK? 3.0 MPa Replace the
2
(31.0 kg/cm , cylinder head
441 psi) at gasket or
200 rpm Go to Step 3 piston ring
3 Are any DTC stored? — Go to indicated
DTC Solved
15-3 Starter motor continues to run after the starter switch is turned off
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed. — Go to
visual/physical
Go to Step 2 check
2 Inspect the magnetic switch contact point. — Repair or
Was the contact point seized? replace the
magnetic
switch. Go to Step 3
3 Inspect the starter switch. — Replace the
Was the starter switch defective? starter switch. Go to Step 4
4 Are any DTC stored? — Go to indicated
DTC. Solved
SECTION 6A
ENGINE MECHANICAL
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6A - 4
Torque Specifications ................................................................................................... 6A - 8
Standard Bolts ........................................................................................................... 6A - 8
Special Parts Fixing Nuts and Bolts ........................................................................ 6A - 9
Recommended Liquid Gasket ...................................................................................... 6A - 22
LOCTITE Application Procedure .................................................................................. 6A - 23
Servicing......................................................................................................................... 6A - 24
Model Identification ................................................................................................... 6A - 24
Air Cleaner .................................................................................................................. 6A - 24
Lubricating System .................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25
Cooling System .......................................................................................................... 6A - 27
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement...................................................................... 6A - 32
General Description....................................................................................................... 6A- 36
Removal and Installation............................................................................................... 6A- 37
Removal ...................................................................................................................... 6A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment.......................................................................................... 6A- 41
Engine Warm-Up..................................................................................................... 6A- 41
Engine Repair Kit........................................................................................................... 6A- 42
Engine Overhaul ............................................................................................................ 6A- 43
Removal ...................................................................................................................... 6A- 43
External Parts ......................................................................................................... 6A- 43
6A – 2 ENGINE MECHANICAL
Engine model
4JA1T (L) 4JA1TC
Item
Oil pump type Gear
Oil filter type Cartridge paper element
Oil capacity lit (US/UK gal) 6.2 (1.64/1.36)
Oil cooler type Water cooled
Cooling system
Water pump type Centrifugal
Thermostat type Wax pellet with jiggle valve
Air cleaner type Dry paper element Viscous paper element
Battery type/voltage ´ No. of units 80D26L ´ 1
95D31L ´ 1 (OPT)
Generator capacity V-A 12 – 60
12 – 80
Starter motor output V-Kw 12 – 2.3
Turbocharger model *IHI RHF 4H
Turbine type Mixed flow type
Compressor type Backward & rake
Engine model
4JH1TC
Item
Cooling system
Water pump type Centrifugal
Thermostat type Wax pellet with jiggle valve
Air cleaner type Dry paper element (except for Euro3 spec)
Viscous paper element (for Euro3 spec)
80D26L ´ 1
Battery type/voltage ´ No. of units
95D31L ´ 1 (OPT)
75D26R ´ 2 (OPT for EC, MT)
80D26R ´ 2 (OPT for EC, AT)
12 – 60/12 – 80
Generator capacity V-A
12 – 2.3
Starter motor output V-Kw
*IHI RHF5
Turbocharger model
Mixed flow type Radial-inflow
Turbine type
Backward & rake type Radial-outflow
Compressor type
*IHI: Ishikawajima-Harima Heavy Industries., Ltd.
6A – 8 ENGINE MECHANICAL
TORQUE SPECIFICATION
STANDARD BOLTS
The torque values given in the following table should be applied whenever a particular torque is not specified.
N·m (kg·m/lb·ft)
Strength 8.8
Class 4.8 (4T) (7T) 9.8 (9T)
Refined Non-Refined
Bolt
Identification
Bolt
Diameter ´
Pitch (mm)
M 6 ´ 1.0 5.88 ± 1.96 7.35 ± 2.45 -
(0.60 ± 0.20/4.33 ± 1.44) (0.75 ± 0.25/5.43 ± 1.80)
M 8 ´ 1.25 12.74 ± 4.90 17.15 ± 5.39 23.52 ± 6.86
(1.30 ± 0.50/9.40 ± 3.62) (1.75 ± 0.55/12.66 ± 4.00) (2.40 ± 0.70/17.36 ± 5.06)
M 10 ´ 1.25 27.44 ± 6.86 36.75 ± 9.31 49.98 ± 12.74
(2.80 ± 0.70/20.25 ± 5.06) (3.75 ± 0.95/27.12 ± 6.87) (5.10 ± 1.30/36.89 ± 9.40)
M 12 ´ 1.25 61.25 ± 12.25 75.95 ± 15.19 94.57 ± 19.11
(6.25 ± 1.25/45.21 ± 9.04) (7.75 ± 1.55/56.06 ± 11.21) (9.65 ± 1.95/69.80 ± 14.10)
M 14 ´ 1.5 95.55 ± 19.11 116.13 ± 23.03 142.10 ± 28.42
(9.75 ±1.95/70.52 ± 14.10) (11.85 ± 2.35/85.71 ± 17.00) (14.50 ± 2.90/104.88 ± 21.00)
M 16 ´ 1.5 130.34 ± 26.46 169.54 ± 34.30 199.92 ± 40.18
(13.30 ± 2.70/96.20 ± 19.53) (17.30 ± 3.50/125.13 ± 25.32) (20.40 ± 4.10/147.55 ± 29.66)
M 18 ´ 1.5 188.16 ± 37.24 244.02 ± 49.00 287.14 ± 57.82
(19.20 ± 3.80/138.87 ± 27.49) (24.90 ± 5.00/180.10 ± 36.17) (29.30 ± 5.90/211.93 ± 42.67)
M 20 ´ 1.5 257.74 ± 51.94 337.12 ± 67.62 395.92 ± 79.38
(26.30 ± 5.30/190.23 ± 38.33) (34.40 ± 6.90/248.82 ± 49.41) (40.40 ± 8.10/292.21 ± 58.59)
M 22 ´ 1.5 332.22 ± 81.34 453.25 ± 90.65 530.18 ± 105.84
(33.90 ± 8.30/245.20 ± 60.03) (46.25 ± 9.25/334.53 ± 66.91) (54.10 ± 10.80/391.30 ± 78.12)
M 24 ´ 2.0 448.84 ± 90.16 570.36 ± 140.14 691.88 ± 138.18
(45.80 ± 9.20/331.27 ± 66.54) (58.20 ± 14.30/420.96 ± 103.43) (70.60 ± 14.10/510.65 ± 101.99)
* M 10 ´ 1.5 26.46 ± 6.86 36.26 ± 8.82 48.02 ± 11.76
(2.70 ± 0.70/19.53 ± 5.06) (3.70 ± 0.90/26.76 ± 6.50) (4.90 ± 1.20/35.44 ±8.68)
* M 12 ´ 1.5 56.84 ± 11.76 70.56 ± 13.72 89.18 ± 17.64
(5.80 ± 1.20/41.95 ± 8.68) (7.20 ± 1.40/52.08 ± 10.13) (9.10 ± 1.80/65.82 ± 13.02)
* M 14 ´ 2.0 89.18 ± 17.64 109.76 ± 21.56 133.28 ± 26.46
(9.10 ± 1.80/65.82 ± 13.02) (11.20 ± 2.20/81.01 ± 15.91) (13.60 ± 2.70/98.37 ± 19.53)
* M 16 ´ 2.0 124.46 ± 24.50 161.70 ± 32.34 191.10 ± 38.22
(12.70 ± 2.50/91.86 ± 18.08) (16.50 ± 3.30/119.34 ± 23.87) (19.50 ± 3.90/141.04 ± 28.21)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting. Those shown in parentheses in the strength class indicate the classification by the old
standard.
FLARE NUTS N·m (kg·m/lb·ft)
4.76 (0.187) 15.2 ± 2.45(1.55 ±0.25/11.2 ± 1.8) 10.00 (0.394) 53.95 ± 4.90(5.50 ± 0.5 /39.7 ± 3.6)
6.35 (0.250) 26.48 ± 2.94(2.70 ± 0.30/19.5 ± 2.1) 12.00 (0.472) 88.29 ± 9.80(9.00 ± 1.0/65.0 ± 7.2)
8.00 (0.315) 44.14 ± 4.90(4.50 ± 0.50/32.5 ± 3.6) 15.00 (0.591) 105.45 ± 12.26(10.75 ± 1.25/77.7 ± 9.0)
ENGINE MECHANICAL 6A – 9
RTW46AXF000501
6A – 10 ENGINE MECHANICAL
Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley,
Flywheel, and Oil Pan
N·m (kg·m/lb·ft)
RTW36AXF000101
ENGINE MECHANICAL 6A – 11
RTW46AXF000601
6A – 12 ENGINE MECHANICAL
RTW46AXF000701
ENGINE MECHANICAL 6A – 13
RTW36AXF000201
6A – 14 ENGINE MECHANICAL
RTW46AXF000801
ENGINE MECHANICAL 6A – 15
RTW46AXF000901
6A – 16 ENGINE MECHANICAL
RTW46AXF001001
ENGINE MECHANICAL 6A – 17
Engine Electricals
N·m (kg·m/lb·ft)
RTW36AXF000501
6A – 18 ENGINE MECHANICAL
RTW46AXF001101
ENGINE MECHANICAL 6A – 19
RTW46AXF001201
6A – 20 ENGINE MECHANICAL
RTW46AXF001301
ENGINE MECHANICAL 6A – 21
022R300001
6A – 22 ENGINE MECHANICAL
Note:
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacturer’s instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of
greater than 0.25 mm (0.01 in). Poor adhesion will result.
ENGINE MECHANICAL 6A – 23
SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand side
of the cylinder body.
The engine number is stamped in the plate in front of the
engine room as well.
RTW36ASH000401
AIR CLEANER
Element cleaning procedures will vary according to the
condition of the element.
LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Drain the engine oil.
2. Retighten the drain plug.
3. Loosen the used oil filter by turning it counterclockwise
with a filter wrench.
Filter Wrench: 5-8840-0200-0
6A-6
4. Clean the oil cooler fitting face. This will allow the new
oil filter to seat properly.
5. Apply a light coat of engine oil to the filter O-ring.
6. Turn in the new oil filter until the filter O-ring is fitted
against the sealing face.
7. Use the filter wrench to turn in the filter an additional
2/3 turns.
8. Check the engine oil level and replenish to the
specified level if required.
RTW36ASH000101
ENGINE MECHANICAL 6A – 25
6A-7
RTW46ASH000501
041RY00009
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.
041RY00011
Air Bleeding
1. Operate the priming pump until strong resistance is
felt.
2. Wait 1 minute, and operate the priming pump until
strong resistance is felt.
3. Once more wait, and operate the priming pump until
strong resistance is felt.
4. Turn the ignition switch to the "ON" position. Wait until
Except EURO III model the glow indicator lamp turns off.
RTW46ASH002901
5. Turn the ignition switch to the "START" position and
For EURO III model crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air
completely form the fuel system and check for fuel
leakage.
Note:
Insufficient air bleeding may cause the Diagnostic
Trouble Code (DTC) store or improper engine
performance.
RTW46ASH000501
ENGINE MECHANICAL 6A – 27
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve
tank as necessary.
If the coolant level falls below the “MIN” line, carefully
check the cooling system for leakage. Then add enough
coolant to bring the level up to the “MAX” line.
111R300001
2
Testing Pressure kPa(kg/cm /psi)
150 (1.5/21)
030LX003
2
Negative Valve (Reference) kPa(kg/cm /psi)
1.9 – 4.9 (0.02 – 0.05/0.28 – 0.71)
ENGINE MECHANICAL 6A – 29
014RY00014
014RY00015
014RY00017
6A – 32 ENGINE MECHANICAL
COMPRESSION PRESSURE
MEASUREMENT
1. Start the engine and allow it to idle until the coolant
temperature reaches 70 – 80 °C (158 – 176 °F).
2. Remove the following parts.
· Leak off pipe
· Injection nozzle holder bracket
· Injection nozzle holder
F06XL056 3. Install the following parts.
· Set the adapter and compression gauge (SST) to
the No.1 cylinder injection nozzle hole.
· Injection nozzle holder bracket
4. Turn the engine over with the starter motor and take
the compression gauge reading.
2
Compression Pressure MPa (kg/cm /psi) at 200 rpm
Standard Limit
3.0 (31.0/441) 2.1 (21.7/309)
GENERAL DESCRIPTION
RTW46AMF000401
The 4J series automotive diesel engine has special designed combustion chambers in the piston. This design
provides superior fuel economy over a wide range of driving conditions.
Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when
the engine is cold.
Chrome plated dry type cylinder liners provide the highest durability.
The laminated steel sheet cylinder head gasket is very durable and, to increase the head gasket reliability.
The crankshaft has been tufftrided to provide a longer service life. Because the crankshaft is tufftrided, it cannot be
reground.
The 4JA1T(L) engine is equipped with the BOSCH VE-Type distributor injection pump.
The 4JH1TC and 4JA1TC engine is equipped with the BOSCH VP44-Type distributor injection pump.
The engine is turbocharger equipped.
ENGINE MECHANICAL 6A – 37
Removal
1. Battery
1) Disconnect the battery cable and the grounding cable
from the battery terminals.
2) Remove the battery clamp. Take care not to
accidentally short the battery with the wrench or some
other tool.
3) Remove the battery.
4) Disconnect the battery cable at the starter motor and
the ground cable at the cylinder body.
P1010011
2. Engine Hood
Apply setting marks to the engine hood and the engine
hood hinges before removing the engine hood. This will
facilitate reinstallation of the engine hood to its original
position.
P1010002
F06R300006
P1010025
F06R300007
ENGINE MECHANICAL 6A – 39
18. Radiator
1) Drain the engine coolant.
2) Remove the reservoir hose.
3) Remove the upper and lower hose.
4) Remove the fan guide.
5) Remove the radiator.
P1010009
19. Fan
20. Air cleaner
1) Remove the MAF sensor connector (4JA1TC/4JH1TC)
from air cleaner duct.
2) Remove the air cleaner duct and the air cleaner box
from engine room.
3) Remove the two air ducts from inter cooler
(4JA1TC/4JH1TC).
P1010034
140R300001
RTW46ASH000501
022R300002
F06R300008
Installation
To reassemble, follow the removal steps in the reverse
order.
ENGINE MECHANICAL 6A – 41
Coolant Replenishment
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
1. Open rediator cap pour coolant up to filler neck
2. Pour coolant into reservoir tank up to "MAX" line
3. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
4. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
5. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
6. When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
7. Pour coolant into the reservoir tank up to "MAX" line.
9.5 (2.5/2.1)
Engine Warm-Up
After completing the required maintenance procedures,
start the engine and allow it to idle until it is warm.
Check the following:
1. Engine idling speed.
2. Engine noise level.
3. Engine lubricating system and cooling system.
Carefully check for oil and coolant leakage.
4. Clutch engagement.
5. Transmission operation.
6. Indicator warning light operation.
6A – 42 ENGINE MECHANICAL
RTW36ALF000601
Removal Steps
1. Cylinder head gasket 11. Vacuum pump gasket
2. Head cover gasket 12. Water pump O-ring
3. Head cover cap nut gasket 13. Water outlet pipe gasket
4. Drain cock gasket 14. Intake pipe gasket
5. Crankshaft rear oil seal 15. Thermostat housing gasket
6. Gear case gasket 16. Intake manifold gasket
7. Oil pan drain plug gasket 17. Exhaust manifold gasket
8. Oil pan gasket 18. Nozzle holder O-ring
9. Oil filter gasket 19. Nozzle holder gasket
10. Joint bolt gasket 20. Crankshaft front oil seal
NOTE
Discard all O-rings, gaskets, and seals removed at disassembly and replace them with new ones. Reuse of
these parts will result in oil, water, and gas leakage.
ENGINE MECHANICAL 6A – 43
ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS
RTW36AMF000401
Removal Steps
1. Clutch Assembly or Flex Plate 15. Oil Pressure Warning Switch
2. Intake Pipe and Throttle Body 16. Fuel Leak Off Pipe
3-1. EGR Pipe 17. Oil Cooler Water Pipe
3-2. EGR cooler (EURO III model only) 18. Cooling Fan Pulley
4. EGR Valve 19. Heat Protector
5. Oil Level Gauge 20. Catalytic Converter
6. Fuel Filter Assembly (Except EURO III) 21. Turbocharger
7. Fuel Filter Bracket (Except EURO III) 22. Compressor Bracket
8. Fuel Injection Pipe with Clip 23. Vacuum Pump Oil Return Hose
9. Power Steering Oil Pump Bracket 24. Generator and Adjusting Plate
10. Intake Manifold 25. Water Inlet Pipe
11. Engine Mounting Bracket and Foot 26. Generator Bracket
12. Injection Pump Cover 27. Oil Cooler with Oil Filter
13. Injection Pump 28. Exhaust Manifold
14. Starter Motor
6A – 44 ENGINE MECHANICAL
Removal
1. Clutch Assembly or Flex Plate
Remove the clutch assembly or the flex plate.
RTW46ASH000801
4JA1TC/4JH1TC
RTW36ASH000201
025R100008
4JH1TC
RTW36ASH000301
4. EGR Valve
4JA1*L
1) Remove four nuts and remove the EGR valve
assembly from the intake manifold.
2) Remove four bolts and remove the adapter from the
EGR valve assembly.
RTW46ASH001001
4JA1*TC
RTW46ASH000901
RTW36ASH000701
027R100007
21. Turbocharger
1) Disconnect the water hose between thermostat
housing cover and turbocharger.
2) Disconnect the water hose between water inlet pipe
and turbocharger.
3) Remove the oil feed pipe.
4) Remove the oil return pipe.
5) Remove the turbocharger and the gasket.
NOTE:
037RY00001
Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.
1
DISASSEMBLY
INTERNAL PARTS
MAJOR COMPONENTS
011R300001
Disassembly Steps-1
1. Water bypass hose 5. Rocker arm shaft and rocker
2. Thermostat housing with thermo arm
switch 6. Push rod
3. Cylinder head cover 7. Cylinder head
4. Injection nozzle and bracket 8. Cylinder head gasket
6A – 48 ENGINE MECHANICAL
RTW46ALF000101
Disassembly Steps-2
9. Crankshaft damper pulley
10. Timing gear case cove
11. Water pump
12. Idle gear "B" and shaft
13. Idle gear "A"
14. Idle gear shaft
15. Crankshaft timing gear
16. Injection pump
ENGINE MECHANICAL 6A – 49
014R300005
Disassembly Steps-3
17. Flywheel 27. Piston and connecting rod with
18. Crank case upper bearing
19. Oil pump with oil pipe 28. Crankshaft bearing cap with
20. Camshaft timing gear lower bearing
21. Camshaft thrust plate 29. Crankshaft thrust bearing
22. Camshaft 30. Crankshaft
23. Timing gear case 31. Crankshaft upper bearing
24. Cylinder body rear plate 32. Tappet
25. Piston cooling oil jet 33. Crankshaft rear oil seal
26. Connecting rod bearing cap with 34. Cylinder body
lower bearing
6A – 50 ENGINE MECHANICAL
Disassembly
1. Water Bypass Hose
2. Thermostat Housing with Thermo Switch
3. Cylinder Head Cover
4. Injection Nozzle and Bracket
1. Remove the injection nozzle bracket bolts.
011R100002
011RY00005
6. Push Rod
011RY00006
7. Cylinder Head
Loosen the cylinder head bolts in numerical order a little at
a time.
Note:
Failure to loosen the cylinder head bolts in numerical
order a little at a time will adversely affect the cylinder
head lower surface.
020L200006
020L200020
NOTE:
Refer to the following items for details on the backlash
and end play measurement procedures.
020RY00019
040R300009
NOTE:
Plug the injection pump delivery ports with the caps to
RTW36ASH001301
prevent the entry of foreign material.
17. Flywheel
Loosen the flywheel bolts in numerical order a little at a
time.
Use the gear stoper to stop the flywheel gear.
Gear stoper: 5-8840-0214-0
015RY00001
ENGINE MECHANICAL 6A – 53
22. Camshaft
Jiggle the camshaft with your hand as you pull it free from
the front of the engine.
052RY00001
6A – 54 ENGINE MECHANICAL
014LX056
015LX018
RTW36ASH001501
30.Crankshaft
015RY00003
015RY00005
MINOR COMPONENTS
ROCKER ARM SHAFT AND ROCKER ARM
011RY00009
Disassembly Steps
1. Rocker arm shaft snap ring 5. Rocker arm shaft spring
2. Rocker arm 6. Rocker arm shaft snap ring
3. Rocker arm shaft bracket 7. Rocker arm shaft
4. Rocker arm
Disassembly
CYLINDER HEAD
RTW46ALF001201
Disassembly Steps
1. Intake manifold 6. Intake and exhaust valve
2. Intake manifold gasket 7. Valve stem oil seal
3. Split collar 8. Valve spring lower seat
4. Valve spring upper seat 9. Cylinder head
5. Valve spring
6A – 58 ENGINE MECHANICAL
Disassembly
1. Intake Manifold
2. Intake Manifold Gasket
3. Split Collar
1. Place the cylinder head on a flat wooden surface.
2. Use the spring compressor to remove the split collars.
Do not allow the valve to fall from the cylinder head.
Spring Compressor: 9-8523-1423-0
4. Valve Spring Upper Seat
011RY00011 5. Valve Spring
011LX022
ENGINE MECHANICAL 6A – 59
RTW46ALF000301
Disassembly Steps
1. Connecting rod bearing 4. Piston pin
2. Piston ring 5. Connecting rod
3. Piston pin snap ring 6. Piston
6A – 60 ENGINE MECHANICAL
Disassembly
1. Connecting Rod Bearing
If the connecting rod bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
cylinder number from which it was removed.
RTW36ASH001501
2. Piston Ring
1. Clamp the connecting rod in a vise.
Take care not to damage the connecting rod.
2. Use a piston ring replacer to remove the piston rings.
Piston Ring Replacer
Do not attempt to use some other tool to remove the
piston rings. Piston ring stretching will result in
reduced piston ring tension.
015RW041
F06MV015
4. Piston Pin
5. Connecting Rod
6. Piston
Tap the piston pin out with a hammer and a brass bar.
If the pistons and piston pins are to be reinstalled, mark
their installation positions by tagging each piston and piston
pin with the cylinder number from which it was removed.
RTW36ASH001601
ENGINE MECHANICAL 6A – 61
CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure the
four sides and the two diagonals of the cylinder head lower
face.
2. The cylinder head lower surface warpage is more than the
limit, it should be replaced.
011RY00012
NOTE:
The cylinder head lower face cannot be reground.
011RY00013
011RY00014
Positive Crankcase Ventilation (PCV) Valve
1. Remove PCV valve assembly from cylinder head cover.
2. Inspect the diaphragm for broken.
3. Inspect the spring for broken or weaken.
4. If find any abnormal condition, replace the PCV valve
assembly.
6A – 62 ENGINE MECHANICAL
Measuring Method-II
1. Measure the valve stem outside diameter.
Refer to the Item "Valve Stem Outside Diameter".
2. Use a caliper calibrator or a telescoping gauge to measure
the valve guide inside diameter.
011RY00023
011LX029
011RY00024
4. Measure the height of the valve guide upper end from the
upper face of the cylinder head.
NOTE:
If the valve guide has been removed, both the valve
and the valve guide must be replaced as a set.
011RY000025
6A – 64 ENGINE MECHANICAL
Valve Thickness
Measure the valve thickness.
If the measured value is less than the specified limit, the valve
and the valve guide must be replaced as a set.
Valve Depression
1. Install the valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with steel rule to
measure the valve depression from the cylinder head lower
surface.
If the measured value exceeds the specified limit, the valve
seat insert must be replaced.
NOTE:
The smooth side of the attachment must contact the
valve seat insert.
014RY00026
2. Use a bench press (3) to gradually apply pressure to the
attachment and press the valve seat insert into place.
NOTE:
Do not apply an excessive amount of pressure with
the bench press. Damage to the valve seat insert will
result.
011LX063
NOTE:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
011LX037
011LX038
ENGINE MECHANICAL 6A – 67
014RY00024
014RY00023
CYLINDER BODY
Cylinder Body Upper Face Warpage
1. Remove the cylinder body dowel.
2. Remove the cylinder liner.
Refer to "Cylinder Liner Replacement".
012RY00009
6A – 70 ENGINE MECHANICAL
NOTE:
Take care not to damage the cylinder body upper face
during the cylinder liner removal procedure.
3. Measure the cylinder body upper face warpage.
Refer to "Cylinder Body Upper Face Warpage".
ENGINE MECHANICAL 6A – 71
012RY00013 * A minus (-) value indicates that the cylinder body bore is
smaller than the liner outside diameter.
012RY00014
012R300001
012RY00022
4JH1TC mm (in)
Liner
Cylinder Body Liner Outside Liner Bore
Outside Service Liner Bore Measurement
Bore Diameter Diameter Grade
Grade
97.001-97.010 97.011-97.020 AX 95.435-95.450 (3.7573-3.7579)
1
(3.8189-3.8193) (3.8193-3.8197) CX 95.451-95.466 (3.7579-3.7585)
97.011-97.020 97.021-97.030 AX 95.435-95.450 (3.7573-3.7579)
2
(3.8193-3.8197) (3.8197-3.8200) CX 95.451-95.466 (3.7579-3.7585)
97.021-97.030 97.031-97.040 AX 95.435-95.450 (3.7573-3.7579)
3
(3.8197-3.8200) (3.8200-3.8205) CX 95.451-95.466 (3.7579-3.7585)
97.031-97.040 97.041-97.050 AX 95.435-95.450 (3.7573-3.7579)
4
(3.8200-3.8205) (3.8205-3.8209) CX 95.451-95.466 (3.7579-3.7585)
ENGINE MECHANICAL 6A – 73
NOTE:
All foreign material must be carefully removed from
012RY00017
the cylinder liner and the cylinder bore before
installation.
3. Insert the cylinder liner (1) into the cylinder body (2)
from the top of the cylinder body.
NOTE:
Check that the cylinder liner is set perpendicular to
the bench press and that there is no wobble.
012RY00018
NOTE:
It is most important that the correct piston grade be
used. Failure to select the correct piston grade will
result in engine failure. Always measure the cylinder
bore and select the correct piston grade.
ENGINE MECHANICAL 6A – 75
NOTE:
Cylinder liner kit clearances are preset. However, the
cylinder liner installation procedure may result in
slight decreases in cylinder liner clearances. Always
measure the cylinder liner clearance after installation
to be sure that it is correct.
NOTE:
The tappet surfaces are spherical. Do not attempt to
grind them with an oil stone or similar tool in an effort
to repair the tappet. If the tappet is damaged, it must
be replaced.
6A – 76 ENGINE MECHANICAL
012LX014
014RY00031
Limit
0.3 (0.012)
CAMSHAFT
Visually inspect the journals, the cams, the oil pump drive gear,
and the camshaft bearings for excessive wear and damage.
The camshaft and the camshaft bearings must be replaced if
these conditions are discovered during inspection.
Cam Height
Measure the cam height (H) with a micrometer. If the
measured value is less than the specified limit, the camshaft
must be replaced.
Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator.
If the measured value exceeds the specified limit, the
camshaft must be replaced.
014RY00035
014RY00036
ENGINE MECHANICAL 6A – 79
NOTE:
To increase crankshaft strength, tufftriding (Nitrizing
Treatment) has been applied. Because of this, it is not
possible to regrind the crankshaft surfaces.
Therefore, under size bearing are not available.
Crankshaft Run-Out
1. Set a dial indicator to the center of the crankshaft journal.
2. Gently turn the crankshaft in the normal direction of
rotation.
Read the dial indicator as you turn the crankshaft.
If the measured value exceeds the specified limit, the
crankshaft must be replaced.
Bearing Spread
Use a vernier caliper to measure the bearing spread.
If the measured value is less than the specified limit, the
bearing must be replaced.
015RY00008
Crankshaft Journal and Diameter mm (in)
Standard Limit
4JA1T (L), 59.921-59.928
59.91 (2.3586)
4JA1TC (2.3591-2.3594)
69.917-69.932
4JH1TC 69.91(2.7524)
(2.7526-2.7532)
015RY00013
6A – 82 ENGINE MECHANICAL
015LX129
015LX060
NOTE:
The crankshaft journal mark No. 4 is stamped on
015RY00016
crankshaft No. 4 journal web front side or rear side.
6A – 84 ENGINE MECHANICAL
REFERENCE
4JH1TC mm (in)
Crankshaft
Crankshaft Journal Crankshaft
Bearing Housing
Bearing
Grade Grade Size Code
Diamaeter Diamaeter
Mark Mark
1 or 69.927-69.932
- (2.7530-2.7532)
73.992- 4
74.000 2 or 69.922-69.927
1
(2.9131- -- (2.7528-2.7530)
2.9134)
3 or 69.917-69.922
5
--- (2.7556-2.7528)
1 or 69.927-69.932
2
- (2.7530-2.7532)
73.983-
73.992 2 or 69.922-69.927
2 3
(2.9127- -- (2.7528-2.7530)
2.9131)
3 or 69.917-69.922
4
--- (2.7556-2.7528)
1 or 69.927-69.932
1
- (2.7530-2.7532)
73.975-
73.983 2 or 69.922-69.927
3
(2.9124- -- (2.7528-2.7530)
2.9127) 2
3 or 69.917-69.922
--- (2.7526-2.7528)
ENGINE MECHANICAL 6A – 85
015RY00018
NOTE:
015RY00010
Strike only the crankshaft pilot bearing outer race with
the hammer. Do not strike the bearing inner race.
Bearing damage and reduced bearing service life will
result.
Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the ring
gear must be replaced.
6A – 86 ENGINE MECHANICAL
020LX008
020LX009
PISTON
Piston Grade Selection and Cylinder Bore
Measurement
Refer to the Section "Cylinder Body", Item "Cylinder Liner Bore
Measurement" for details on piston grade selection and
cylinder liner bore measurement.
015LX023
2. Push the piston ring into the cylinder bore until it reaches
the measuring point 1 or 2 where the cylinder liner bore is
the smallest.
Do not allow the piston ring to slant to one side or the
other. It must be perfectly horizontal.
Measuring Point 1 10 mm (0.4 in)
or
Measuring Point 2 120 mm (4.7 in)
015RY00020
ENGINE MECHANICAL 6A – 87
4JH1TC
Standard Limit
1st Compression Ring 0.3-0.5
2nd Compression Ring (0.0118-0.0197) 1.5
(0.059)
0.250-0.450
Oil Ring
(0.0098-0.0177)
4JH1TC
Standard Limit
0.09-0.130
1st Compression Ring
(0.0035-0.0051)
0.05-0.090 0.15
2nd Compression Ring
(0.0020-0.0035) (0.0059)
0.03-0.070
Oil Ring
(0.0012-0.0028)
6A – 88 ENGINE MECHANICAL
015RW048
Piston Pin and Piston Pin Hole Clearance mm (in)
4JA1T (L) 0.002-0.015 (0.00008-0.0006)
4JA1TC, 4JH1TC 0.005-0.018 (0.0002-0.0007)
RTW36ASH001701
011RY00027
4JH1TC mm (in)
Gasket Thickness
Gasket Grade Mark Piston Projection
(Reference)
0.215-0.265 1.3
A
(0.0085-0.0104) (0.5118)
0.265-0.315 1.35
B
(0.0104-0.0124) (0.5315)
0.315-0.365 1.4
C
(0.0124-0.0144) (0.5512)
NOTE:
Difference of the each piston projection and must be
equal or within 0.1 mm (0.004 in).
6A – 90 ENGINE MECHANICAL
CONNECTING ROD
Connecting Rod Alignment
Use a connecting rod aligner to measure the distortion and the
parallelism between the connecting rod big end hole and the
connecting rod small end hole.
If either the measured distortion or parallelism exceed the
specified limit, the connecting rod must be replaced.
NOTE:
Install the oil seal after assembling the timing pulley
housing. The oil seal lip section is applied with oil.
Take notice of the press-in direction of the oil seal.
ENGINE MECHANICAL 6A – 93
REASSEMBLY
INTERNAL PARTS
MINOR COMPONENT
ROCKER ARM SHAFT AND ROCKER ARM
020RY00029
Reassembly Steps
1. Rocker arm shaft 5. Rocker arm
2. Rocker arm shaft snap ring 6. Rocker arm shaft spring
3. Rocker arm 7. Rocker arm shaft snap ring
4. Rocker arm shaft bracket
Reassembly
1. Rocker Arm Shaft
1. Position the rocker arm shaft with the large oil hole (4
) facing the front of the engine.
2. Install the rocker arm shaft together with the rocker
arm, the rocker arm shaft bracket, and the spring.
2. Rocker Arm Shaft Snap Ring
3. Rocker Arm
4. Rocker Arm Shaft Bracket
014RY00037 5. Rocker Arm
6. Rocker Arm Shaft Spring
7. Rocker Arm Shaft Snap Ring
6A – 94 ENGINE MECHANICAL
CYLINDER HEAD
RTW46ALF001301
Reassembly Steps
1. Cylinder head 6. Valve spring upper seat
2. Valve spring lower seat 7. Split collar
3. Valve stem oil seal 8. Intake manifold gasket
4. Intake and exhaust valve 9. Intake manifold
5. Valve spring
ENGINE MECHANICAL 6A – 95
Reassembly
1. Cylinder Head
2. Valve Spring Lower Seat
3. Valve Stem Oil Seal
1. Apply a coat of engine oil to the oil seal inner face.
2. Use an oil seal installer to install the oil seal to the
valve guide.
Oil Seal Installer: 5-8840-2033-0
4. Intake and Exhaust Valve
011RW027
1. Apply a coat of engine oil to each valve stem before
installation.
2. Install the intake and exhaust valves.
3. Turn the cylinder head up to install the valve
springs.Take care not to allow the installed valves to
fall free.
5. Valve Spring
Install the valve spring with their fine pitched end (painted)
facing down.
011LX055
7. Split Collar
1. Use the spring compressor to compress the valve
spring into position.
Spring Compressor: 9-8523-1423-0
2. Install the split collars to the valve stem.
3. Set the split collars by tapping around the head of the
collar with a rubber hammer.
014RY00039
RTW46ALF000301
Reassembly Steps
1. Piston 5. Piston pin snap ring
2. Connecting rod 6. Piston ring
3. Piston pin snap ring 7. Connecting rod bearing
4. Piston pin
ENGINE MECHANICAL 6A – 97
Reassembly
1. Piston
2. Connecting Rod
1. Clamp the connecting rod in a vise.Take care not to
damage the connecting rod.
2. Use a pair of pliers to install the piston pin snap ring to
the piston.
F06MV015
RTW36ASH001801
4. Piston Pin
1. Apply a coat of engine oil to the piston pin and the
piston pin hole.
2. Use your fingers to force the piston pin into the piston
until it makes contact with the snap ring.
RTW36ASH001901
015R100001
6A – 98 ENGINE MECHANICAL
6. Piston Ring
1. Use a piston ring replacer to install the three piston
rings.
Piston Ring Replacer
Install the piston rings in the order shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring
RTW36ASH002001
NOTE:
Install the compression rings with the stamped side
facing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.
015R100006
ENGINE MECHANICAL 6A – 99
RTW46AMF000101
Reassembly Steps
Positive Crankcase Ventilation
1. 5. Fixing bolt
(PCV) Valve
2. Rubber space 6. Oil filler cap
3. Cylinder head insulator cover
4. Breather pipe
6A – 100 ENGINE MECHANICAL
Reassembly
1. PCV Valve
Install the PCV valve and tighten the bolts to specified
torque.
2. Rubber Spacer
010R100014
3. Cylinder Head Insulator Cover
4. Breather Hose
Apply LOCTITE 262 or equivalent to the new breather pipe.
Do not reuse the breather pipe.
5. Fixing Bolt
MAJOR COMPONENT
014R300004
Reassembly Steps-1
1. Cylinder body 10. Camshaft timing gear
Piston and connecting rod with
2. Tappet 11.
upper bearing
Connecting rod bearing cap with
3. Crankshaft upper bearing 12.
lower bearing
4. Crankshaft 13. Piston cooling oil pipe
5. Crankshaft thrust bearing 14. Oil pump with oil pipe
Crankshaft bearing cap with
6. 15. Crankshaft rear oil seal
lower bearing
7. Camshaft 16. Crank case
8. Timing gear case 17. Cylinder body rear plate
9. Camshaft thrust plate 18. Flywheel
6A – 102 ENGINE MECHANICAL
RTW46ALF000501
Reassembly Steps-2
19. Crankshaft timing gear 23. Injection pump
20. Idler gear shaft 24. Water pump
21. Idler gear "A" 25. Timing gear case cover
22. Idler gear "B" and shaft 26. Crankshaft damper pulley
ENGINE MECHANICAL 6A – 103
011R300002
Reassembly Steps-3
Thermostat housing with thermo
27. Cylinder head gasket 31.
switch
28. Cylinder head 32. Water by-pass hose
29. Push rod 33. Injection nozzle and bracket
Rocker arm shaft and rocker
30. 34. Cylinder head cover with gasket
arm
6A – 104 ENGINE MECHANICAL
Reassembly
1. Cylinder Body
Use compressed air to thoroughly clean the inside and
outside surfaces of the cylinder body, the oil holes, and the
water jackets.
015R100003
2. Tappet
1. Apply a coat of engine oil to the tappet and the
cylinder body tappet insert holes.
2. Locate the position mark applied at disassembly (if
the tappet is to be reused).
NOTE:
The tappet must be installed before the camshaft
installation.
014LX088
NOTE:
Do not apply engine oil to the bearing back faces and
the cylinder body bearing fitting surfaces.
015LX125
2. Locate the position mark applied at disassembly if the
removed upper bearings are to be reused.
4. Crankshaft
Apply an ample coat of engine oil to the crankshaft journals
and the crankshaft bearing surfaces before installing the
crankshaft.
015R100004
ENGINE MECHANICAL 6A – 105
015LX115
015LX128
7. Camshaft
1. Apply a coat of engine oil to the camshaft and the
camshaft bearings.
2. Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.
014RY00019
020R300003
020RY00032
RTW36ASH000901
ENGINE MECHANICAL 6A – 107
015R100006
015LX096
015R100007
6A – 108 ENGINE MECHANICAL
052LX010
Relief Valve Torque N·m(kg·m/lbft)
29 (3.0/22)
NOTE:
Check that there is no interference between the piston
and the oiling jet by slowly rotating the crankshaft.
NOTE:
051R100004 Take care not to damage the O-rings when tightening
the oil pipe bolts.
015LX112
ENGINE MECHANICAL 6A – 109
013RW011
NOTE:
Be sure that the crank case fitting surface is
completely free of oil and dust before applying the
liquid gasket.
013LV003
013R100001
6A – 110 ENGINE MECHANICAL
020R100001
18. Flywheel
1. Apply a coat of engine oil to the threads of the flywheel
bolts.
2. Align the flywheel with the crankshaft dowel pin.
3. Tighten the flywheel bolts in the numerical order shown
in the illustration.
Gear stoper: 5-8840-0214-0
020RY00034
020RY00036
Idler Gear "A" Bolt Torque N·m(kg·m/lbft)
30 (3.1/22)
020L200019
020L200007
6A – 112 ENGINE MECHANICAL
RTW31BSH000101
RTW31BSH000201
RTW31BSH000301
RTW31BSH000501
ENGINE MECHANICAL 6A – 113
8) Insert the bolts of the special tool into the rear gear
setting hole. Rotate the rear gear to mesh the teeth
of main gear and rear gear.
9) Insert a lock bolt (M6 ´ 1 L=30) into scissors gear
fixing hole to prevent the scissors gear from turning.
10) Place the main gear in a vise with copper plate so
that the front side of the main gear facing up.
11) Repeat steps 4 to 8 to install the front gear.
12) Lock the front gear, the main gear, and the rear gear
RTW31BSH000401 with lock bolt (inserted at Step 8).
6A – 114 ENGINE MECHANICAL
020RY00039
4JA1TC/4JH1TC:
4. Tighten the injection pump bolts (5) to the specified
torque.
Injection Pump Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)
NOTE:
Tighten the bracket bolt (7) first.
RTW36AMH000101
ENGINE MECHANICAL 6A – 115
4JA1T(L):
4. Tighten the injection pump bolts to the specified torque.
5. Install the injection pump bracket (4) and the bracket
bolts (5) and (6) to the cylinder body. Temporarily tighten
the bracket bolts.
6. Tighten the bracket bolts (5) to the specified torque.
7. Tighten the bracket bolts (6) to the specified torque.
NOTE:
Before the gasket installation, measure the piston
head projection and select the appropriate head
gasket.
Refer to "INSPECTION AND REPAIR", "Cylinder Head
Gasket Selection".
28. Cylinder Head
1. Align the cylinder body dowels and the cylinder head
dowel holes.
Carefully place the cylinder head on the cylinder head
gasket.
2. Apply a coat of engine oil to the cylinder head bolt
threads and setting faces.
011LX073
3rd step 60° - 75°
014LX083
031R300002
ENGINE MECHANICAL 6A – 117
RTW46ASH001201
014RY00015
INSTALLATION
EXTERNAL PARTS
RTW36AMF000701
Installation Steps
1. Exhaust Manifold 18. Engine Mounting Bracket and
2. Oil Cooler with Oil Filter Foot
3. Generator Bracket 19. Intake Manifold
4. Water Inlet Pipe 20. Power Steering Oil Pump
5. Generator and Adjusting Plate Bracket
6. Vacuum Pump Oil Return Hose 21. Fuel Injection Pipe with Clip
Fuel Filter Bracket (Except
7. Compressor Bracket 22.
EURO III)
Fuel Filter Assembly (Except
8. Turbocharger 23.
EURO III)
9. Catalytic Converter 24. Oil Level Gauge
10. Heat Protector 25. EGR Valve
11. Cooling Fan Pulley 26-1. EGR Pipe
EGR Cooler (EURO III model
12. Oil Cooler Water Pipe 26-2.
only)
Intake Pipe and Throttle Body
13. Fuel Leak Off Pipe 27.
(4JA1TC/4JH1TC only)
14. Oil Pressure Warning Switch 28. Clutch Assembly or Flex Plate
15. Starter Motor
16. Injection Pump
17. Injection Pump Cover
ENGINE MECHANICAL 6A – 119
Installation
1. Exhaust Manifold
1) Install the exhaust manifold to the cylinder head with
the manifold gasket.
2) Tighten the exhaust manifold bolts and nuts to the
specified torque a little at a time.
Exhaust Manifold Bolt and Nuts
Torque N·m(kg·m/Ib ft)
027R100003
27 (2.7/20)
027R100004
RTW46ASH001301
3. Generator Bracket
Install the generator bracket to the cylinder body and
tighten the bracket bolts to the specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
40 (4.1/30)
066RY00001
6A – 120 ENGINE MECHANICAL
032R300001
066RY00002
052R300001
7. Compressor Bracket
1) Install the compressor bracket to the cylinder head.
2) Tighten the bracket bolts to the specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
M8b1.25 19 (1.9/14)
M10b1.25 40 (4.1/30)
042RY00003
ENGINE MECHANICAL 6A – 121
8. Turbocharger
1) Install the turbocharger and the gasket.
2) Temporarily tighten the turbocharger nuts at this time.
They will be fully tightened after the installation of the
turbocharger oil pipe.
Always install new nuts and new gasket.
027R100002
036R100001
027R100005
6A – 122 ENGINE MECHANICAL
10) Install the water feed pipe with the gaskets and tighten
to the specified torque.
Water Return Pipe Torque N·m(kg·m/Ib ft)
39 (4.0/29)
11) Install the water return pipe with the gaskets and
tighten to the specified torque.
Water Return Torque N·m(kg·m/Ib ft)
39 (4.0/29)
12) Clamp the water feed pipe to the oil return pipe of the
turbocharger.
Fixing Bolt (3) Torque N·m(kg·m/Ib ft)
8 (0.8/6)
RTW46ASH001601
13) Install the hoses for the water feed and return.
9. Catalytic Converter
Install the catalytic converter with gasket and tighten the
nut to the specified torque.
Catalytic converter Nut Torque N·m(kg·m/Ib ft)
27 (2.7/20)
022R300003
4JA1TC
RTW46ASH002601
5) Install the fan drive belt and adjust the belt tension
referring SERVICING of this section
6A – 124 ENGINE MECHANICAL
431RY00013
M8 19 (1.9/14)
M6 8 (0.8/6)
ENGINE MECHANICAL 6A – 125
025R100008
RTW36ASH000301
RTW48ASH001801
RTW36ASH000201
LUBRICATION SYSTEM
LUBRICATING OIL FLOW
1. Oil Pump Relief Valve Operating Pressure: 6.2 - 7.8kg/cm 2 (608 - 764Kpa)
2. Regulating Valve Operating Pressure: 5.7 - 6.3kg/cm 2 (558.6 - 617.4Kpa)
3. Oil Cooler Relief Valve Opening Pressure: 2.8 - 3.4kg/cm 2 (270 - 330Kpa)
4. Oil Filter Relief Valve Opening Pressure: 0.8 - 1.2kg/cm 2 (78.4 - 117.6Kpa)
5. Oil Pressure Switch Operating Pressure: 0.3 - 0.5kg/cm 2 (29.4 - 49.0Kpa)
6. Regulating Valve: 1.8 - 2.2kg/cm 2 (176 - 216Kpa)
RTW46ALF001501
OIL PUMP
DISASSEMBLY
051R100005
Disassembly Steps
1. Oil pipe 5. Driven gear
2. Strainer 6. Relief valve assembly
3. Pump cover 7. Pinion gear
4. Driven gear with bushing 8. Oil pump body
Disassembly procedure is shown in the illustration above numerical order.
ENGINE MECHANICAL 6A – 129
REASSEMBLY
051R100006
Reassembly Steps
1. Oil pump body 5. Pinion gear
2. Drive gear 6. Strainer
3. Driven gear 7. Relief valve assembly
4. Pump cover 8. Oil pipe
Reassembly procedure is shown in the illustration above numerical order.
Pump cover fixing bolts torque: 16 N·m (1.6 kg·m/12 lb ft)
ENGINE MECHANICAL 6A – 131
050R300004
Disassembly Steps
1. Oil filter cartridge 5. Body
2. Bolt 6. Oil cooler relief valve
3. Gasket 7. Regulating valve
4. Oil cooler
Disassembly procedure is shown in the illustration above numerical order.
6A – 132 ENGINE MECHANICAL
050RY00002
ENGINE MECHANICAL 6A – 133
REASSEMBLY
050R300003
Reassembly Steps
1. Body 5. Gasket
2. Regulating valve 6. Bolt
3. Oil cooler relief valve 7. Oil filter cartridge
4. Oil cooler
Reassembly procedure is shown in the illustration above numerical order.
6A – 134 ENGINE MECHANICAL
1. Body
2. Oil Filter Safety Valve
3. Oil Cooler Safety Valve
Tighten the oil filter A and oil cooler B relief valve to the
specified torque.
Regulating Valve N·m(kg·m/lb ft)
A 64 (6.5/48)
RTW46ASH001701
4. Oil Cooler
5. Gasket
6. Bolt
Tighten bolt with gasket and oil cooler to the specified
torque.
Bolt Torque N·m(kg·m/lb ft)
40 (4.1/30)
050R300006
050RY00004
ENGINE MECHANICAL 6A – 135
INTER COOLER
REMOVAL AND INSTALLATION
RTW46ALF001001
Removal
1. Radiator Grille
· Refer to removal procedure in Sheet Metal section.
RTW36ASH000601
RTW36ASH000501
RTW46ASH002101
4. Inter Cooler
· Remove the nut and two bolts.
· Disconnect the air hose.
Installation
4. Inter Cooler
· Tighten the nut and two bolts.
1. Radiator grille
· Refer to installation procedure in Sheet Metal section.
ENGINE MECHANICAL 6A – 137
SPECIAL TOOLS
Illustration Tool Number Tool Name
5-8840-2040-0 (4JA1L/TC)
Cylinder Liner Installer
5-8840-2313-0 (4JH1TC)
5-8840-2039-0 (4JA1L/TC)
Cylinder Liner Remover
5-8840-2304-0 (4JH1TC)
ENGINE MECHANICAL 6A – 139
MEMO
ENGINE COOLING 6B – 1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6B - 3
General Description .................................................................................................. 6B - 4
Coolant Flow .............................................................................................................. 6B - 4
Water Pump................................................................................................................ 6B - 5
Thermostat ................................................................................................................. 6B - 5
Radiator ...................................................................................................................... 6B - 6
Diagnosis........................................................................................................................ 6B - 7
Draining and Refilling Cooling System........................................................................ 6B - 8
Water Pump.................................................................................................................... 6B - 10
Removal and Installation .......................................................................................... 6B - 10
Removal...................................................................................................................... 6B - 10
Inspection and Repair ............................................................................................... 6B - 11
Installation.................................................................................................................. 6B - 11
Thermostat ..................................................................................................................... 6B - 13
Removal and Installation .......................................................................................... 6B - 13
Removal...................................................................................................................... 6B - 13
Inspection and Repair ............................................................................................... 6B - 13
Installation.................................................................................................................. 6B - 14
Radiator .......................................................................................................................... 6B - 15
Removal and Installation .......................................................................................... 6B - 15
Radiator and Associated Parts................................................................................. 6B - 15
Removal...................................................................................................................... 6B - 16
Inspection and Repair ............................................................................................... 6B - 17
Installation.................................................................................................................. 6B - 18
6B – 2 ENGINE COOLING
PAGE
Engine coolant change ............................................................................................. 6B - 19
Fan Clutch with Cooling Fan ........................................................................................ 6B - 20
Inspection and Repair ............................................................................................... 6B - 20
ENGINE COOLING 6B – 3
GENERAL DESCRIPTION
COOLANT FLOW
RTW46ALF001101
The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the
water pump and thermostat through the bypass hose and back to the cylinder body.
The coolant does not circulate through the radiator.
When the coolant temperature reaches specified value, the thermostat will begin to open and a gradually increasing
amount of coolant will circulate through the radiator.
The thermostat will be fully open when the coolant temperature reaches specified value. All of the coolant is now
circulating through the radiator for effective engine cooling.
ENGINE COOLING 6B – 5
WATER PUMP
RTW46ASF000101
A centrifugal type water pump forcefully circulates the coolant through the cooling system.
The water pump is not disassembled type.
THERMOSTAT
030RY00005
RADIATOR
The radiator is a tube type with corrugated fins. In order to
raise the boiling point of the coolant, the radiator is fitted with a
cap in which the valve is operated at 93.3 ~ 122.7 kPa (13.5 ~
17.8 psi) pressure. (No oil cooler provided for M/T)
110RS001
Antifreeze Solution
NOTE: Antifreeze solution + Water = Total cooling system
capacity.
Total Cooling System Capacity Lit (US / UK gal)
9.4 (2.5/21) 4JA1L/TC
M/T 10.1 (2.7/2.2) 4JH1TC
A/T 10.0 (2.6/2.2) 4JH1TC
See section 0B MAINTENACE AND LUBRICATION.
F06RW005
NOITE:
To maintain the corrosion resistance of the aluminum
radiator, water and antifreeze must be combined in a 1:1
solution (50% antifreeze and 50% water)
NOTE
PTW46BSH000201
ENGINE COOLING 6B – 7
DIAGNOSIS
P1010064
WATER PUMP
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
Removal
1. Radiator Upper Hose
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.
030R300001
7. Water Pump
1) Remove the water pump bolts.
2) Remove the water pump.
030R300002
ENGINE COOLING 6B – 11
030R300001
6B – 12 ENGINE COOLING
5. Thermostat
Install the thermostat to the thermostat housing.
6. Water Outlet Pipe
1) Install the water outlet pipe with new gasket to the
thermostat housing.
2) Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque N·m(kg·m/lb ft)
19(1.9/14)
THERMOSTAT
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
Removal
1. Radiator Upper Hose
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.
031R300003
Q Thermometer
R Agitating rod
S Wooden piece
Installation
1. Thermostat
Install the thermostat to the thermostat housing.
2. Water Outlet Pipe
3) Install the water outlet pipe with new gasket to the
thermostat housing.
4) Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque N·m(kg·m/lb ft)
031R300003 19(1.9/14)
RADIATOR
REMOVAL AND INSTALLATION
Radiator and Associated Parts
RTW36BLF000101
Legend
1. Radiator Hose 6. Reserve Tank Hose
2. Drain Plug 7. Reserve Tank
3. Fan Guide, Lower 8. Radiator Cap
4. Fan Guide 9. Radiator Assembly
5. Bracket
6B – 16 ENGINE COOLING
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from the
engine.
P1010064
PTW46BSH000101
7. Remove bracket(5).
RTW36BMH000101
110RS006
Radiator Core
1. A bent fin may result in reduced ventilation and overheating
may occur. All bent fins must be straightened. Pay close
attention to the base of the fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.
110RS005
Installation
1. Install radiator assembly (9) with hose, taking care not to
damage the radiator core with a fan blade.
2. Support the radiator upper tank with the bracket (5) and
secure the radiator.
3. Connect reserve tank hose (6).
4. Install lower fan guide (3).
5. Connect radiator inlet hose and outlet hose (1) to the
engine.
RTW36BMH000101
ENGINE COOLING 6B – 19
RTW36BSH000101
033RY00011
FUEL SYSTEM 6C – 1
SECTION 6C
FUEL SYSTEM
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6C - 3
General Description....................................................................................................... 6C - 4
Fuel Flow.................................................................................................................... 6C - 4
Fuel Filter and Water Separator ............................................................................... 6C - 5
Injection Pump........................................................................................................... 6C - 7
Injection Nozzle ......................................................................................................... 6C - 8
Fuel Tank ........................................................................................................................ 6C - 9
Removal ..................................................................................................................... 6C - 9
Installation ................................................................................................................. 6C - 10
Fuel Pump ...................................................................................................................... 6C - 12
Removal...................................................................................................................... 6C - 13
Installation.................................................................................................................. 6C - 13
Fuel Tube / Quick - Connector Fittings........................................................................ 6C - 14
Filler Neck ...................................................................................................................... 6C - 16
Removal...................................................................................................................... 6C - 16
Installation.................................................................................................................. 6C - 16
Fuel Filler Cap ................................................................................................................ 6C - 17
Injection Pump ............................................................................................................... 6C - 18
Removal and Installation .......................................................................................... 6C - 18
Removal...................................................................................................................... 6C - 18
Installation.................................................................................................................. 6C - 21
6C – 2 FUEL SYSTEM
PAGE
Injection Nozzle.............................................................................................................. 6C - 25
Inspection................................................................................................................... 6C - 25
Special Tools.................................................................................................................. 6C - 36
FUEL SYSTEM 6C – 3
Description
Item
4JA1T (L) 4JA1TC 4JH1TC
Injection pump type Bosch distributor Bosch distributor VP44 type
VE type
Governor type Mechanical variable Electrical controled
(Half speed oil
pressure)
Timer type Oil pressure Electrical controled
Fuel feed pump type Vane with input shaft
Injection nozzle type Hole type
Number of injection nozzle orifices 5
Injection nozzle orifices
Inside diameter mm (in) 0.19 (0.0075) 0.17 (0.0067) 0.21 (0.0083)
Injection nozzle designed operating 19.1 (195) 19.0 (194) 19.5 (199)
2
pressure MPa (kg/cm ) 1st
25.0 (255) 33.5 (328) 33.8 (331)
2nd
Main fuel filter type Disposable cartridge paper element
Precautions
When working on the fuel system, there are several things
to keep in mind:
• Any time the fuel system is being worked on,
disconnect the negative battery cable except for
those tests where battery voltage is required.
• Always keep a dry chemical (Class B) fire
extinguisher near the work area.
• Replace all pipes with the same pipe and fittings that
were removed.
• Clean and inspect “O" rings. Replace if required.
• Always relieve the line pressure before servicing any
fuel system components.
• Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
• Adhere to all Notices and Cautions.
NOTE:
Injection nozzle adjustment is possible only on the 4JA1L
engine.
6C – 4 FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FLOW
RTW46CMF000201
The fuel system consists of the fuel tank, the fuel filter, the water separator, the injection pump, and the injection
nozzle.
The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other
foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum
timing for efficient engine operation.
NOTE:
1 If it find abnormal condition on the fuel injector, refer to section 6E ENGINE DRIVEABILITY AND
EMISSIONS.
2 Do not contain "Additive for water drain" with fuel.
FUEL SYSTEM 6C – 5
RTW36CLF000701
6C – 6 FUEL SYSTEM
RTW46AMF000201
FUEL SYSTEM 6C – 7
INJECTION PUMP
RTW46CLF000201
4JA1T(L):
A Bosch Distributor Type Injection Pump is used. A single reciprocating/revolving plunger delivers the fuel uniformly
to the injection nozzles, regardless of the number of cylinders.
The governor, the injection timer, and the feed pump are all contained in the injection pump housing. The injection
pump is compact, light weight, and provides reliable high-speed operation.
The vacuum-type fast idle actuator increases the engine idling speed to provide the additional power required to
operate the air conditioner.
Fast idler diaphragm movement is caused by changes in the negative pressure created by the engine’s vacuum
pump.
The diaphragm motion is transferred to the injection pump control lever to increase or decrease the idling speed.
4JA1TC/4JH1TC:
The Bosch VP44 injection pump is electronically controlled. The pump controller combine to injection pump.
Signals from the pump controller are sent to the engine control module (ECM). In response to these signals, the
ECM selects the optimum fuel injection timing and volume for the existing driving conditions.
6C – 8 FUEL SYSTEM
INJECTION NOZZLE (4JA1L)
RTW46CMF000301
NOTE:
· Injection nozzle adjustment is possible only on the 4JA1L engine.
A hole (with 5 orifices) type injection nozzle. It consists of the nozzle body and the needle valve assembly.
The injection nozzle assembly sprays pressurized fuel from the injection pump into the combustion chamber through
the nozzle body injection orifice.
FUEL SYSTEM 6C – 9
FUEL TANK
Fuel Tank and Associated Parts
RTW46CLF000401
Legend
1. Bolt; Fuel Tank
2. Fuel Tank Band
3. Fuel Tube/Quick Connector
4. Fuel Filler Hose
5. Fuel Tank
6. Under Shield Band
7. Under Shield (only, specified model)
8. Evapo Pipe (only specified model)
6C – 10 FUEL SYSTEM
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Disconnect battery ground cable.
2. Loosen slowly the fuel filler cap.
NOTE: Be careful not to spouting out fuel because of change
the pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any dust
entering.
3. Jack up the vehicle.
4. Support underneath of the fuel tank with a lifter.
5. Remove the inner liner of the wheel house at rear left side.
6. Remove fixing bolt of the filler neck from the body.
7. Disconnect the quick connector (3) of the fuel tube from the
fuel pipe.
NOTE: Cover the quick connector to prevent any dust entering
and fuel leakage.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.
8. Remove fixing bolt (1) of the tank band and remove the
tank band (2).
9. Disconnect the pump and sender connector on the fuel
pump and remove the harness from weld clip on the fuel
tank.
10.Lower the fuel tank (5).
NOTE: When lower the fuel tank from the vehicle, don’t scratch
each hose and tube by around other parts.
Installation
1. Raise the fuel tank.
NOTE: When raise the fuel tank to the vehicle, don’t scratch
each hose and tube by around other parts.
2. Connect the pump and sender connector to the fuel pump
and install the harness to weld clip on the tank.
NOTE: The connector must be certainly connected against
stopper.
3. Install the tank band and fasten bolt.
Torque N·m (kg·m / lb ft)
68 (6.9 / 50)
RTW46CLF000501
Legend
1. Fuel Feed Port 6. Fuel Tube/Quick Connector
2. Fuel Return Port 7. Retainer Ring (Fuel Gauge Unit Lock)
3. Fuel Emission Port 8. Seal; Fuel Gauge Unit
4. Fuel Gauge Unit and Sender Assembly 9. Fuel Tank Assembly
5. Connector; Fuel Gauge Unit 10. Evapo Tube/Quick Connector
FUEL SYSTEM 6C – 13
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Remove fuel tank assembly (9). Refer to “Fuel Tank
Removal" in this section.
2. Disconnect the quick connector (6) of the fuel tube from fuel
gauge unit.
3. Disconnect the quick connector (10) of the evapo tube from
fuel gauge unit.
3. Remove the retainer ring (7) from the fuel tank with the
removal tool 5-8840-2602-0.
4. Remove slowly the fuel gauge unit (4) from the fuel tank as
no bend float arm.
NOTE: Cover opening for the fuel gauge unit on fuel tank to
prevent any dust entering.
5. Discard fuel gauge unit seal (8) because it cannot be
reusable.
140R100035
Installation
1. Clean the seal surface of the fuel tank and the fuel gauge
unit.
NOTE: If there is dust on the seal surface, it becomes cause of
fuel leak.
2. Install the new fuel gauge unit seal (8) to opening of the fuel
tank as along the groove.
3. Install slowly the fuel gauge unit (4) into the fuel tank as no
bend float arm.
4. Set flange of the fuel gauge unit on fuel gauge unit seal as
mating convexity of the fuel gauge unit and reentrant of the
fuel tank.
5. Lock slowly the retainer ring (7) to the fuel tank with the
remover tool 5-8840-2602-0.
6. Connect the quick connector (10) of the evapo tube from
fuel gauge unit.
7. Connect the quick connector (6) of the fuel tube to to gauge
unit.
NOTE: Pull off the left ckecker of the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.
6C – 14 FUEL SYSTEM
8. Check leak.
Methed of leak check.
(1) Plug end of quick connector and breather hose (Pull off
the breather hose from fuel tank) and tighten fuel filler
cap until at least one click are heard.
(2) Apply water soap around the fuel gauge unit seal area.
(3) Pressure air into the fuel tank from end of breather pipe
2
at 5psi (34.3 kPa/2.8kgf/cm ) over 15 seconds.
(4) Verify no bubbles around the fuel gauge unit seal area.
9. Install the fuel tank assembly (9).
NOTE: Refer to “Install the fuel tank” in this section.
FUEL SYSTEM 6C – 15
FUEL TUBE / QUICK – CONNECTOR FITTINGS
Precautions
· Do not light a match or create a flame.
· Keep flames away from your work area to prevent
flammable materials from catching fire.
· Disconnect battery ground cable to prevent electrical shorts.
· Pre-treat piping system or associated parts from thermal
damage or from spattering when welding or similar
heat-generating work.
140R100032
Legend
(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube
Removal
1. Open the fuel cap to relieve the fuel pressure in the tank.
Use compressed air to remove any dirt on the fuel quick
connect fittings prior to disconnecting the fittings.
When disconnecting the fuel pipe, cover the area with a
cloth to prevent fuel from splashing as the fuel pipe may
still have some pressure in it.
141R100002
6C – 16 FUEL SYSTEM
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connector with the
other hand while pressing the square relieve button of the
connector, as illustrated.
NOTE: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light oil)
and/or push and pull the connector until the pipe is
disconnected.
140R100037
140R100028
Reuse of Quick–Connector
· Replace the port and connector if scratch, dent or crack is
found.
· Remove any dirt build up on the port when installing the
connector. Replace the connector, if there is any forms of
rust, dent, scratch.
· After cleaning the port, insert it straight into the connector
until it clicks. After it clicks, try pulling at 49N (5kgf) it out to
make sure that it is not drawn and is securely locked.
140R100036
Assembling Advice
By applying engine oil or light oil to the pipe, port makes pipe
assembly easier. The pipe assembly should take place
immediately after applying oil (to prevent dust from sticking to
the pipe surface – which may decrease sealing ability).
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Start the engine and observe the engine idle speed. The
presence of dirt in the fuel system may affect the fuel
injection system.
3. Check for fuel leakage from the connector.
FUEL SYSTEM 6C – 17
FILLER NECK
Removal
1. Remove the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
2. Put a marking the following point as the filler neck assembly
is restored.
· Each joint area of the hose (to restore axial direction and
insertion length of the hose)
· Each fasten area of the clamp (to restore axial direction
and position of the clamp)
· Each bolt in the clamp (to restore fasten length of bolt in
the clamp)
· The band clip (to restore position and fasten length of
the band clip)
NOTE: Cover end of each hose and pipe to prevent any dust
entering.
Installation
1. Align each marking and restore the following point.
· Each joint area of the hose (Restore axial direction and
insertion length of the hose)
· Each fasten area of the clamp (Restore axial direction
and position of the clamp)
· Each bolt in the clamp (Restore fasten length of bolt in
the clamp)
Torque N·m (kg·m / lb ft)
2.5 (0.25 / 21.7)
General Description
A vacuum valve and pressure valve are built into the fuel filler
cap which adjusts the fuel pressure in the fuel tank to prevent
fuel tank damage.
RTW36CSH000401
Legend
(1) Pressure Valve
(2) Vacuum Valve
(3) Seal Ring
Inspection
The fuel filler cap must be inspected for seal condition.
The fuel filler cap must be replaced if found defective
Removal
1. Battery
Remove the battery from the battery tray.
6C-1
2. Drive Belt
1) Loosen the adjust bolt of the power steering pump
pulley.
2) Remove the drive belt.
3. Power Steering Pump Assembly
P1010003
5. Vacuum Hose
Disconnect the vacuum hose from the EGR valve and the
intake throttle.
6. Fan
6C – 20 FUEL SYSTEM
7. Power Steering Pump Bracket
6C-4
6C-5
RTW46CSH000201
3) Insert the lock bolt (M6 x 30) into the scissors gear idle
gear “B” fixing hole to prevent the scissors gear from
turning.
6C-7
020L200017
6C-7
FUEL SYSTEM 6C – 23
4JA1T (L)
RTW46CSH000101
080L200009
Disassembly Steps
1. Retaining nut 9. Collar
2. Nozzle & pin 10. Spring seat
3. Spacer & pin 11. First spring
4. Lift Piece 12. Shim (First nozzle opening
pressure adjustment)
5. Spring seat 13. Nozzle holder body
6. Push rod 14. Eye bolt
7. Shim (Second nozzle opening 15. Gasket
pressure adjustment)
8. Second spring
Important Operations
Injection nozzle adjustment is possible only on the 4JA1L
engine.
The two-spring nozzle holder has been developed to
reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
Before disassembly remove carbon deposit from nozzle
and nozzle holder using a wire brush and wash the outside
nozzle holder assembly.
Caution:
Do not touch nozzle holes with the wire brush during
cleaning it.
Disassemble the nozzle holder assembly to numerical
order.
FUEL SYSTEM 6C – 27
REASSEMBLY
080L200010
Reassembly Steps
1. Nozzle holder body 9. Spring seat
2. Shim (First opening pressure 10. Lift Piece
adjustment)
3. First spring 11. Spacer & pin
4. Spring seat 12. Nozzle & pin
5. Collar 13. Retaining nut
6. Second spring 14. Gasket
7. Push rod 15. Eye bolt
8. Shim (Second opening pressure
adjustment)
Important Operations
The nozzle holder is adjusted as the components are
reassembled in the sequence above.
As adjustment of the two-spring nozzle holder is made in
hundredths of a millimeter, clean the parts thoroughly in
light oil to completely remove any dirt or foreign matter.
6C – 28 FUEL SYSTEM
REASSEMBLY AND ADJUSTMENT PROCEDURE
1 Adjust the first nozzle opening pressure using the shim.
First nozzle opening pressure adjustment
4 Second nozzle opening pressure Confirm the second nozzle opening pressure in accordance
confirmation with the closed method.
5 Second nozzle opening pressure Adjust the second nozzle opening pressure using the shim.
adjustment
6 Confirm the condition of the fuel spray with the nozzle and
Final inspection nozzle holder assembled.
040MV015.tif
040MV016.tif
040MV017.tif
040MV018.tif
6C – 30 FUEL SYSTEM
5. Install the pins in the spacer.
6. Install the nozzle on the spacer.
040MV019.tif
040MV010.tif
040MV014-1.tif
CAUTION:
• Use a micrometer to measure shim thickness.
040MV030.tif
FUEL SYSTEM 6C – 31
• First nozzle opening pressure adjusting shims
Parts No. (ISUZU) Thickness (mm)
115349-0420 0.40
115349-0430 0.50
115349-0440 0.52
115349-0450 0.54
115349-0460 0.56
040LX010.tif
115349-0470 0.58
115349-0480 0.60
115349-0490 0.70
040MV013.tif
040MV012.tif
040MV011.tif
6C – 32 FUEL SYSTEM
4. Install the pin to the dial gauge.
Note:
The lengths of the pins do not include the
threaded portions.
Pin (L=100 mm): 157892-5200 (Bosch AS)
Dial gauge: 157954-3800 (Bosch AS)
185317-0150 (ISUZU)
040MV029.tif
CAUTION:
• Secure the dial gauge so that a stroke of 2 mm can
be measured.
• Do not over-tighten the nut as the dial gauge shaft
may jam. (Confirm from the dial gauge that the
shaft moves smoothly.)
040MV009.tif
040MV030.tif
FUEL SYSTEM 6C – 33
8. Operate the nozzle tester and increase the in-line
2
pressure to 34.3 - 44.1 MPa (350 - 450 kg/cm ) so that
the nozzle’s needle valve moves through its full lift.
Record full lift ‘L’. (Read dial gauge)
Nozzle Full Lift mm (in)
0.25 H 0.02 (0.0098 H 0.00008)
Note:
The above operation is used to determine whether
040MV008.tif
the nozzle seat is worn and whether the nozzle
assembly is in good condition.
Pre-lift confirmation
1. With the needle valve at full lift, release the nozzle
tester handle.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
040MV007.tif
040R300008
6C – 34 FUEL SYSTEM
2. Read the needle valve “pre-lift” point from the dial
gauge indication (once the needle valve has
descended when the second spring has stopped
operating).
Pre-lift measuring point:
Read the dial gauge at first nozzle opening pressure +approx
2
1 MPa (10 kg/cm ).
Pre-lift mm
Pressure Mpa
2
(psi/ kg/cm ) Lift mm (in)
040H100007
4JA1T(L) 20.1 (2,858/205) 0.04 (0.0016)
Note:
This point can be found while the pressure is
decreasing.
040MV005.tif
040MV031.tif
040MV030.tif
FUEL SYSTEM 6C – 35
2. Release the nozzle tester handle so that in-line
pressure decreases.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
040MV022.tif
Pressure Mpa
2 Lift mm (in)
(psi/ kg/cm )
4JA1T(L) 25.5-27.0 0.09 (0.0035)
(3768-3911/260-275)
040M100006
6C – 36 FUEL SYSTEM
Second nozzle opening pressure adjustment
If the second nozzle opening pressure is not as specified,
disassemble the nozzle from the nozzle holder and
replace the shim until the pressure is as specified.
CAUTION:
• Because the second opening pressure changes
when the first opening pressure changes, the
second opening pressure must be adjusted when
the first opening pressure changes.
• Use a micrometer to measure shim thickness.
040MV017.tif • Use some combination of 3 adjusting shims to
adjust the pressure.
Final inspection
1. Remove the dial gauge, nut and dial gauge holder.
040MV028.tif
040MV014-1.tif
FUEL SYSTEM 6C – 37
4. Set the nozzle holder to the nozzle tester and check
first nozzle opening pressure, spray condition, seat oil
tightness and each part for oil leaks.
5. When replacing the nozzle, replace the nozzle, lift
piece, pins and spacer as a set with the nozzle service
kit.
CAUTION:
Pre-lift will not be as specified if only the nozzle is
replaced.
040MV030.tif
6C – 38 FUEL SYSTEM
SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER TOOL NAME
5-8840-2602-0
Remover: fuel pump retainer ring
(J-39765)
ENGINE ELECTRICAL 6D – 1
SECTION 6D
ENGINE ELECTRICAL
TABLE OF CONTENTS
PAGE
Main Data and Specifications ......................................................................................... 6D - 2
General Description......................................................................................................... 6D - 3
Torque Specifications ..................................................................................................... 6D - 5
Generator.......................................................................................................................... 6D - 7
Removal and Installation ............................................................................................ 6D - 7
Disassembly................................................................................................................. 6D - 9
Inspection and Repair ................................................................................................. 6D - 12
Reassembly.................................................................................................................. 6D - 18
Starter Motor .................................................................................................................... 6D - 22
Removal and Installation ............................................................................................ 6D - 22
Disassembly................................................................................................................. 6D - 23
Inspection and Repair ................................................................................................. 6D - 26
Reassembly.................................................................................................................. 6D - 29
Pre-heating System ......................................................................................................... 6D -33
Inspection and Repair ................................................................................................. 6D -33
Glow Relay ................................................................................................................... 6D -33
Glow Plug..................................................................................................................... 6D -33
EGR System ................................................................................................................. 6D -33
6D – 2 ENGINE ELECTRICAL
Generator
Type AC generator with IC regulator and vacuum pump
Hitachi LR160-503E Hitachi LR180-513B
Voltage V 12
Drive and rotation V-belt, clockwise viewed from the drive pulley
Ground polarity Negative
Maximum output A 60 80
Engine speed ratio to 1 1.788
Maximum speed rpm 11,000
Weight with vacuum pump kg(lb) 5.8(12.8) 6.4(14.1)
Vacuum Pump
3
Delivery volume cm /rev 50
Exhaust Characteristic -66.7 kPa (-500 mmHg) bulid up time 21 seconds or less at 1,000
rpm
GENERAL DESCRIPTION
GENERATOR STARTER MOTOR
066L300004 065L300002
The basic charging system is the IC integral regulator charging system. The internal components are connected
electrically as shown in charging circuit diagram.
The generator features a solid state regulator that is mounted inside the generator. All regulator components are
enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the slip ring end frame.
The generator voltage setting cannot be adjusted.
The starter motor circuit is composed of a 4-pole 4-brush type direct current series motor. The starter motor circuit
utilizes negative ground polarity.
6D – 4 ENGINE ELECTRICAL
RTW46DSH005101
RTW46DSH005501
ENGINE ELECTRICAL 6D – 5
TORQUE SPECIFICATIONS
GENERATOR N m (kg m/Ib ft)
RTW46DLF000201
6D – 6 ENGINE ELECTRICAL
RTW46DLF000301
ENGINE ELECTRICAL 6D – 7
GENERATOR
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
Important Operations-Removal
Cooling Fan Belt
1. Disconnect the battery cables at the battery terminals.
2. Loosen and remove the fan belt adjusting plate bolts.
3. Remove the fan belt from the generator drive pulley.
Generator
P1010002
1. Remove the vacuum pump hose.
2. Remove the generator bolt and the generator from the
bracket.
Important Operations-Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.
Generator
1. Install the generator to the bracket.
2. Tighten the generator bolt to the specified torque.
3. Install the vacuum pump hose.
033RY00009
3. Adjust the fan belt tension
Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98N (10
kg/22 Ib) force.
Cooling Fan Drive Belt Deflection mm (in)
New belt 4 - 7 (0.16 - 0.28)
Reuse belt 6 - 9 (0.24 - 0.35)
DISASSEMBLY
RTW46DLF000401
Disassembly Step
1. Vacuum pump
2. O-ring
3. Through bolt
4. B Terminal nut
5. Rear cover
6. Pulley
7. Rotor assembly
8. Front cover assembly
9. Rear rotor bearing
10. Rectifier assembly
11. Stator assembly
12. Rotor assembly
6D – 10 ENGINE ELECTRICAL
Important Operations
1. Vacuum Pump
1. Loosen the vacuum pump fixing screws.
2. Support the vacuum pump O-ring.
3. Carefully remove the O-ring.
2. Cover
RTW46DSH000101
3. Through Bolt
1. Remove the M5 through bolt.
2. Separate the front and rear sides of the vacuum pump.
3. Insert the tips of 2 ordinary screwdrivers into the space
between the front cover and the stator core. Remove
the front cover and rotor together with the rear cover
and stator.
If removal is difficult, push the rear cover to the side and
lightly tap the end of the shaft with a plastic hammer to
loosen it.
· The front cover oil seal must be replaced with a new
one when the front cover is removed.
RTW46DSH000201
· Take care not to damage the stator core with the
screwdriver tips.
RTW46DSH000601
4. Pulley
1. Carefully clamp the rotor assembly in a vise.
2. Loosen the pulley nut.
3. Remove the pulley and the front cover from the rotor.
RTW46DSH002101
ENGINE ELECTRICAL 6D – 11
7. Rotor Assembly
1. Remove the rotor from front cover assembly.
RTW46DSH000301
RTW46DSH000701
RTW46DSH000801
RTW46DSH000401
6D – 12 ENGINE ELECTRICAL
ROTOR ASSEMBLY
1. Inspect the slip ring faces for dirt and pitting.
Wipe away any dirt with a clean cloth soaked in
alcohol.
2. Measure the slip ring diameter.
Slip Ring Diameter mm (in)
Standard Limit
31.6 (1.245) 30.6 (1.183)
RTW06DSH000101
If the slip ring diameter is less than the specified limit, the
slip rings must be replaced.
RTW46DSH001001
RTW46DSH001101
ENGINE ELECTRICAL 6D – 13
066RY00022
066RY00023
BRUSH
Measure the length of the brush. If abrasion has reduced
the brush length to less than 6.5 mm, the brush must be
replaced with a new one.
A wear line is inscribed in the brush. If the line is not
visible, the brush must be replaced.
Brush Length (Reference) mm (in)
Standard Limit
RTW46DSH004801 25 (1.0) 6.5 (0.25)
Rectifier
RTW46DSH001201
Tester wire
⊕ ⊕
E BAT
U, V, and WN U, V, and WN
⊕ ⊕
No
----- Conductivity -----
conductivity
No
----- Conductivity -----
conductivity
Negative side diode check Positive side diode check
6D – 14 ENGINE ELECTRICAL
RECTIFIER ASSEMBLY
RTW46DSF000301
1. Voltmeter
2. Switch 1
3. DC regulated power supply
4. Lamp 2
5. Lamp 1
6. Switch 3
7. Switch 2
8. Pulse generator
9. Output signal
Test circuit
Refer to the judgment criteria shown in the Table below.
Carefully check Items 1~5. If all the items are OK, the IC
regulator is normal.
Circuit components
1 DC regulated power supply 0~20 volts variable with output of 1 ampere or more
2 Lamps (2) 12 volts, 1.4~3.4 watts
3 Switches (3) -----
4 DC voltmeter 0~30 volts, 0.5 grade
5 Pulse generator (Oscillator) 5~30 volt output at a frequency of 1kHz
Judgment criteria
Switch Switch Switch Voltmeter Lamp condition
No. Remarks
1 2 3 reading Lamp 1 Lamp 2
On
1 ON OFF OFF ON Initial excitation check
(dim)
12V
On or
2 ON ON OFF Full excitation check
flashing
OFF Lamp 1 off or dimly lit when the
Off or
3 ON ON OFF 16V voltmeter shows less than 12 volts or
on (dim)
16 volts
On or
4 OFF ON OFF 12V Stator and brush separation check
flashing ON
5 ON ON ON 18V On Excess voltage check
ENGINE ELECTRICAL 6D – 15
Oil seal
The oil seal must be replaced with a new one whenever
the alternator is disassembled.
RTW46DSF000101
6D – 16 ENGINE ELECTRICAL
Vacuum Pump
Vacuum Pump Disassembly
1. Remove the center plate from the vacuum pump
housing.
2. Remove the vacuum pump rotor and the vanes from
the housing.
RTW46DSH000901
Inspection
Vacuum Pump Housing and Center Plate
Inspect the vacuum pump housing and the center plate for
excessive wear, abrasion, and scoring.
If any of these conditions are present, the vacuum pump
housing and center plate must be replaced.
Vane
Inspect the vanes for excessive wear and damage.
Replace all four vanes if either of these conditions are
present.
Never replace only one vane.
Rotor
1. Inspect the rotor for excessive wear, abrasion, and
scoring.
Pay particular attention to the internal spline.
Replace the rotor if any of these conditions are
present.
2. Inspect the generator rotor shaft splines for backlash.
Replace the rotor if backlash is present.
Check Value
1. Carefully force the valve from the “B” side as shown in
the illustration.
The valve must move smoothly.
If it does not, the check valve must be replaced.
2. Apply compressed air to the “A” side.
2
Air Pressure kPa (kg/cm /psi)
98 - 490 (1-5/14 – 71)
RTW46DSH001801
2. Install the rotor with the concave side facing the center
plate.
RTW46DSH001901
RTW46DSH002001
6D – 18 ENGINE ELECTRICAL
REASSEMBLY
RTW46DLF000501
Reassembly Step
1. Front cover
2. Rear rotor bearing
3. Rotor Assembly
4. Pulley
5. Rectifier Assembly
6. Stator Assembly
7. Rear cover
8. B Terminal nuts
9. Through bolt
10. O-ring
11. Vacuum pump
ENGINE ELECTRICAL 6D – 19
Important Operations
2. Rear rotor bearing
· Re-use improper parts.
RTW46DSH000401
5. Rectifier
6. Stator
Use a pair of long-nose plier to connect the stator coil
leads and the rectifier leads.
Finish the work as quickly as possible to prevent the
rectifier from heat transferred by the soldering.
3. Rotor Assembly
4. Pulley Assembly
Clamp the rotor in a vise and install the pulley nut.
Pulley Nut Torque N×m (kg×m/lb×ft)
83.3 ~ 98.0 (8.5 ~ 10.0 / 61 ~ 72)
RTW46DSH002101
RTW46DSH006001
RTW46DSH004901
6D – 20 ENGINE ELECTRICAL
RTW46DSH002201
Insert the pin from the outside of the rear cover. Press the
brushes into the brush holder. Complete the assembly
procedure.
RTW46DSH005301
ENGINE ELECTRICAL 6D – 21
9. Through Bolt
1. Place a pilot bar into the through bolt hole to align the
front cover and the rear cover.
2. Install the through bolts and tighten them to the
specified torque.
Through Bolt Torque N×m (kg×m/lb×ft)
3.1 ~ 3.9 (0.32 ~ 0.41 / 2.6 ~ 3.5)
RTW06DSH000201
RTW46DSH006101
RTW46DSH002401
Install the housing in the generator and fix it with the three
bolts.
Supply engine oil (5cc or so) from the oil port and check
that the generator pulley can be turned smoothly with your
hand.
Generator Housing Bolt Torque N×m (kg×m/lb×ft)
5.9 ~ 6.9 (0.6 ~ 0.7 / 5.2 ~ 6.1)
RTW46DSH002501
6D – 22 ENGINE ELECTRICAL
STARTER MOTOR
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
Starter Motor
1. Install the starter motor to the rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque N×m (kg×m/lb×ft)
85 (8.7/63)
DISASSEMBLY
RTW460LF000201
Disassembly Step
1. Lead wire 14. Armature
2. Bolt 15. Bolt
3. Magnetic switch assembly 16. Bearing retainer
4. Torsion spring 17. Pinion assembly
5. Plunger 18. Pinion stopper clip
6. Dust cover 19. Pinion stopper
7. Magnetic switch 20. Return spring
8. Screw 21. Pinion shaft
9. Through bolt 22. Clutch
10. Rear cover 23. Dust cover
11. Motor assembly 24. Shift lever
12. Brush holder 25. Gear case
13. Yoke
6D – 24 ENGINE ELECTRICAL
Important Operations
1. Lead Wire
Disconnect the lead wire at the magnetic switch.
RTW46DSH002601
RTW46DSH002701
RTW46DSH002801
8. Through Bolt
9. Screw
10. Rear Cover
Remove the through bolts, then remove the rear cover.
RTW46DSH002901
RTW46DSH003001
ENGINE ELECTRICAL 6D – 25
Remove the yoke along with the armature and the brush
holder from the gear case.
Remove the brushes and commutator carefully so as not
to allow them in contact with the adjacent parts.
RTW46DSH003101
RTW46DSH003201
RTW46DSH003301
RTW46DSH003401
6D – 26 ENGINE ELECTRICAL
ARMATURE
1. Measure the commutator run-out.
Replace the commutator if the measured run-out
exceeds the specified limit.
Commutator Run-Out mm (in)
Standard Limit
0.05 (0.002) 0.2 (0.008)
RTW46DSH003501
065RY00026
5. Use a circuit tester to check the armature for
grounding.
1 Hold one probe of the circuit tester against the
commutator segment.
2 Hold the other circuit tester probe against the
armature core.
If the circuit tester indicates continuity, the armature is
grounded.
The armature must be replaced.
RTW46DSH003601
ENGINE ELECTRICAL 6D – 27
RTW46DSH003701
YOKE
1. Use a circuit tester to check the field winding ground.
1 Hold one circuit tester probe against the field
winding end or brush.
2 Hold the other circuit tester probe against the bare
surface of the yoke body.
There should be no continuity.
If there is continuity, the field coil is grounded.
The yoke must be replaced.
RTW46DSH003801
RTW46DSH003901
6D – 28 ENGINE ELECTRICAL
065RY00035
BEARING
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.
RTW46DSH004401
ENGINE ELECTRICAL 6D – 29
REASSEMBLY
RTW46DLF000601
Reassembly Steps
1. Magnetic switch assembly 14. Pinion stopper
2. Magnetic switch 15. Pinion stopper clip
3. Dust cover 16. Bearing retainer
4. Plunger 17. Bolt
5. Torsion spring 18. Motor assembly
6. Shift lever 19. Armature
7. Gear case 20. Yoke
8. Dust cover 21. Brush holder
9. Bolt 22. Rear cover
10. Pinion assembly 23. Screw
11. Clutch 24. Through bolt
12. Pinion shaft 25. Lead wire
13. Rerurn spring
6D – 30 ENGINE ELECTRICAL
Important Operations
1. Magnetic Switch Assembly
1. Attach the torsion spring to the hole in the magnetic
switch as illustrated.
2. Insert the shift lever into the plunger hole of the
magnetic switch.
RTW46DSH005601
7. Gear Case
3,8. Dust Cover
1. Install the magnetic switch assembly in the gear case.
2. Install the dust cover.
RTW46DSH005701
065RY00041
RTW46DSH004501
ENGINE ELECTRICAL 6D – 31
065RY00044
RTW46DSH002601
RTW46DSH005801
6D – 32 ENGINE ELECTRICAL
MAGNETIC SWITCH
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “M”
terminal.
To prevent coil burning, complete each test as quickly as
possible (within three to five seconds).
RTW46DSH004601
RTW46DSH005901
3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.
RTW46DSH004701
ENGINE ELECTRICAL 6D – 33
PRE-HEATING SYSTEM
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacement if excessive wear of damage is discovered during
inspection.
VISUAL CHECK
Check the main fuses and glow indicator for damage.
Replace the part(s) if required.
GLOW RELAY
The glow relay is located in the relay box the engine
compartment.
Use an ohmmeter to measure the resistance between
terminals No.2 and No.3.
If the measured value is outside the specified range, the
glow relay must be replaced.
Glow Relay Resistance Ohms
94 - 114
825R300046
GLOW PLUG
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference) Ohms
Approximately 0.9
LNW21KSH001401
MEMO
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–1
ENGINE
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
ABBREVIATION CHARTS
Abbreviations Appellation
A/C Air conditioner
A/T Automatic transmission
ACC Accessory
BLK Black
BLU Blue
BRN Brown
CAN Controller Area Network
CEL Check engine lamp
CKP Crankshaft position sensor
DLC Data link connector
DTC Diagnosis trouble code
DVM Digital voltage meter
ECM Engine control module
ECT Engine coolant temperature
EEPROM Electrically erasable & programmable read only memory
EGR Exhaust gas recirculation
EVRV Electric vacuum regulating valve
GND Ground
GRY Gray
IAT Intake air temperature
IG Ignition
M/T Manual transmission
MAB High pressure solenoid valve cutoff (German abbreviation)
MAF Mass air flow
MIL Malfunction indicator lamp
OBD On-board diagnostic
ORN Orange
PNK Pink
RED Red
PSG Pump control unit (German abbreviation)
SW Switch
TCM Transmission control module
TCV Timing control valve
TDC Top dead center
TPS Throttle position sensor
VCC Voltage constunt control
VIO Violet
VSS Vehicle speed sensor
WHT White
YEL Yellow
6E–10 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
COMPONENT LOCATOR
Engine Component Locator Table
4JA1-TC
3 1 2 6 4 5
(1) Mass Air Flow (MAF) & Intake Air Temperature (4) Battery
(IAT) Sensor Assembly (5) Relay & Fuse Box
(2) Throttle Cable (6) EGR Cooler
(3) Air Cleaner Case
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–11
4JH1-TC
4 5
2 6 4
3 1
(1) Mass Air Flow (MAF) & Intake Air Temperature (4) Battery
(IAT) Sensor Assembly (5) Relay & Fuse Box
(2) Throttle Cable (6) EGR Cooler (Euro3) / EGR Pipe (Except Euro3)
(3) Air Cleaner Case
6E–12 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
3 2 4
2 3 1
(1) Mass Air Flow (MAF) & Intake Air Temperature (3) Air Cleaner Case
(IAT) Sensor Assembly
(2) EGR EVRV
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–13
3 2 1
2 1
CONNECTOR LIST
No. Connector face No. Connector face
B-24 C-56
Natural
green Neutral switch White Engine room ~ INST
E-12 H-18
Natural
green Neutral switch White Engine room ~ INST
E-22 H-22
LHD
RHD
6E–44 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
RELAY AND FUSE BOX LOCATION (LHD & RHD)
RELAY & FUSE BOX
RELAY
RELAY
No.
(4JA1-TC/4JH1-TC)
X-1 RELAY; TAIL LIGHT
X-2 RELAY; FRT FOG LIGHT
X-3 RELAY; HORN
X-4 RELAY; DIMMER
X-5 RELAY; GLOW
X-6 RELAY; COND, FAN
X-7 RELAY; RR FOG
X-8 RELAY; STARTER
X-9 SHORT CONNECTOR
(with Cooler) (LHD)
RELAY; HAZARD-RH (RHD)
X-10 SHORT CONNECTOR
(with Cooler) (LHD)
RELAY; HAZARD-LH (RHD)
X-11 RELAY; HEATER
X-12 RELAY; HEAD LIGHT
X-13 RELAY; ECM MAIN
X-14 RELAY; A/C COMP
X-15 RELAY; THERMO
FUSE
FUSE
NO.
(4JA1-TC/4JH1-TC)
EB-1 10A ECM
EB-2 10A RR FOG
EB-3 15A FRT FOG
EB-4 —
EB-5 10A ILLUMI & TAIL-RH
EB-6 10A TAIL-LH
EB-7 10A H/LIGHT RH-LOW
EB-8 10A H/LIGHT LH-LOW
EB-9 10A TRA ILER
EB-10 10A AC G (S)
EB-11 10A H/LIGHT RH-HIGH
EB-12 10A H/LIGHT LH-HIGH
EB-13 10A A/C
EB-14 10A 4WD
EB-15 10A HORN
EB-16 10A HAZARD
FUSE BOX
FUSE
No. Capacity Indication on label No. Capacity Indication on label
1 — — 12 15A CIGER
2 10A ABS 13 15A AUDIO (+B)
3 — — 14 20A DOOR LOCK
4 15A BACK UP 15 10A METER (+B)
5 15A METER 16 10A ROOM
6 10A TURN 17 10A ANTI THEFT
7 15A ELEC.IG 18 15A STOP
8 15A ENGINE 19 15A ACC SOCKET
9 20A FRT WIPER 20 10A STARTER
10 15A EGR 21 10A SRS
11 10A AUDIO
SLOW BLOW FUSE
No. Capacity Indication on label
SBF-10 20A RR DEF
SBF-11 30A POWER WINDOW
RELAY
Connector No. B-7 B-8 B-40
4JA1-TC, 4JH1-TC REAR POWER ACC
DEFOGGER WINDOW SOCKET
6E–46 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
ECM WIRING DIAGRAM (1/7)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–47
ECM WIRING DIAGRAM (2/7)
6E–48 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
ECM WIRING DIAGRAM (3/7)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–49
ECM WIRING DIAGRAM (4/7)
6E–50 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
ECM WIRING DIAGRAM (5/7)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–51
ECM WIRING DIAGRAM (6/7)
6E–52 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
ECM WIRING DIAGRAM (7/7)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–53
Pin B/Box Pin Function Wire Key SW Key SW Engine Engine ECM Range (+) (-)
No. No. Color Off On Idle 2000rpm Connec-
tion
1 1 ECM Ground BLK Continuity - - - Discon- Ohm 1 GND
with nect
ground
2 2 ECM Ground BLK Continuity - - - Discon- Ohm 2 GND
with nect
ground
3 3 Battery Power Supply BLU/ Less than 10-14V Connect DC V 3 GND
RED 1V
25 25 No Connection - - - - - - - - -
26 26 No Connection - - - - - - - - -
27 27 Engine Speed Output LGN - - Approx. Approx. Connect AC V 27 GND
(To Tacho Meter) 23Hz by 67Hz by
wave form wave form
or approx. or approx.
6.3V 6.8V
28 28 No Connection - - - - - - - - -
29 29 No Connection - - - - - - - - -
30 30 Brake Switch 1 Signal GRN Less than Pedal is not stepped on: Less than 1V Connect DC V 30 GND
1V Pedal is stepped on: 10-14V
31 31 Clutch Switch Signal YEL Less than Pedal is not stepped on: 10-14V Connect DC V 31 GND
(MT Only) 1V Pedal is stepped on: Less than 1V
32 32 No Connection - - - - - - - - -
33 33 A/C ON Signal Relay GRN/ Less than A/C request switch is turned on: 10- Connect DC V 33 GND
YEL 1V 14V
A/C request switch is turned off: Less
than 1V
34 34 No Connection - - - - - - - - -
35 35 To Data Link Connec- YEL - - - - - - - -
tor No. 6 & Immobi-
lizer Control Unit (ICU
B8)
36 36 No Connection - - - - - - - - -
37 37 No Connection - - - - - - - - -
38 38 Throttle Position Sen- GRN/ Less than Less than 1V Approx. Connect DC V 38 49
sor (TPS) Output Sig- ORG 1V 0.5V
nal
39 39 Key Switch Input Sig- WHT Less than 10-14V Connect DC V 39 GND
nal Via Engine Fuse 1V
40 40 No Connection - - - - - - - - -
6E–54 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Pin B/Box Pin Function Wire Key SW Key SW Engine Engine ECM Range (+) (-)
No. No. Color Off On Idle 2000rpm Connec-
tion
41 41 A/C Compressor WHT/ Less than 10-14V A/C comp. is operated: Connect DC V 41 GND
Relay GRN 1V Less than 1V
A/C comp. is not oper-
ated: 10 - 14V
42 42 Check Engine Lamp GRN/ Less than Lamp is turned on: Less than 1V Connect DC V 42 GND
YEL 1V Lamp is turned off: 10-14V
43 43 Glow Lamp ORG/ Less than Lamp is turned on: Less than 1V Connect DC V 43 GND
BLU 1V Lamp is turned off: 10-14V
44 44 No Connection - - - - - - - - -
45 45 To Data Link Connec- BLU Less than 10-14V Connect DC V 45 GND
tor No. 6 1V
46 46 No Connection - - - - - - - - -
47 47 No Connection - - - - - - - - -
48 48 No Connection - - - - - - - - -
49 49 Throttle Position Sen- BLK/ Idle: - - - Discon- Ohm 38 49
sor (TPS) Ground GRN Approx. nect
0.4K ohm /
WOT:
Approx.
4.0K ohm
50 50 No Connection - - - - - - - - -
51 51 No Connection - - - - - - - - -
52 52 No Connection - - - - - - - - -
53 53 No Connection - - - - - - - - -
54 54 No Connection - - - - - - - - -
55 55 No Connection - - - - - - - - -
56 56 No Connection - - - - - - - - -
57 57 Throttle Position Sen- RED/ Less than Approx. 5V Connect DC V 57 49
sor (TPS) Power Sup- GRN 1V
ply
58 58 ECM Relay BLU/ 10-14V Less than 1V Connect DC V 58 GND
BLK
59 59 No Connection - - - - - - - - -
60 60 No Connection - - - - - - - - -
61 61 No Connection - - - - - - - - -
62 62 No Connection - - - - - - - - -
63 63 ECM Power Supply Less than 10-14V - DC V 63 GND
1V
64 64 No Connection - - - - - - - - -
65 65 Brake Switch 2 Signal WHT/ Less than Pedal is not stepped on: 10-14V Connect DC V 65 GND
BLK 1V Pedal is stepped on: Less than 1V
66 66 No Connection - - - - - - - - -
67 67 No Connection - - - - - - - - -
68 68 Vehicle Speed Sen- YEL/ - Approx. 14.5Hz by wave form or Connect AC V 68 GND
sor (VSS) GRN approx. 6.0V at vehicle speed 20km/h
69 69 Idle Switch GRN/ Less than Pedal is not stepped on: Less than 1V Connect DC V 69 GND
BLK 1V Pedal is stepped on: Approx. 5V
70 70 No Connection - - - - - - - - -
71 71 No Connection - - - - - - - - -
72 72 No Connection - - - - - - - - -
73 73 No Connection - - - - - - - - -
74 74 No Connection - - - - - - - - -
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–55
Pin B/Box Pin Function Wire Key SW Key SW Engine Engine ECM Range (+) (-)
No. No. Color Off On Idle 2000rpm Connec-
tion
75 75 No Connection - - - - - - - - -
76 76 No Connection - - - - - - - - -
77 77 No Connection - - - - - - - - -
78 78 No Connection - - - - - - - - -
79 79 No Connection - - - - - - - - -
80 80 No Connection - - - - - - - - -
81 81 No Connection - - - - - - - - -
82 82 No Connection - - - - - - - - -
83 83 Mass Air Flow (MAF) WHT/ Less than Approx. 5V Connect DC V 83 92
Sensor Power Supply RED 1V
84 84 Intake Air Tempera- BLK/ Less than 0 deg. C: Approx. 3.6V / 20 deg. C: Connect DC V 84 92
ture (IAT) Sensor Sig- BLU 1V Approx. 2.6V / 40 deg. C: Approx.
nal 1.7V / 60 deg. C: 1.1V / 80 deg. C:
0.7V
85 85 No Connection - - - - - - - - -
86 86 No Connection - - - - - - - - -
87 87 Neutral Switch BLK/ Less than In neutral: Less than 1V Connect DC V 87 GND
WHT 1V Other than neutral: 10-14V
88 88 Mass Air Flow (MAF) GRN/ Less than Approx. 1V Approx. Approx. Connect DC V 88 92
Sensor Signal RED 1V 1.8V 2.5V
89 89 Engine Coolant Tem- GRY Less than 0 deg. C: Approx. 4.4V / 20 deg. C: Connect DC V 89 93
perature (ECT) Sen- 1V Approx. 3.8V / 40 deg. C: Approx.
sor Signal 2.9V / 60 deg. C: 2.1V / 80 deg. C:
1.4V
90 90 CKP Sensor Signal RED - - Approx. Approx. Connect AC V 90 98
47Hz by 134Hz by
wave form wave form
or approx.
1.1V
91 91 CKP Sensor Output PNK - - Approx. Approx. Connect AC V 91 GND
To Pump Control Unit 47Hz by 134Hz by
(PSG) No.8 wave form wave form
or approx.
0.7V
92 92 Mass Air Flow (MAF) BLK/ Continuity - - - Connect Ohm 92 GND
Sensor Ground RED with
ground
93 93 Engine Coolant Tem- BLK/ Continuity - - - Connect Ohm 93 GND
perature (ECT) Sen- PNK with
sor Ground ground
94 94 Glow Relay BLK/ Less than Glow system is operated: Less than Connect DC V 94 GND
RED 1V 1V
Glow system is not operated: 10 - 14V
95 95 No Connection - - - - - - - - -
96 96 No Connection - - - - - - - - -
97 97 EGR EVRV BLK/ - - Approx. 140Hz by wave - - - -
ORG form when EVRV is
operated
98 98 CKP Sensor Ground WHT Continuity - - - Connect Ohm 98 GND
with
ground
99 99 CAN (Controller Area BLU - - - - - - - -
Network) to PSG No.1
100 100 CAN (Controller Area YEL - - - - - - - -
Network) to PSG No.2
6E–56 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Pin B/Box Pin Function Wire Key SW Key SW Engine Engine ECM Range (+) (-)
No. No. Color Off On Idle 2000rpm Connec-
tion
101 101 CKP Sensor Shield BLK Continuity - - - Connect Ohm 101 GND
Line with
ground
102 102 No Connection - - - - - - - - -
103 103 No Connection - - - - - - - - -
104 104 No Connection - - - - - - - - -
105 105 Solenoid Valve Shut ORG - - - - - - - -
Off (MAB) Output Sig-
nal to PSG No.5
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–57
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into PSG Case
Pin B/ Pin Function Wire Key SW Key SW Engine Engine ECM & Rang (+) (-)
No. Box Color Off On Idle 2000rpm PSG Con- e
No. nection
3 - No Connection - - - - - - - - -
4 - No Connection - - - - - - - - -
9 - No Connection - - - - - - - - -
6E–58 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
4JH1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into ECM Case
Pin B/ Pin Function Wire Key SW Key SW Engine Engine ECM Ran (+) (-)
No. Box Color Off On Idle 2000rpm Connec- ge
No. tion
25 25 No Connection - - - - - - - - -
26 26 No Connection - - - - - - - - -
28 28 No Connection - - - - - - - - -
30 30 Brake Switch 1 Sig- GRN Less Pedal is not stepped on: Less than Connect DC V 30 GND
nal than 1V 1V
Pedal is stepped on: 10-14V
31 31 Clutch Switch Signal YEL Less Pedal is not stepped on: 10-14V Connect DC V 31 GND
(MT Only) than 1V Pedal is stepped on: Less than 1V
32 32 No Connection - - - - - - - - -
33 33 A/C ON Signal Relay GRN/ Less A/C request switch is turned on: 10- Connect DC V 33 GND
YEL than 1V 14V
A/C request switch is turned off:
Less than 1V
34 34 No Connection - - - - - - - - -
36 36 No Connection - - - - - - - - -
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–59
Pin B/ Pin Function Wire Key SW Key SW Engine Engine ECM Ran (+) (-)
No. Box Color Off On Idle 2000rpm Connec- ge
No. tion
37 37 No Connection - - - - - - - - -
40 40 No Connection - - - - - - - - -
41 41 A/C Compressor WHT/ Less 10-14V A/C comp. is oper- Connect DC V 41 GND
Relay GRN than 1V ated: Less than 1V
A/C comp. is not oper-
ated: 10 - 14V
42 42 Check Engine Lamp GRN/ Less Lamp is turned on: Less than 1V Connect DC V 42 GND
YEL than 1V Lamp is turned off: 10-14V
43 43 Glow Lamp ORG/ Less Lamp is turned on: Less than 1V Connect DC V 43 GND
BLU than 1V Lamp is turned off: 10-14V
44 44 No Connection - - - - - - - - -
46 46 No Connection - - - - - - - - -
47 47 No Connection - - - - - - - - -
48 48 No Connection - - - - - - - - -
50 50 No Connection - - - - - - - - -
51 51 No Connection - - - - - - - - -
52 52 No Connection - - - - - - - - -
53 53 No Connection - - - - - - - - -
54 54 No Connection - - - - - - - - -
55 55 No Connection - - - - - - - - -
56 56 No Connection - - - - - - - - -
59 59 No Connection - - - - - - - - -
60 60 No Connection - - - - - - - - -
61 61 No Connection - - - - - - - - -
62 62 No Connection - - - - - - - - -
6E–60 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Pin B/ Pin Function Wire Key SW Key SW Engine Engine ECM Ran (+) (-)
No. Box Color Off On Idle 2000rpm Connec- ge
No. tion
64 64 No Connection - - - - - - - - -
65 65 Brake Switch 2 Sig- WHT/ Less Pedal is not stepped on: 10-14V Connect DC V 65 GND
nal BLK than 1V Pedal is stepped on: Less than 1V
66 66 No Connection - - - - - - - - -
67 67 No Connection - - - - - - - - -
68 68 Vehicle Speed Sen- YEL/ - Approx. 14.5Hz by wave form or Connect AC V 68 GND
sor (VSS) GRN approx. 6.0V at vehicle speed
20km/h
69 69 Idle Switch GRN/ Less Pedal is not stepped on: Less than Connect DC V 69 GND
BLK than 1V 1V
Pedal is stepped on: Approx. 5V
70 70 No Connection - - - - - - - - -
71 71 No Connection - - - - - - - - -
72 72 No Connection - - - - - - - - -
73 73 No Connection - - - - - - - - -
74 74 No Connection - - - - - - - - -
75 75 No Connection - - - - - - - - -
76 76 No Connection - - - - - - - - -
77 77 No Connection - - - - - - - - -
78 78 No Connection - - - - - - - - -
79 79 No Connection - - - - - - - - -
80 80 No Connection - - - - - - - - -
81 81 No Connection - - - - - - - - -
84 84 Intake Air Tempera- BLK/ Less 0 deg. C: Approx. 3.6V / 20 deg. C: Connect DC V 84 92
ture (IAT) Sensor BLU than 1V Approx. 2.6V / 40 deg. C: Approx.
Signal 1.7V / 60 deg. C: 1.1V / 80 deg. C:
0.7V
86 86 No Connection - - - - - - - - -
87 87 Neutral Switch BLK/ Less In neutral (A/T: P or N): Less than Connect DC V 87 GND
WHT than 1V 1V
Other than neutral (A/T: other than
P or N): 10-14V
88 88 Mass Air Flow (MAF) GRN/ Less Approx. Approx. Approx. Connect DC V 88 92
Sensor Signal RED than 1V 1V 1.8V 2.5V
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–61
Pin B/ Pin Function Wire Key SW Key SW Engine Engine ECM Ran (+) (-)
No. Box Color Off On Idle 2000rpm Connec- ge
No. tion
89 89 Engine Coolant Tem- GRY Less 0 deg. C: Approx. 4.4V / 20 deg. C: Connect DC V 89 93
perature (ECT) Sen- than 1V Approx. 3.8V / 40 deg. C: Approx.
sor Signal 2.9V / 60 deg. C: 2.1V / 80 deg. C:
1.4V
94 94 Glow Relay BLK/ Less Glow system is operated: Less than Connect DC V 94 GND
RED than 1V 1V
Glow system is not operated: 10 -
14V
95 95 No Connection - - - - - - - - -
101 101 CKP Sensor Shield BLK Continu- - - - Connect Ohm 101 GND
Line ity with
ground
Pin B/ Pin Function Wire Key SW Key SW Engine Engine ECM & Rang (+) (-)
No. Box Color Off On Idle 2000rp PSG Con- e
No. m nection
3 - No Connection - - - - - - - - -
4 - No Connection - - - - - - - - -
9 - No Connection - - - - - - - - -
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–63
Crankshaft Position (CKP) Sensor Reference Wave Form Crankshaft Position (CKP) Sensor & TDC Output Signal
Reference Wave Form
CH1
0V
0V
CH2
0V
Engine Speed Output Signal Reference Wave Form Vehicle Speed Sensor (VSS) Reference Wave Form
0V 0V
100000
• Engine speed
• Fuel temperature
1000
• Pump speed
• Cylinder identifier
100
1 2
The mass air flow (MAF) sensor is part of the intake air
system.
It is fitted between the air cleaner and turbocharger and
measure the mass air flowing into the engine.
The mass air flow (MAF) sensor uses a hot film element
to determine the amount of air flowing into the engine.
The mass air flow (MAF) sensor assembly consist of a
mass air flow (MAF) sensor element and an intake air
temperature sensor that are both exposed to the air flow
to be measured.
The mass air flow (MAF) sensor element measures the
partial air mass through a measurement duct on the
sensor housing.
Using calibration, there is an extrapolation to the entire
mass air flow to the engine.
6E–66 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Throttle Position Sensor (TPS) Crankshaft Position (CKP) Sensor
1 2
1 2
(1) Throttle Position Sensor (TPS) (1) Crankshaft Position (CKP) Sensor
(2) Idle Switch (2) Fly wheel with sensor slot
2.5
2
1.5
1
0.5
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Pedal Position (%) (Tech2 Reading
2 1
100000
10000
Resistance (ohm) (Solid Line)
1000
100
10
A/T 2WD
4 5 6
1 2 3
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–69
7.1ms
Time
0.7ms
Off duty 10% =EGR Pulse Ratio 10%
7.1ms
Time
6.4ms
Off duty 90% =EGR Pulse Ratio 90%
(1) Pump Control Unit (PSG) (1) Pump Camshaft Speed Sensor
(2) Distributor Head (2) Sensor Wheel
(3) High Pressure Solenoid Valve (3) Pump Camshaft Speed Sensor Retaining Ring
(4) Constant Pressure Valve (CPV) (4) Flexible Connector Harness
(5) Radial Plunger High Pressure Pump (5) Drive Shaft
In addition high pressure generating device, the high When the drive shaft rotates, the pump camshaft speed
pressure circuit also consists of fuel piping, and devices sensor receives signal form the sensor wheel, and an
to set the beginning of injection and fuel injection electric pulse is sent through the flexible connecting
quantity. harness to the pump control unit (PSG).
From these signals the pump control unit (PSG) can
The main components are as follows. determine the average pump speed and the momentary
• High pressure generation: Radial Plunger High pump speed.
Pressure Pump The pump camshaft speed sensor is mounted to the
cam ring. Thus, the relationship between the cam ring
• Fuel distribution: Distributor Head
and the pump camshaft speed sensor signal is
• Beginning of injection timing: Timing Device constant.
• Prevention of secondary injection: Constant Pressure
Valve (CPV)
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–73
The pump camshaft speed sensor signal is utilized for High Pressure Solenoid Valve
the following purposes.
To determine the momentary angular position of the
cam ring.
To calculate the actual speed of the fuel injection pump.
To determine the actual timing plunger position.
The pump camshaft sensor signal has a tooth gap, and Fuel injection quantity control is performed from the
the crankshaft position (CKP) sensor on the flywheel beginning of pressure delivery at the beginning of cam
housing is used as a reference signal of engine top lift until the high pressure solenoid valve opens at the
dead center (TDC) for the start timing of fuel delivery or end of pressure delivery.
injection which is to be set. This interval is called the pressure delivery interval.
Accordingly, the interval that the high pressure solenoid
valve is closed determines the fuel injection quantity
(high pressure fuel supply ends when the high pressure
solenoid valve opens).
6E–74 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
When current from the pump control unit (PSG) flows to Timing Control Valve (TCV)
the high pressure solenoid valve coil, the magnet
anchor (a movable iron core) pushes the valve needle,
toward the valve seat.
When the valve seat is completely closed by the valve
needle, the way, of the fuel in the high pressure
passage to the low pressure circuit is closed.
The pressure of the fuel in the high pressure passage is
rapidly increased by radial plunger lift, and the high
pressure fuel is delivered through the constant pressure
valve (CPV) to the nozzle holder assembly and is
injected into the engine cylinder.
When the fuel injection quantity demanded by the The pressure of the fuel fed from the feed pump is
engine is reached, the current to the coil is cut and the adjusted in accordance with speed by the regulating
valve needle re-opens the valve seat. valve. This delivery pressure acts on the hydraulic
As a result of this, a path is opened for the fuel in the stopper's annular chamber as control pressure.
high pressure passage to the low pressure circuit and The chamber pressure of the annular chamber is
the pressure decreases. With a decrease in injection controlled by the timing control valve (TCV).
pressure the nozzle closes and injection ends. The timing plunger is connected to the cam ring by a
ball pin. Axial movement of the timing plunger is
transferred to the cam ring in the form of rotational
movement. Movement to the right of the timing plunger
(to the spring side) advances injection timing.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–75
Engine Load
Engine Pump Timing
Control Control Control
Engine Speed Module Unit Valve
(ECM) (PSG) (TCV)
Engine Coolant
Temperature
Pump Camshaft
Speed Sensor
(1) Coil
The engine control module (ECM) contains
(2) From Annular Chamber characteristic maps of the start of injection,
(3) To Feed Pump corresponding to engine operating conditions (engine
(4) Orifice load, engine speed and engine coolant temperature).
(5) Valve Needle The pump control unit (PSG) is constantly comparing
the set start of injection timing and the actual start of
When control current flows to the timing control valve injection timing. If there is a difference, the timing
(TCV) coil, the valve needle opens and the fuel annular control valve (TCV) is controlled by the duty ratio. (The
chamber flows through the orifice to the feed pump inlet. actual start of injection timing is determined from the
Consequently, the pressure of the annular chamber pump camshaft speed sensor.)
decreases and the hydraulic stopper is moved to the
retard side.
• Technical equipment (for viewing DTCs and – Is the power switched or is the ground
analyzing data) switched?
• Digital multimeter and circuit testing tools – Is it a variable resistance circuit (ECT sensor
or TP sensor, for example)?
• Other tools as needed
– Is it a signal generating device (MAF sensor of
VSS, for example)?
5a and 5b. Perform Service Manual – Does it rely on some mechanical/vacuum
Diagnostic Procedures device to operate?
NOTE: An estimated 40 percent of successful vehicle • Physical:
repairs are diagnosed with these steps! – Where are the circuit components (component
locators and wire harness routing diagrams):
What you should do – Are there areas where wires could be chafed
When directed by service manual diagnostic checks, or pinched (brackets or frames)?
you must then carefully and accurately perform the – Are there areas subjected to extreme
steps of diagnostic procedures to locate the fault related temperatures?
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–79
– Are there areas subjected to vibration or at the component
movement (engine, transmission or • If a number of components do no operate, begin tests
suspension)? at the area of commonality (such as power sources,
– Are there areas exposed to moisture, road salt ground circuits, switches or major connectors)
or other corrosives (battery acid, oil or other
fluids)? What resources you should use
– Are there common mounting areas with other Whenever appropriate, you should use the following
systems/components? resources to assist in the diagnostic process:
– Have previous repairs been performed to wiring, • Service manual
connectors, components or mounting areas
• Technical equipment (for data analysis)
(causing pinched wires between panels and
drivetrain or suspension components without • Experience
causing and immediate problem)? • Technical Assistance
– Does the vehicle have aftermarket or dealer- • Circuit testing tools
installed equipment (radios, telephone, etc.)
Tech 2 CONNECTION
• Turn the key switch of the vehicle ON and press
the “PWR” key of the Tech 2.
• Check the display of the Tech 2.
NOTE: Be sure to check that the power is not supplied
to the Tech 2 when attaching or removing the PCMCIA
card.
1. Configuration of Tech 2
• Tech 2 scan tool kit (No. 7000086), Tech 2 scan
tool (No. 7000057) and DLC cable (No.
3000095).
• SAE 16/19 adapter (No. 3000098) (3), RS232
loop back connector (No. 3000112) (2) and
PCMCIA card (No. 3000117) (1).
2. Tech 2 Connection
• Check the key switch is turn OFF.
• Insert the PCMCIA card (1) into the Tech 2 (5).
6E–86 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
TECH 2 OPERATING FLOW CART (START UP)
Vehicle Identification
(UB) Trooper, Bighorn
(UE) Rodeo,/Amigo, Wizard/Mu
(TF/UC) LUV, Frontier, LAO-Rodeo
(TBR)
(N*) ELF, NPR, NQR
Press (ENTER) to Continue
Symptom Code:
P0100 Present
(7) Mass Air Flow (MAF) Sensor
DTC No. Voltage Supply Circuit High Input
Symptom Code
4JA1-TC ENGINE
Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were
noted, and you have determined that the On-Board Diagnostic are functioning properly.
Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately
80 deg. C)
4JH1-TC ENGINE
Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were
noted, and you have determined that the On-Board Diagnostic are functioning properly.
Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately
80 deg. C)
1 Engine Speed rpm 675 - 725 1475 - 1975 - The engine speed is measured by ECM from the CKP
1525 2025 sensor.
2 Vehicle Speed km/h / MPH 0 0 0 This displays vehicle speed. The vehicle speed is
measured by ECM from the vehicle speed sensor.
3 Pump Speed rpm 335 - 375 725 - 775 975 - 1025 This displays injection pump speed. The injection speed is
measured by ECM from the pump cam sensor.
4 Accelerator Position % 0 3-5 5-7 Throttle position operating angle is measured by the ECM
Sensor Signal from throttle position output voltage. This should display
0% at idle and 99 - 100% at full throttle.
5 Idle Switch Active/ Active Active/ Inactive 0V This displays operating status of the idle switch. This
Inactive 0V Inactive 0V should display "Active" until the accelerator position nearly
4 - 5%.
6 Mass Air Flow mg/strk 420 - 490 380 - 460 410 - 480 This displays calculated intake air volume for one cylinder
Sensor stroke. The mass air flow is measured by ECM from the
MAF sensor output voltage.
7 Desired Mass Air mg/strk 430 - 470 380 - 420 410 - 470 This displays desired intake air volume for one cylinder
Flow stroke. The desired mass air flow is calculated by ECM
depending on engine condition.
8 Barometric Pressure hpa Depends Depends Depends The barometric pressure is measured by ECM from the
on altitude on altitude on altitude sensor in the ECM. This data is changing by altitude.
9 Desired Injection mg/stk 6 - 10 6 - 10 7 - 11 This displays desired value from the ECM. The ECM
Quantity compensates for fuel rate by throttle position and various
sensor signals.
10 Injection Quantity mg/stk 6 - 10 6 - 10 7 - 11 This displays calculated actual fuel quantity from the PSG.
The PSG receives desired injection quantity from the ECM.
And, it compensates actual injection depending on timer
position to determine duration of the high pressure
solenoid valve operation.
11 Desired Fuel Injection deg. CA 1-3 2-4 3-5 This displays desired injection timing from the ECM. The
Start ECM compensates for fuel injection timing by throttle
position and various sensor signal.
12 Actual Injection Start deg. CA 1-3 2-4 3-5 This displays calculated actual injection timing based on
CKP signal and pump cam signal. The PSG controls TCV
duty ratio to meet desired injection timing from the ECM.
13 Coolant Temperature deg. C / deg. 80 - 85 80 - 85 80 - 85 The ECT is measured by ECM from ECT sensor output
F voltage. This data is changing by coolant temperature.
When the engine is normally warm upped, this data
displays approximately 80 deg. C.
14 Fuel Temperature deg. C / deg. Depends Depends Depends The FT is measured by PSG from FT sensor. This data is
F on fuel on fuel on fuel changing by fuel temperature.
temp. temp. temp.
15 Intake Air deg. C / deg. Depends Depends Depends The IAT is measured by ECM from IAT sensor output
Temperature F on ambient on ambient on ambient voltage. This data is changing by intake air temperature.
temp. temp. temp.
16 Ignition Status On12V/ On 12V On 12V On 12V This displays the key switch status indicated by the ECM
Off0V with key switch signal. This should display "Off 0V" at key
OFF and "On12V" at key ON.
17 Brake Switch 1 Active/ Inactive Inactive Inactive This displays operating status of the brake switch. This
Inactive should display "Active" when the brake pedal is stepped
on.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–91
18 Brake Switch 2 Active/ Inactive Inactive Inactive This displays operating status of the brake switch. This
Inactive should display "Active" when the brake pedal is stepped
on.
19 Clutch Switch (M/T Active/ Inactive Inactive Inactive This displays operating status of the clutch switch. This
Only) Inactive should display "Active" when the clutch pedal is stepped
on.
20 Neutral Switch On/Off On On On This displays operating status of the neutral switch. This
should display "On" when the gear position is neutral (M/T)
or P, N position (A/T).
21 A/C Information Active 12V/ Inactive 0V Inactive 0V Inactive 0V This displays the air conditioner request signal. This
Switch Inactive 0V should display "Active 12V" when the air conditioner switch
is switched on.
22 Diagnostic Request Active 0V/ Inactive Inactive Inactive This displays the diagnostic request signal. This should
Inactive 12V 12V 12V 12V display "Inactive 12V" when the Tech 2 is connected.
23 System Voltage V 10 - 15 10 - 15 10 - 15 This displays the system voltage measured by the ECM at
ignition feed.
24 Main Relay Active/ Active Active Active This displays operating status for the ECM main relay. This
Inactive should display "Active" when the key switch is turned on
and while engine is running.
25 Glow Time Relay Active 0V/ Inactive Inactive Inactive This displays operating status for the glow relay. This
Inactive12V 12V 12V 12V should display "Inactive 12V" when the engine is warm
upped.
26 Check Engine Light On/Off Off Off Off This displays operating status for the Check Engine Lamp.
This should display "On" when the Check Engine Lamp is
turned on.
27 Glow Time Telltale On/Off Off Off Off This displays operating status for the glow indicator lamp.
This should display "On" when the glow lamp is turned on.
28 Desired Engine Idle rpm 700 700 700 The desired engine idle speed that the ECM commanding.
Speed The ECM compensates for various engine loads based on
engine coolant temperature.
29 A/C Request Active 0V/ Inactive Inactive Inactive This displays operating status of the A/C compressor. This
Inactive 12V 12V 12V 12V should display "Active 0V" when the compressor relay is
operated.
30 Immobilizer Active/ Inactive Inactive Inactive This should display "Inactive" when the immobilizer is
Inactive correctly operated.
31 Immobilizer Signal Received/ Not Not Not This should display "Not Received" when the immobilizer is
Not Received Received Received not activated.
Received
32 Immobilizer Function Yes/ No Yes Yes Yes This should display "Yes" when the immobilizer is correctly
Programmed programmed.
33 EGR Pulse Ratio % 85 - 90 85 - 90 85 - 90 This displays the duty signal from the ECM to control the
(Exhaust Gas EGR flow amount.
Recirculation)
6E–92 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
MISCELLANEOUS TEST F3: Engine Speed (RPM) Control
When the Tech 2 is operated, "Desired Idle Speed"
The state of each circuit can be tested by using increases 50rpm-by-50rpm up to 1200rpm.
miscellaneous test menus. Especially when DTC The circuit is correct if engine speed is changed in
cannot be detected, a faulty circuit can be diagnosed by accordance with this operation.
testing each circuit by means of these menus.
Even DTC has been detected, the circuit tests using
Engine Speed (RPM) Control
these menus could help discriminate between a
mechanical trouble and an electrical trouble. Engine Speed 850 rpm
Connect Tech 2 and select "Powertrain", "4JA1-TC Desired Idle Speed 850 rpm
Bosch" or "4JH1-TC Bosch" & "Miscellaneous Test".
Injection Quantity 7.5 mg/ strk
F0: Lamps
F0: Glow Time Telltale Test
• Press "Increase" key.
When the Tech 2 is operated, "Glow Time Indicator
Then, Desired Idle speed is increases
Lamp" is turned on or off.
50rpm-by-50rpm up to 1200rpm. Engine speed is
The circuit is correct if the "Glow Time Indicator Lamp"
also
in the instrument panel is turned on or off in accordance
with this operation.
F1: Relays
F0: Glow Time Relay Test
When the Tech 2 is operated, glow relay turns ON or
OFF.
The circuit is correct if glow relay is operated in
accordance with this operation.
F2: Solenoids
F0: EGR Solenoid Test
When the Tech 2 is operated, control duty ratio of EGR
EVRV changes to 5% to 95%.
The circuit is correct if glow relay is operated in
accordance with this operation.
Procedures for transferring and displaying Tech2 By analyzing these data in various methods, trouble
snapshot data by using TIS2000 [Snapshot Upload] conditions can be checked.
function is described below. Snapshot data is displayed by executing the three steps
Snapshot data can be displayed with [Snapshot Upload] below shown:
function included in TIS2000.
1. Click the icon for graph display. [Graph Parameter] cursor is changed to the magnifying glass form, click
window opens. the screen. Graph screen is displayed on the whole
2. Click the first graph icon of the window upper part, screen.
and select one parameter from the list of the window
lower part. Selected parameter is displayed nest to
the graph icon. Graph division can be selected in
the field on the parameter right side.
3. Repeat the same procedures with the 2nd and 3rd
icons.
4. After selecting all parameters to be displayed (Max.
3 parameters), click [OK] button.
5. Parameter selected is displayed in graph form on
the right of the data parameter on the screen.
6. Graph display can be moved with the navigation
icon.
7. For displaying another parameter by graph, click the
parameter of the list, drug the mouse to the display
screen while pressing the mouse button and release
the mouse button. New parameter is displayed at
the position of the previous parameter. For
displaying the graph display screen in full size,
move the cursor upward on the screen. When the
6E–98 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Display of graphs on one screen (Max. 6 graphs):
5. On the screen of “Diagnostic Tester and Processing 6. Upon completion of the selection, push the button of
Program Selection”, choose the one that will comply “Next”.
with the following.
• Tech-2 in use
• New programming by the existing module or new
programming by the replaced/new module.
• Fixing position of the control unit.
6E–100 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
2. Demand of Data 5. Where vehicle data has been already saved in Tech
1. Connect Tech-2 to the vehicle. When activated by 2, the existing data come on display. In this
turning on the power of Tech-2, push the “Enter” instance, as Tech-2 starts asking whether to keep
switch. the data or to continue obtaining anew data from the
control unit, choose either of them
2. Turn on the ignition switch (without starting the
engine)
3. In the main menu of Diagnostic Tester, push “F1:
Service Programming System (SPS)”.
4. Push “F0: Request Info” of Tech-2.
5. After choosing the data, click the “Next” button. 4. Programming of ECM
6. When all the necessary information is entered, the 1. Check to see if batteries are fully charged, while
“details” of software within the database that match ABS connectors shall be removed from the vehicle.
the entered data will appear for confirmation. Click 2. Connect Tech-2 to Vehicle Diagnostic Connectors.
the “Program” switch and then download the new
3. Turn on the power of Tech-2 and the title screen
software onto Tech-2.
comes on display.
7. “Data Transfer” comes on display. The progress of
4. Turn on the ignition (without allowing the engine to
downloading will be displayed on the screen in the
start)
form of bar graph.
5. On the title screen of Tech-2, push the “Enter”
8. Upon finishing the data transfer, turn off the power
button.
of Tech-2, removing from P/C.
6. Choose “F1: Service Programming System” on the
main screen and then choose “Fl: Program ECU”.
7. While data is being transferred, “Programming in
Progress” will be displayed on the Tech-2 screen.
8. Upon finishing the data transfer, Tech-2 will display
“Reprogramming Was Successful”. Push the “Exit”
button to bring program to completion
9. Following “Procedure 2: Demand of Data”, try over
again “Information Obtaining” and check to confirm
if the data has been correctly re-loaded.
10. Upon finishing confirmation, turn off the ignition of
the vehicle and then turn off the power of Tech-2,
removing from the vehicle.
6E–102 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
HOW TO USE BREAKER BOX
3 4 2 5 1
B-58
V Repair faulty
harness and
— verify repair Go to Step 8
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–107
B-58
4 5
Repair faulty
harness and
— verify repair Go to Step 9
9 Using the DVM and check the data link connector
ground circuit.
1. Ignition “On”, engine “Off”.
2. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
B-58
4 5
Repair faulty
V V
harness and
Less than 1V Go to Step 10 verify repair
10 Using the DVM and check the data link connector
communication circuit.
1. Ignition “On”, engine “Off”.
2. Check the circuit for short to power supply circuit.
Was the DVM indicated fixed battery voltage?
B-58
6
Repair faulty
V harness and
— verify repair Go to Step 11
6E–108 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
C-56
B-58
Repair faulty
harness and
— verify repair Go to Step 12
12 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 13
13 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–109
Circuit Description wire broken inside the insulation. Check for the
following items:
The check engine lamp should be illuminated and
steady for about five seconds with the ignition “ON” and • Inspect the ECM harness and connections for
the engine stopped. Ignition feed voltage is supplied to improper mating, broken locks, improperly formed or
the check engine lamp bulb through the meter fuse. damaged terminals, poor terminal-to-wire connection,
The Engine Control Module (ECM) turns the check and damaged harness.
engine lamp “ON” by grounding the check engine lamp • If the engine runs OK, check for a faulty light bulb, an
driver circuit. open in the check engine lamp driver circuit, or an
open in the instrument cluster ignition feed.
Diagnostic Aids • If the engine cranks but will not run, check for an
open ECM ignition or battery feed, or a poor ECM to
An intermittent check engine lamp may be cased by a
engine ground.
poor connection, rubbed-through wire insulation, or a
6E–110 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
C-56
42
V
10-14.5V Go to Step 5 Go to Step 3
3 Check the “CHECK ENGINE” lamp bulb.
If the bulb is burnt out, repair as necessary.
Was the problem found? — Verify repair Go to Step 4
4 Using the DVM and check the “CHECK ENGINE”
lamp circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the meter connector and ECM
connector.
3. Check the circuit for open circuit.
Was the problem found?
C-56
42
B-24
C-56
42
B-24
17
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
65 P0100 7 ON Mass Air Flow (MAF) Sensor MAF sensor power supply ECM uses mass air flow MAF sensor power supply 1. Sensor power supply
Voltage Supply Circuit High voltage is more than 5.2V. 1600mg/strk & EGR 10% voltage is below 5.2V. circuit short to battery
Input conditions as substitute. voltage circuit. 83 —
2. MAFsensormalfunction.
3. ECM malfunction.
9 ON Mass Air Flow (MAF) Sensor MAF sensor power supply MAF sensor power supply 1. Sensor power supply
Voltage Supply Circuit Low voltage is below 4.6V. voltage is more than 4.6V. circuit short to ground
Input circuit. 83 —
2. MAFsensormalfunction.
3. ECM malfunction.
B ON Mass Air Flow (MAF) Sensor 1. Engine speed is between MAF sensor output is more 1. Sensor power supply
Output Circuit Low Input 600rpmand5000rpm. than -27.4mg/strk. circuit open circuit.
2. MAF sensor output is 2. Sensor signal circuit
below -33.7mg/strk. open or short to ground
circuit.
3. Sensor heater harness 83/
P0110(1)
open circuit. 88
4. Poor connector
connection.
5. MAFsensormalfunction.
6. ECM malfunction.
C ON Mass Air Flow (MAF) Sensor 1. Engine speed is between MAF sensor output is below 1. Sensor signal circuit
Output Circuit High Input 600rpmand5000rpm. 1378mg/strk (4JA1-TC) or shortto voltagecircuit.
2. MAF sensor output is 1784mg/strk (4JH1-TC). 2. Sensor ground circuit
more than 1378mg/strk open or short to voltage 88/
P0110(1)
(4JA1-TC) or 1784mg/ circuit. 92
strk (4JH1-TC). 3. MAFsensormalfunction.
4. ECM malfunction.
34 P0105 1 ON Vacuum Pressure Sensor Vacuum sensor output 1. Fuel injection quantity is Vacuum sensor output 1. Sensor signal circuit
Circuit High Input voltage is more than 4.4V. reduced. voltage is below 4.4V. shortto voltagecircuit.
2. ECM use 615hpa 2. Sensor ground circuit
conditions for open or short to voltage 85/
turbocharger waste gate circuit. P0115(1) —
93
control. 3. Vacuum sensor
malfunction.
4. ECM malfunction.
2 ON Vacuum Pressure Sensor Vacuum sensor output Vacuum sensor output 1. Sensor power supply
Circuit Low Input voltage is below 0.5V. voltage is more than 0.5V. circuit open circuit.
2. Sensor signal circuit
open or short to ground
circuit. 82/
— —
3. Poor connector 85
connection.
4. Vacuum sensor
malfunction.
5. ECM malfunction.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–115
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
34 P0105 7 ON Vacuum Pressure Sensor Vacuum sensor power 1. Fuel injection quantity is Vacuum sensor power 1. Sensor power supply
Voltage Supply Circuit High supply voltage is more than reduced. supply voltage is below 5.2V. circuit short to battery
Input 5.2V. 2. ECM use vacuum sensor voltage circuit.
82 — —
output voltage 5.0V 2. Vacuum sensor
condition as substitute. malfunction.
3. ECM malfunction.
9 ON Vacuum Pressure Sensor Vacuum sensor power Vacuum sensor power 1. Sensor power supply
Voltage Supply Circuit Low supply voltage is below 4.5V. supply voltage is more than circuit short to ground
Input 4.5V. circuit.
82 — —
2. Vacuum sensor
malfunction.
3. ECM malfunction.
23 P0110 1 ON Intake Air Temperature (IAT) IAT sensor output voltage is ECM use 0 deg. C conditions IAT sensor output voltage is 1. Sensor signal circuit
Sensor Circuit High Input more than 4.7V. as substitute. below 4.7V. open or short to voltage
circuit.
2. Sensor ground circuit
open or short to voltage 84/ P0100(B)/
circuit. 92 P0100(C)
3. Poor connector
connection
4. IATsensormalfunction.
5. ECM malfunction.
2 ON Intake Air Temperature (IAT) IAT sensor output voltage is IAT sensor output voltage is 1. Sensor signal circuit
Sensor Circuit Low Input below 0.3V. more than 0.3V. shortto groundcircuit.
84 —
2. IATsensormalfunction.
3. ECM malfunction.
14 P0115 1 ON Engine Coolant Temperature ECT sensor output voltage is 1. ECM uses fuel ECT sensor output voltage is 1. Sensor signal circuit
(ECT) Sensor Circuit High more than 4.7V. temperature as below 4.7V. open or short to voltage
Input substitute. circuit.
2. ECM uses 60 deg. C 2. Sensor ground circuit
condition for injection open or short to voltage
89/
timing control. circuit. P0105(1)
93
3. ECM uses -25 deg. C 3. Poor connector
condition (4JA1-TC) or - connection
15 deg. C condition 4. ECTsensormalfunction.
(4JH1-TC) for glow time
5. ECM malfunction.
control.
2 ON Engine Coolant Temperature ECT sensor output voltage is ECT sensor output voltage is 1. Sensor signal circuit
(ECT) Sensor Circuit Low below 0.3V. more than 0.3V. shortto groundcircuit.
Input 89 —
2. ECTsensormalfunction.
3. ECM malfunction.
15 P0180 B ON Fuel Temperature Sensor FT sensor output is high The ECM use 75 deg. C FT sensor output is correct 1. ECM malfunction.
Circuit Range/Performance temperature (more than 150 conditions as substitute. temperature range between 2. PSG (pump control unit) — —
deg. C) or low temperature 150 deg. C and -40 deg. C. malfunction.
(below -40 deg. C).
6E–116 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
52 P0215 A ON Fuel Cutoff Solenoid Valve 1. Ignition key switchoff. 1. MAB (fuel cutoff solenoid No recovery until condition 1. PSG (pump control unit)
Malfunction 2. Engine speed is below valve) is operated. match in the next ignition key malfunction.
1500rpm. 2. Desired injection quantity cycle. 2. MAB (fuel cutoff solenoid
3. Vehicle speed is below becomes 0mg/strk. valve) malfunction.
1.5km/h.
4. PSG (pump control unit) — —
recognizes MAB (fuel
cutoff solenoid valve)
signal from the ECM, but
the MAB could not
operate.
B ON Fuel Cutoff Solenoid Valve ECM does not command Engine does not start. No recovery. 1. MAB (fuel cutoff solenoid
Circuit High Input MAB (fuel cutoff solenoid valve) signal circuit short
valve) signal to the PSG to voltage circuit.
105 —
(pump control unit), but PSG 2. PSG (pump control unit)
detected MAB signal line malfunction.
circuit is high level.
C ON Fuel Cutoff Solenoid Valve 1. Ignition key switchoff. 1. MAB (fuel cutoff solenoid No recovery until condition 1. MAB (fuel cutoff solenoid
Always Active 2. Engine speed is below valve) is operated. match in the next ignition key valve) signal circuit open
1500rpm. 2. Desired injection quantity cycle. orshorttogroundcircuit.
3. Vehicle speed is below becomes 0mg/strk. 2. PSG (pump control unit)
1.5km/h. malfunction.
105 —
4. PSG (pump control unit)
does not recognize MAB
(fuel cutoff solenoid
valve) signal from the
ECM.
D ON Fuel Cutoff Solenoid Valve 1. Ignition key switch off. No fail-safe function. 1. ECM malfunction.
Malfunction 2. CAN controller does not 2. PSG (pump control unit) — —
operate Bus-off. malfunction.
54 P0216 A ON Injection Timing Control 1. Engine speed is more Fuel injection quantity is Deviation of actual injection 1. Timing control valve
Circuit Malfunction than 700rpm. reduced. timing and desired injection malfunction.
2. Fuel injection quantity is timing is more than +3 deg. 2. Timer piston sticking.
more than 4mg/stk. CA or -6 deg. CA for 8
3. Pump camshaft speed
seconds. — —
3. Deviation of actual sensor malfunction.
injection timing and
desired injection timing is
more than +3 deg. CA or
-6 deg. CA for 8 seconds.
B ON Injection Timing Control 1. Engine speed is more 1. Engine speed is more 1. Insufficient air bleeding of
Circuit Malfunction than 2014rpm. than 2014rpm. fuel line.
2. Fluctuation of actual 2. Fluctuation of actual 2. Fuel filterclogging.
injection timing is more injection timing is more 3. Timing control valve — —
than +-5.2 deg. CA. than +-5.2 deg. CA. malfunction.
4. Pump camshaft speed
sensor malfunction.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–117
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
64 P0243 3 ON Turbocharger Wastegate 1. Intake air temperature is 1. Fuel injection quantity is 1. Engine speed is between 1. Turbocharger wastegate
Solenoid "A" Range/ between -50 deg. C and reduced. 500rpm and 6000rpm. control EVRV
Performance 200 deg. C. 2. EGR EVRV becomes 2. Correct vacuum pressure malfunction.
2. Engine coolant 10% condition. condition. (Desired 2. Vacuum line is
temperature is between - vacuum pressure - actual obstructed.
50 deg. C and 150 deg. vacuum pressure is less 3. Vacuum is leaking.
C. than 50hpa.)
4. Vacuum pump 85/
3. Barometric pressure is malfunction. — —
96
between 0hpa and
5. Vacuum sensor
3500hpa.
malfunction.
4. Low vacuum pressure
6. Turbocahrger wastegate
condition. (Desired
valve malfunction.
vacuum pressure - actual
vacuum pressure is more 7. ECM malfunction.
than 50hpa.)
4 ON Turbocharger Wastegate Wastegate control EVRV 1. Fuel injection quantity is Wastegate control EVRV 1. Wastegate control EVRV
Solenoid "A" Low circuit open or short to reduced. circuit is correct condition. circuit open or short to
ground circuit. 2. EGR EVRV becomes ground circuit.
96 — —
10% condition. 2. Wastegate control EVRV
3. Wastegate control EVRV malfunction.
becomes 32% condition. 3. ECM malfunction.
5 ON Turbocharger Wastegate 1. Intake air temperature is 1. Fuel injection quantity is 1. Engine speed is between 1. Turbocharger wastegate
Solenoid "A" Range/ between -50 deg. C and reduced. 500rpm and 6000rpm. control EVRV
Performance 200 deg. C. 2. EGR EVRV becomes 2. Correct vacuum pressure malfunction.
2. Engine coolant 10% condition. condition. (Desired 2. Vacuum regulating valve
temperature is between - vacuum pressure - actual malfunction.
50 deg. C and 150 deg. vacuum pressure is more 3. Vacuum pump
C. than -50hpa.) malfunction. 85/
3. Barometric pressure is 4. Vacuum sensor — —
96
between 0hpa and malfunction.
3500hpa.
5. ECM malfunction.
4. High vacuum pressure
condition. (Desired
vacuum pressure - actual
vacuum pressure is less
than -50hpa.)
6 ON Turbocharger Wastegate 1. Engine coolant 1. Correct amount of mass 1. Turbocharger wastegate
Solenoid "A" Malfunction temperature is between - air flow. (= Correct boost actuator malfunction.
50 deg. C and 150 deg. pressure condition) 2. Vacuumlinemalfunction.
C. (Desired mass air flow -
3. ECM malfunction.
2. EGR control EVRV 0% actual mass air flow is
condition. more than -56mg/strk.)
3. No DTC relating to MAF
sensor, vacuum sensor & — — —
IAT sensor.
4. Large amount of mass air
flow. (= Incorrect boost
pressure condition)
(Desired mass air flow -
actual mass air flow is
less than -56mg/strk.)
6E–118 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
64 P0243 8 ON Turbocharger Wastegate Wastegate control EVRV 1. Fuel injection quantity is Wastegate control EVRV 1. Wastegate control EVRV
Solenoid "A" High circuit short to voltage circuit. reduced. circuit is correct condition. circuit short to voltage
2. EGR EVRV becomes circuit.
96 — —
10% condition. 2. Wastegate control EVRV
3. Wastegate control EVRV malfunction.
becomes 32% condition. 3. ECM malfunction.
53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft 1. MAB (fuel cutoff solenoid No recovery until condition 1. PSG (pump control unit)
speed sensor error. valve) is operated. match in the next ignition key malfunction.
2. High pressure solenoid 2. Desired injection quantity cycle. 2. Pump camshaft speed
valve control pulse width becomes 0mg/strk. sensor malfunction. — —
does not match with
desired fuel injection
quantity.
7 ON Injection Pump Malfunction 1. No pump camshaft 1. No pump camshaft 1. Missing CKP sensor
speed sensor error. speed sensor error. pulses.
2. No CKP sensor error. 2. No CKP sensor error. 2. Electrical interference.
3. Difference of engine 3. Difference of engine 3. Magneticinterference.
speed and doubled pump speed and doubled pump 4. PSG (pump control unit) 91 —
camshaft speed is more camshaft speed is below malfunction.
than 720rpm (4JA1-TC) 800rpm (4JA1-TC) or
or 690rpm (4JH1-TC). 690rpm (4JH1-TC).
No recovery until in the
next ignition key cycle.
9 ON Injection Pump Malfunction No pump map programmed No recovery until condition PSG (pump control unit)
in the PSG (pump control match in the next ignition key malfunction. — —
unit) or PSG malfunction. cycle.
A ON Injection Pump Malfunction EEPROM or A/D converter Fuel injection quantity is EEPROM or A/D converter PSG (pump control unit)
malfunction in the PSG reduced. no malfunction in the PSG malfunction.
(pump control unit). (pump control unit). — —
No recovery until in the next
ignition key cycle.
B ON Injection Pump Malfunction PSG (pump control unit) No fail-safe function. No recovery until condition PSG (pump control unit)
recognized high pressure match in the next ignition key malfunction.
— —
solenoid valve drive circuit cycle.
error.
D ON Injection Pump Malfunction PSG (pump control unit) PSG (pump control unit)
could not measure the high malfunction.
— —
pressure solenoid valve drive
voltage.
E ON Injection Pump Malfunction ECM could not accept PSG 1. MAB (fuel cutoff solenoid ECM accepts PSG (pump 1. CAN high circuit open,
(pump control unit) message. valve) is operated. control unit) message. short to ground or short
2. Desired injection quantity to voltage circuit.
becomes 0mg/strk. 2. CAN low circuit open,
short to ground or short 99/ P1650(A)/
to voltage circuit. 100 P1651(B)
3. ECM malfunction.
4. PSG (pump control unit)
malfunction.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–119
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
43 P0335 B ON Crankshaft Position Sensor 1. Engine speed is more When pump camshaft speed ECM detects correct CKP 1. During engine run:
Circuit Malfunction than 665rpm. sensor is OK: pulse width. 1. CKP sensor harness
2. CKP sensor pulse width ECM uses doubled pump open circuit, short to
error. camshaft speed as substitute ground or short to
enginespeed. voltage circuit.
When pump camshaft speed 2. Poor connector
sensor is not OK: connection. 90/
1. MAB (fuel cutoff solenoid 3. CKPsensormalfunction. 98/ P1335 (A)
valve) is operated. 101
4. Pulse sensing gap
2. Desired injection quantity incorrect.
becomes 0mg/strk.
5. Pulser malfunction.
6. Electrical interference.
7. Magnetic interference.
8. ECM malfunction.
D ON Crankshaft Position Sensor 1. No pump camshaft When pump camshaft speed 1. Engine speed is more During engine crank:
Circuit Malfunction speed sensor error. sensor is OK: than 0rpm. 1. CKP sensor harness
2. "Crankshaft Position ECM uses doubled pump 2. Doubled pump camshaft open circuit, short to
Sensor Circuit camshaft speed as substitute speed is below 100rpm. ground or short to
Malfunction (Symptom enginespeed. voltage circuit.
CodeB)" isnotstored. Other than pump camshaft
2. Poor connector
speed sensor is OK:
3. Engine speed is 0rpm. connection. 90/
Fuel injection quantity is
4. Doubled pump camshaft 3. CKPsensormalfunction. 98/ P1135 (A)
reduced.
speed is more than 101
4. Pulse sensing gap
50rpm. incorrect.
5. Pulser malfunction.
6. Electrical interference.
7. Magnetic interference.
8. ECM malfunction.
E ON Engine Speed Input Circuit Engine speed is more than When intermittent Engine speed is below 1. Engine over-running.
Range/Performance 5700rpm. malfunction: 5700rpm. 2. CKPsensormalfunction.
1. MAB (fuel cutoff solenoid 3. Pulser malfunction.
valve) is operated.
4. ECM malfunction.
2. Desired injection quantity 90/
becomes 0mg/strk. 98/ —
When preliminary 101
malfunction:
ECM uses doubled pump
camshaft speed as substitute
engine speed.
66 P0380 4 ON Glow Relay Circuit Voltage Glow relay circuit open or No fail-safe function. Glow relay circuit is correct 1. Glow relay circuit open or
Low short to ground circuit. condition. short to groundcircuit.
94 —
2. Glowrelaymalfunction.
3. ECM malfunction.
8 ON Glow Relay Circuit Voltage Glow relay circuit short to ECM malfunction.
High voltage circuit. — —
6E–120 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
67 P0381 4 ON Glow Plug Indicator Circuit Glow plug indicator circuit No fail-safe function. Glow plug indicator circuit is 1. Glow plug indicator
Voltage Low open or short to ground correct condition. circuit open or short to
circuit. ground circuit.
43 —
2. Glow plug indicator lamp
malfunction.
3. ECM malfunction.
8 ON Glow Plug Indicator Circuit Glow plug indicator circuit ECM malfunction.
Voltage High short to voltage circuit. — —
32 P0400 3 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is 1. Engine speed is between 1. EGR valve is stuck at
Flow Excessive Detected between 15 deg. C and reduced. 1500rpm and 3100rpm open position.
100 deg. C. (4JA1-TC) or 1500rpm 2. EGREVRVmalfunction.
2. Engine coolant and3200rpm(4JH1-TC).
3. Air intake is obstructed.
temperature is between 2. Injection quantity is
4. Airintakeisleaking.
55 deg. C and 100 deg. below 32mg/strk (4JA1-
C (4JA1-TC) or 35 deg. C TC) or 40mg/stk (4JH1- 5. MAFsensormalfunction.
and 100 deg. C (4JH1- TC). 6. ECM malfunction. 88/
TC). —
3. Correct amount of mass 97
3. Barometric pressure is air flow.
between 850hpa and
1100hpa.
4. Small amount of mass air
flow. (Desired mass air
flow - mass air flow is
more than 150mg/strk)
4 ON Exhaust Gas Recirculation EGR EVRV circuit open or Fuel injection quantity is EGR EVRV circuit is correct 1. EGR EVRV circuit open
Circuit Short to Ground or short to ground circuit. reduced and EGR EVRV condition. orshorttogroundcircuit.
Open Circuit 10% conditions as substitute. 97 —
2. EGREVRVmalfunction.
3. ECM malfunction.
5 ON Exhaust Gas Recirculation 1. Intake air temperature is Fuel injection quantity is 1. Engine speed is between 1. EGR valve is stuck at
Flow Insufficient Detected between 15 deg. C and reduced. 1500rpm and 3100rpm close position.
100 deg. C. (4JA1-TC) or 1500rpm 2. EGR valve operating
2. Engine coolant and3200rpm(4JH1-TC). vacuum hose is clogged
temperature is between 2. Injection quantity is or disconnected.
55 deg. C and 100 deg. below 32mg/strk (4JA1- 3. EGREVRVmalfunction.
C (4JA1-TC) or 35 deg. C TC) or 40mg/stk (4JH1-
4. MAF sensor signal circuit
and 100 deg. C (4JH1- TC). 88/
short to voltagecircuit. —
TC). 3. Correct amount of mass 97
5. MAFsensormalfunction.
3. Barometric pressure is air flow.
between 850hpa and 6. ECM malfunction.
1100hpa.
4. Large mount of mass air
flow. (Desired mass air
flow - mass air flow is
below -150 mg/strk)
8 ON Exhaust Gas Recirculation EGR EVRV circuit short to Fuel injection quantity is EGR EVRV circuit is correct 1. EGR EVRV circuit short
Circuit Short to Battery voltage circuit. reduced & EGR EVRV 10% condition. to voltage circuit.
conditions as substitute. 97 —
2. EGREVRVmalfunction.
3. ECM malfunction.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–121
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
24 P0500 1 ON Vehicle Speed Sensor Circuit Vehicle speed is more than ECM uses vehicle speed Vehicle speed is below 1. VSS signal circuit open,
at High Input 200km/h. 5km/h condition as 200km/h. short to ground or short
next substitute. to voltage circuit.
igniti 2. VSS malfunction.
on
3. Speed meter 68 —
cycle
malfunction.
4. TCM malfunction (AT
2WD).
5. ECM malfunction.
A ON Vehicle Speed Sensor Input Input signal frequency is too ECM uses vehicle speed Correct vehicle speed signal 1. VSS malfunction.
at Signal Frequency Too High high. 5km/h condition as frequency. 2. Speed meter
next substitute. malfunction.
igniti 68 —
3. Electrical interference.
on
cycle 4. Magneticinterference.
5. ECM malfunction.
B ON Vehicle Speed Sensor 1. Engine speed is more Fuel injection quantity is Vehicle speed is more than 1. VSS open circuit, short
at Incorrect Signal than 3200rpm (4JA1-TC) reduced. 1.5km/h. to ground or short to
next or3600rpm(4JH1-TC). voltage.
igniti 2. Fuel injection quantity is 2. Poor connector
on more than 30mg/strk connection. 68 —
cycle (4JA1-TC) or 41mg/strk 3. VSS malfunction.
(4JH1-TC).
4. Speed meter
3. Vehicle speed is below malfunction.
1.5km/h.
5. ECM malfunction.
35 P0560 1 OFF System Voltage Too High System voltage is more than ECM uses 9V conditions as System voltage is below 20V. 1. Charge system
20V. substitute. malfunction.
3/
2. Battery jump start cable —
39
misconnect.
3. ECM malfunction.
2 OFF System Voltage Too Low System voltage is below 7V. System voltage is more than 1. Battery power feed
7V. harness open circuit or
short to ground circuit.
2. ECM ground harness
openorpoorconnection.
3. Poor connector 3/
—
connection. 39
4. Battery malfunction.
5. Charge system
malfunction.
6. ECM malfunction.
6E–122 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
35 P0560 A OFF System Voltage Malfunction System voltage of PSG PSG uses default voltage as System voltage of PSG is 1. Battery power feed
(pump control unit) is below substitute. between 4.5V and 27V. harness open circuit or
4.5V or more than 27V. short to ground circuit.
2. PSG (pump control unit)
ground harness open or
poor connection.
3. Poor connector
connection. — —
4. Battery malfunction.
5. Charge system
malfunction.
6. Battery jump start cable
misconnect.
7. PSG (pump control unit)
malfunction.
18 P0561 A OFF Ignition Switch Circuit The ECM recognized ignition ECM stops engine. No recovery until condition 1. Ignition switch circuit
Malfunction switch turn off signal during match in the next ignition key open or short to ground
ECM is activated. cycle. circuit.
2. Poor connector
connection. 39 —
3. Ignition switch
malfunction.
4. ECM malfunction.
B OFF Ignition Switch Circuit Ignition switch circuit is 1. Ignition switch circuit
Malfunction malfunction. open or short to ground
circuit.
2. Poor connector
connection. 39 —
3. Ignition switch
malfunction.
4. ECM malfunction.
- P0602 - Control Module ECM memory area error. Engine control disabled. Memory are is OK. ECM is not programmed.
Programming Error — —
28 P0606 A ON ECU Malfunction Gate Array communication 1. MAB (fuel cutoff solenoid No recovery. ECM malfunction.
error. valve) is operated.
— —
2. Desired injection quantity
becomes 0mg/strk.
B ON ECU Malfunction 1. Throttle position is below MAB (fuel cutoff solenoid Desired injection quantity is 1. ECM malfunction.
1%. valve) is operated. below 0mg/strk. 2. PSG (pump control unit)
2. Desired injection quantity malfunction.
— —
is more than 0mg/strk.
3. Engine speed is more
than 2000rpm.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–123
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
46 P0645 4 ON A/C Compressor Relay A/C compressor relay circuit No fail-safe function. A/C compressor relay circuit 1. A/C compressor relay
Circuit Voltage Low open or short to ground is correct condition. circuit open or short to
circuit. ground circuit.
2. Poor connector
connection. 41 —
3. A/C compressor relay
malfunction.
4. ECM malfunction.
8 ON A/C Compressor Relay A/C compressor relay circuit ECM malfunction.
Circuit Voltage High short to voltage circuit. — —
25 P0703 A ON Brake Switch Circuit 1. Throttle position is more No fail-safe function. Brake switch 1 signal and 1. Brake switch 1 circuit
Malfunction than 0%. brake switch 2 signal are open, short to ground or
2. Engine speed is more correctly inputted to the short to voltage circuit.
than 693rpm (4JA1-TC) ECM. 2. Poor connector
or665rpm(4JH1-TC). connection.
3. Vehicle speed is more 3. Brake switch 1 30 —
than 0km/h. malfunction.
4. Brake switch 1 signal and 4. ECM malfunction.
brake switch 2 signal are
differently inputted to the
ECM since the ignition
switch was turned on.
B ON Brake Switch Circuit 1. Throttle position is more 1. Brake switch 2 circuit
Malfunction than 0%. open or short to ground
2. Engine speed is more circuit.
than 693rpm (4JA1-TC) 2. Poor connector
or665rpm(4JH1-TC). connection.
3. Vehicle speed is more 3. Brake switch 2 65 —
than 0km/h. malfunction.
4. Brake switch 1 signal and 4. ECM malfunction.
brake switch 2 signal are
differently inputted to the
ECM.
57 P0704 6 ON Clutch Switch Input Circuit Clutch signal does not No fail-safe function. Clutch signal correctly 1. Clutch switch circuit
Malfunction change between vehicle changes. open, short to ground or
speed 1.5km/h and 80km/h shorttovoltage circuit.
since ignition switch was 2. Poor connector
tuned on. connection. 31 — —
3. Clutch switch
malfunction.
4. ECM malfunction.
86 P1105 1 ON Barometric Pressure Sensor Barometric pressure sensor ECM uses 1013hpa Barometric pressure sensor ECM malfunction.
Circuit High Input output voltage is more than condition as substitute. output voltage is below 4.4V. — —
4.4V.
2 ON Barometric Pressure Sensor Barometric pressure sensor Barometric pressure sensor ECM malfunction.
Circuit Low Input output voltage is below 1.5V. output voltage is more than — —
1.5V.
6E–124 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
21 P1120 1 ON Pedal/Throttle Position Throttle position sensor ECM increases idle speed up Throttle position sensor 1. Sensor power supply
Sensor Circuit High Input output voltage is more than to 1400rpm. output voltage is below 4.5V. circuit short to voltage
4.5V. circuit.
2. Sensor signal circuit
short to voltagecircuit.
3. Sensor ground circuit 38/
open or short to voltage 49/ —
circuit. 57
4. Poor connector
connection.
5. TPS malfunction.
6. ECM malfunction.
7 ON Pedal/Throttle Position Throttle position sensor Throttle position sensor 1. Sensor power supply
Sensor Voltage Supply power supply voltage is more power supply voltage is circuit short to battery
Circuit High Input than 5.2V. below 5.2V. voltage circuit. 57 —
2. TPS malfunction.
3. ECM malfunction.
9 ON Pedal/Throttle Position Throttle position sensor Throttle position sensor 1. Sensor power supply
Sensor Voltage Supply power supply voltage is power supply voltage is more circuit short to ground
Circuit Low Input below 4.6V. than 4.6V. circuit. 57 —
2. TPS malfunction.
3. ECM malfunction.
D ON Pedal/Throttle Position 1. Engine speed is more Throttle position is more than 1. Throttle sticking.
Sensor Brake Switch Error than 1700rpm. 20% or brake pedal is 2. TPSincorrectadjusting.
2. Vehicle speed is more released(switchisinactive).
3. TPS malfunction. 30/
than 1.5km/h.
4. Brake switch 38/ —
3. When brake pedal is malfunction. 65
depressed during
5. ECM malfunction.
accelerator pedal is
depressing.
E ON Pedal/Throttle Position 1. When idle switch is 1. When throttle position 1. TPS malfunction.
Sensor Idle Position Switch turned off, throttle sensor is 100%, idle 2. Idle switch malfunction.
Error position sensor was switch turns off.
3. ECM malfunction.
below 0.35%. 2. When throttle position
or 38/
sensor is 0%, idle switch —
69
2. When idle switch is tuned turns on.
on, throttle position
sensor was more than
7.8%.
22 P1173 3 OFF Fuel Reduction Caused By Excessive high engine No fail-safe function. Engine coolant temperature 1. Engine overheat.
High Coolant Temperature coolant temperature is is normal range. 2. ECTsensormalfunction. 89 —
detected.
3. ECM malfunction.
7 OFF Fuel Reduction Caused By Fuel temperature is more PSG (pump control unit) Fuel temperature is below 1. ECM malfunction.
High Fuel Temperature than 100 deg. C. controls fuel injection 100 deg. C. 2. PSG (pump control unit) — —
quantity based on engine malfunction.
speed and fuel temperature.
A OFF Fuel Reduction Caused By Excessive low fuel No fail-safe function. Fuel temperature is normal 1. ECM malfunction.
Low Fuel Temperature temperature is detected. range. 2. PSG (pump control unit) — — —
malfunction.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–125
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
43 P1335 A ON Engine Speed Output Circuit The PSG (pump control unit) Fuel injection quantity is Correct engine speed signal. 1. CKP sensor harness
Malfunction is recognized defective reduced. open circuit, short to
engine speed signal form the ground or short to
ECM. voltage.
2. CKP sensor output
harness open circuit,
short to ground or short
to voltage.
3. Poor connector 90/
connection. 91/ P0335(B)/
4. CKPsensormalfunction. 98/ P0335(D)
5. Pulse sensing gap 101
incorrect.
6. Pulser malfunction.
7. Electrical interference.
8. Magnetic interference.
9. ECM malfunction.
10. PSG (pump control unit)
malfunction.
45 P1345 A ON Camshaft Speed Malfunction The PSG (pump control unit) No fail-safe function. Correct camshaft speed. 1. Pump camshaft speed
is recognized incorrect sensor malfunction.
camshaft speed signal. 2. Pulse sensing gap
incorrect.
3. Pulser malfunction.
— —
4. Electrical interference.
5. Magnetic interference.
6. ECM malfunction.
7. PSG (pump control unit)
malfunction.
47 P1520 A ON Neutral Switch ON Error Neutral switch signal is No fail-safe function. Correct neutral switch signal 1. Neutral switch circuit
inputted "On" three times is inputted two times shorttovoltage circuit.
consecutively under driving consecutively under driving 2. Neutral switch 87 —
conditions. conditions. malfunction.
3. ECM malfunction.
B ON Neutral Switch OFF Error Neutral switch signal is 1. Neutral switch circuit
inputted "Off" three times open, short to ground
consecutively under driving circuit.
conditions. 2. Poor connector
connection. 87 — —
3. Neutral switch
malfunction.
4. ECM malfunction.
55 P1605 C ON Seed and Key File Destroyed Seed or key file in EEPROM No fail-safe function. No recovery. ECM malfunction.
is destroyed. — —
D ON EEPROM Defect Write and read from the ECM uses default values Write and read from the ECM malfunction.
EEPROM are failed during from the EPROM. EEPROM are correct during — —
initialization of the ECM. initialization of the ECM.
6E–126 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
55 P1605 E ON EEPROM Defect EEPROM checksum does EEPROM checksum match ECM malfunction.
not match with the read with the read check sum
— —
check sum during during initialization of the
initialization of the ECM. ECM.
56 P1610 A - Security Key and Security Immobilizer functions are not 1. Engine does not start. No recovery. ECM malfunction.
Code not Programmed programmed in the ECM. 2. Check engine lamp flash. — B****
56 P1611 A - Wrong Security Code Received security code is not 1. Engine does not start. No recovery. 1. ECM malfunction.
Entered correct. 2. Check engine lamp flash. 2. Immobilizer control unit
malfunction. — B****
3. Transponder key
malfunction.
56 P1612 A - Immobilizer No or Wrong Received challenge signal is 1. Engine does not start. No recovery. 1. ECM and immobilizer
Signal not correct or not received. 2. Check engine lamp flash. control unit
communication circuit
open circuit, short to
ground circuit or short to
voltage circuit. 27/
B****
2. ECM malfunction. 35
3. Immobilizer control unit
malfunction.
4. Transponder key
malfunction.
56 P1613 A - Immobilizer No or Wrong Received response signal is 1. Engine does not start. No recovery. 1. ECM and immobilizer
Signal not correct or not received. 2. Check engine lamp flash. control unit
communication circuit
open circuit, short to
ground circuit or short to
voltage circuit. 27/
B****
2. ECM malfunction. 35
3. Immobilizer control unit
malfunction.
4. Transponder key
malfunction.
56 P1614 A - Wrong Transponder Key Received response signal is 1. Engine does not start. No recovery. 1. ECM malfunction.
not correct from the 2. Check engine lamp flash. 2. Immobilizer control unit
transponder key. malfunction. — B****
3. Transponder key
malfunction.
76 P1625 A OFF ECM Main Relay Switched When ignition switch was No fail-safe function. No recovery. ECM malfunction.
Off Too Early turned off, timing of the ECM 3/
—
main relay turning off is too 58
early.
B OFF ECM Main Relay Switched When ignition switch was No recovery. 1. ECM main relay
Off Too Late turned off, timing of the ECM malfunction. 3/
—
main relay turning off is too 2. ECM malfunction. 58
late or does not off.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–127
Related Related
Flash Symptom 4JA1-TC 4JH1-TC 4JH1-TC
Code MIL DTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure Parts ECM Pin Multiple
Code Code (MT) (MT) (AT)
No. DTC
51 P1630 A ON Fuel Injection Quantity The PSG (pump control unit) Fuel injection quantity is The PSG (pump control unit) PSG (pump control unit)
Circuit Malfunction detects high pressure reduced. detects correct high pressure malfunction.
solenoid valve control circuit solenoid valve control circuit. — —
malfunction due to high
current.
B ON Fuel Injection Quantity The PSG (pump control unit) 1. MAB (fuel cutoff solenoid No recovery. PSG (pump control unit)
Circuit Malfunction detects high pressure valve) is operated. malfunction.
solenoid valve control circuit 2. Desired injection quantity — —
malfunction due to becomes 0mg/strk.
continuous current.
44 P1650 A ON CAN Device Offline CAN controller detects Bus- MAB (fuel cutoff solenoid CAN controller detects 1. CAN high circuit open,
off or canceling. valve) is operated. correct Bus signal. short to ground or short
to voltage circuit.
2. CAN low circuit open,
short to ground or short
to voltage circuit. 99/
3. Poor connector P1651(B)
100
connection.
4. Electricalinterference.
5. ECM malfunction.
6. PSG (pump control unit)
malfunction.
B ON CAN Device Hang-up CAN controller does not CAN controller reacts 1. ECM malfunction.
react under engine running. correctly under engine 2. PSG (pump control unit) — —
running. malfunction.
45 P1651 A ON CAN Malfunction The PSG (pump control unit) 1. MAB (fuel cutoff solenoid The PSG (pump control unit) 1. ECM malfunction.
does not recognize CAN valve) is operated. recognizes CAN signal from 2. PSG (pump control unit)
signal from the CAN the CAN controller. — —
2. Desired injection quantity malfunction.
controller. becomes 0mg/strk.
B ON CAN Malfunction The ECM does not read CAN The ECM reads CAN signal 1. CAN high circuit open,
signal from the PSG (pump from the PSG (pump control short to ground or short
control unit). unit). to voltage circuit.
2. CAN low circuit open,
short to ground or short
to voltage circuit. 99/
3. Poor connector P1650(A)
100
connection.
4. Electrical interference.
5. ECM malfunction.
6. PSG (pump control unit)
malfunction.
77 P1690 4 OFF Check Engine Lamp (MIL) Check engine lamp circuit No fail-safe function. Check engine lamp circuit is 1. Check engine lamp
Circuit Voltage Low open or short to ground correct condition. circuit open or short to
circuit. ground circuit.
42 B****
2. Check engine lamp
malfunction
3. ECM malfunction.
8 OFF Check Engine Lamp (MIL) Check engine lamp circuit ECM malfunction.
Circuit Voltage High short to voltage circuit. — —
6E–128 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
65 P0100 7 ON Mass Air Flow (MAF) Sensor MAF sensor power supply ECM uses mass air flow
Voltage Supply Circuit High voltage is more than 5.2V. 1600mg/strk & EGR 10% con-
Input ditions as substitute.
9 ON Mass Air Flow (MAF) Sensor MAF sensor power supply
Voltage Supply Circuit Low voltage is below 4.6V.
Input
B ON Mass Air Flow (MAF) Sensor 1. Engine speed is between
Output Circuit Low Input 600rpm and 5000rpm.
2. MAF sensor output is
below -33.7mg/strk.
C ON Mass Air Flow (MAF) Sensor 1. Engine speed is between
Output Circuit High Input 600rpm and 5000rpm.
2. MAF sensor output is more
than 1378mg/strk (4JA1-TC)
or 1784mg/strk (4JH1-TC).
Diagnostic Trouble Code (DTC) P0100 (Symptom Code 7) (Flash Code 65)
Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0100 (Symptom Code 7) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
6E–130 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
C-57(B) 92 C-116
2 3 4
5
4
83 — Verify repair Go to Step 8
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–131
C-116
2 4
4
83 — Verify repair Go to Step 13
11 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved? — Go to Step 12 Go to Step 13
12 Replace the MAF & IAT sensor assembly.
Is the action complete? — Verify repair —
13 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 14
14 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–132 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0100 (Symptom Code 9) (Flash Code 65)
Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0100 (Symptom Code 9) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0100 (Symptom Code 9) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the MAF sensor or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
C-57(B) 92 C-116
2 3 4
5
V Approximately
5.0V Go to Step 10 Go to Step 7
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–133
C-116
3 4
C-57(B) C-116
4
83 — Verify repair Go to Step 12
10 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved? — Go to Step 11 Go to Step 12
11 Replace the MAF & IAT sensor assembly.
Is the action complete? — Verify repair —
12 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 13
13 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–134 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0100 (Symptom Code B) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output Circuit Low Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0100 (Symptom Code B) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0100 (Symptom Code B) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the MAF sensor or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
C-57(B) 92 C-116
2 3 4
5
C-57(B) C-116
88 5
Repair faulty
harness and
— verify repair Go to Step 7
7 Using the DVM and check the MAF sensor power
supply circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the MAF & IAT sensor connector.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
C-116
4
V Approximately
5.0V Go to Step 9 Go to Step 8
6E–136 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
4
83 — Verify repair Go to Step 13
9 Using the DVM and check the MAF sensor +12V
supply circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the MAF & IAT sensor connector.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
C-116
2
V
10-14.5V Go to Step 11 Go to Step 10
10 Repair the open circuit between the ECM main relay
and MAF sensor.
Was the problem solved? — Verify repair Go to Step 11
11 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved? — Go to Step 12 Go to Step 13
12 Replace the MAF & IAT sensor assembly.
Is the action complete? — Verify repair —
13 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 14
14 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–137
Diagnostic Trouble Code (DTC) P0100 (Symptom Code C) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output Circuit High Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0100 (Symptom Code C) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0100 (Symptom Code C) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the MAF sensor or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
C-57(B) 92 C-116
2 3 4
5
C-57 C-116
3 Repair faulty
92 harness and
— verify repair Go to Step 7
7 Using the DVM and check the MAF sensor ground
circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the MAF sensor connector .
3. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
C-116
3
Repair faulty
V
harness and
Less than 1V Go to Step 8 verify repair
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–139
C-116
5
Repair faulty
V harness and
Less than 1V Go to Step 9 verify repair
9 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved? — Go to Step 10 Go to Step 11
10 Replace the MAF & IAT sensor assembly.
Is the action complete? — Verify repair —
11 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 12
12 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–140 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0105 (Symptom Code 1) (Flash Code 34)
Vacuum Pressure Sensor Circuit High Input
Step Action Value(s) Yes No
1 Was the "On-Board Diagnostic (OBD) System Check" Go to On Board
performed? Diagnostic
(OBD) System
- Go to Step 2 Check
2 1. 1Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor As Stored By ECU" in Refer to
"F0: Diagnostic Trouble Codes". Diagnostic Aids
Is the DTC P0105 (Symptom Code 1) stored as and Go to Step
"Present Failure"? - Go to Step 3 3
3 1. Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0: Refer to
Diagnostic Trouble Codes". Diagnostic Aids
Was the DTC P0105 (Symptom Code 1) stored in this and Go to Step
ignition cycle? - Go to Step 4 4
4 Check for poor/faulty connection at the vacuum
pressure sensor or ECM connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
C-57 C-124
- Verify repair Go to Step 5
5 Visually check the vacuum sensor.
Was the problem found? - Go to Step 9 Go to Step 6
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–143
Repair faulty
harness and
- verify repair Go to Step 7
7 Using the DVM and check the vacuum pressure
sensor ground circuit.
1. Ignition "On", engine "Off".
2. Disconnect the vacuum pressure sensor
connector.
3. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
C-124
V Repair faulty
harness and
Less than 1V Go to Step 8 verify repair
6E–144 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
V Repair faulty
harness and
Less than 1V Go to Step 9 verify repair
9 Substitute a known good vacuum pressure sensor
and recheck.
Was the problem solved? - Go to Step 10 Go to Step 11
10 Replace the vacuum pressure sensor.
Is the action complete? - Verify repair -
11 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved? - Verify repair Go to Step 12
12 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
(if equipped) must be linked to the ECM. Refer to
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Verify repair -
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–145
Diagnostic Trouble Code (DTC) P0105 (Symptom Code 2) (Flash Code 34)
Vacuum Pressure Sensor Circuit Low Input
Step Action Value(s) Yes No
1 Was the "On-Board Diagnostic (OBD) System Check" Go to On Board
performed? Diagnostic
(OBD) System
- Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor As Stored By ECU" in Refer to
"F0: Diagnostic Trouble Codes". Diagnostic Aids
Is the DTC P0105 (Symptom Code 2) stored as and Go to Step
"Present Failure"? - Go to Step 3 3
3 1. Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0: Refer to
Diagnostic Trouble Codes". Diagnostic Aids
Was the DTC P0105 (Symptom Code 2) stored in this and Go to Step
ignition cycle? - Go to Step 4 4
4 Check for poor/faulty connection at the vacuum
pressure sensor or ECM connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
C-57 C-124
- Verify repair Go to Step 5
5 Visually check the vacuum pressure sensor.
Was the problem found? - Go to Step 9 Go to Step 6
6E–146 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
C-57 C-124
Repair faulty
harness and
- verify repair Go to Step 7
7 Using the DVM and check the vacuum pressure
sensor power supply circuit.
1. Ignition "On", engine "Off".
2. Disconnect the vacuum pressure sensor
connector.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
C-124
V
Approximately
5.0V Go to Step 9 Go to Step 8
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–147
C-57 C-124
- Verify repair Go to Step 11
9 Substitute a known good vacuum pressure sensor
assembly and recheck.
Was the problem solved? - Go to Step 10 Go to Step 11
10 Replace the vacuum sensor assembly.
Is the action complete? - Verify repair -
11 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved? - Verify repair Go to Step 12
12 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
(if equipped) must be linked to the ECM. Refer to
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Verify repair -
6E–148 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0105 (Symptom Code 7) (Flash Code 34)
Vacuum Pressure Sensor Voltage Supply Circuit High Input
Step Action Value(s) Yes No
1 Was the "On-Board Diagnostic (OBD) System Check" Go to On Board
performed? Diagnostic
(OBD) System
- Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor As Stored By ECU" in Refer to
"F0: Diagnostic Trouble Codes". Diagnostic Aids
Is the DTC P0105 (Symptom Code 7) stored as and Go to Step
"Present Failure"? - Go to Step 3 3
3 1. Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0: Refer to
Diagnostic Trouble Codes". Diagnostic Aids
Was the DTC P0105 (Symptom Code 7) stored in this and Go to Step
ignition cycle? - Go to Step 4 4
4 Check for poor/faulty connection at the vacuum
pressure sensor or ECM connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
C-57 C-124
- Verify repair Go to Step 5
5 Visually check the vacuum pressure sensor.
Was the problem found? - Go to Step 8 Go to Step 6
6 Using the DVM and check the vacuum pressure
sensor power supply circuit.
1. Ignition "On", engine "Off".
2. Disconnect the vacuum pressure sensor
connector.
3. Check the circuit for short to battery voltage
circuit.
Was the DVM indicated specified value?
C-124
V
Approximately
5.0V Go to Step 8 Go to Step 7
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–149
C-57 C-124
- Verify repair Go to Step 10
8 Substitute a known good vacuum pressure sensor
assembly and recheck.
Was the problem solved? - Go to Step 9 Go to Step 10
9 Replace the vacuum pressure sensor assembly.
Is the action complete? - Verify repair -
10 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved? - Verify repair Go to Step 11
11 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
(if equipped) must be linked to the ECM. Refer to
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Verify repair -
6E–150 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0105 (Symptom Code 9) (Flash Code 34)
Vacuum Pressure Sensor Voltage Supply Circuit Low Input
Step Action Value(s) Yes No
1 Was the "On-Board Diagnostic (OBD) System Check" Go to On Board
performed? Diagnostic
(OBD) System
- Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor As Stored By ECU" in Refer to
"F0: Diagnostic Trouble Codes". Diagnostic Aids
Is the DTC P0105 (Symptom Code 9) stored as and Go to Step
"Present Failure"? - Go to Step 3 3
3 1. Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0: Refer to
Diagnostic Trouble Codes". Diagnostic Aids
Was the DTC P0105 (Symptom Code 9) stored in this and Go to Step
ignition cycle? - Go to Step 4 4
4 Check for poor/faulty connection at the vacuum
pressure sensor or ECM connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
C-57 C-124
- Verify repair Go to Step 5
5 Visually check the vacuum pressure sensor.
Was the problem found? - Go to Step 10 Go to Step 6
6 Using the DVM and check the vacuum pressure
sensor power supply circuit.
1. Ignition "On", engine "Off".
2. Disconnect the vacuum pressure sensor
connector.
3. Check the circuit for short to ground circuit.
Was the DVM indicated specified value?
C-124
V
Approximately
5.0V Go to Step 10 Go to Step 7
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–151
C-124
No continuity Go to Step 9 Go to Step 8
8 Repair the circuit for short to vacuum pressure sensor
ground.
Is the action complete? - Verify repair -
9 Repair the short to ground circuit between the vacuum
pressure sensor.
Was the problem solved? - Verify repair Go to Step 12
10 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved? - Go to Step 11 Go to Step 12
11 Replace the MAF & IAT sensor assembly.
Is the action complete? - Verify repair -
12 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved? - Verify repair Go to Step 13
13 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
(if equipped) must be linked to the ECM. Refer to
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Verify repair -
6E–152 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
23 P0110 1 ON Intake Air Temperature (IAT) IAT sensor output voltage is ECM use deg.C conditions as
Sensor Circuit High Input more than 4.7V. substitute.
2 ON Intake Air Temperature (IAT) IAT sensor output voltage is
Sensor Circuit Low Input below 0.3V.
Diagnostic Trouble Code (DTC) P0110 (Symptom Code 1) (Flash Code 23)
Intake Air Temperature (IAT) Sensor Circuit High Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0110 (Symptom Code 1) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0110 (Symptom Code 1) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the IAT sensor or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
C-57(B) C-116
92
IAT Sensor
5 4 3 2 1
Standard
3 1
resistance Go to Step 7 Go to Step 12
7 Using the DVM and check the IAT sensor signal
circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the MAF & IAT sensor connector.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
C-116
C-57(B) C-116
84 1
— Verify repair Go to Step 14
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–155
C-57(B) C-116
84 1
— Verify repair Go to Step 14
10 Using the DVM and check the IAT sensor ground
circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the MAF & IAT sensor connector.
3. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
C-116
3
Repair faulty
V harness and
Less than 1V Go to Step 11 verify repair
6E–156 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
3 Repair faulty
92
harness and
— verify repair Go to Step 14
12 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved? — Go to Step 13 Go to Step 14
13 Replace the MAF & IAT sensor assembly.
Is the action complete? — Verify repair —
14 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 15
15 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–157
Diagnostic Trouble Code (DTC) P0110 (Symptom Code 2) (Flash Code 23)
Intake Air Temperature (IAT) Sensor Circuit Low Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0110 (Symptom Code 2) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0110 (Symptom Code 2) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the IAT sensor or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
C-57(B) C-116
92
IAT Sensor
5 4 3 2 1
Standard
3 1
resistance Go to Step 7 Go to Step 8
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–159
Breaker Box
84 92
92
84
Repair faulty
harness and
— verify repair Go to Step 10
8 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved? — Go to Step 9 Go to Step 10
9 Replace the MAF & IAT sensor assembly.
Is the action complete? — Verify repair —
10 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 11
11 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–160 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
14 P0115 1 ON Engine Coolant Temperature ECT sensor output voltage is 1. ECM uses fuel temperature
(ECT) Sensor Circuit High more than 4.7V. as substitute.
Input 2. ECM uses 60 deg.C
condition for injection timing
2 ON Engine Coolant Temperature ECT sensor output voltage is
control.
(ECT) Sensor Circuit Low below 0.3V.
Input 3. ECM uses -25 deg.C
condition (4JA1-TC) or -15
deg.C condition (4JH1-TC)
for glow time control.
Diagnostic Trouble Code (DTC) P0115 (Symptom Code 1) (Flash Code 14)
Engine Coolant Temperature Sensor Circuit High Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0115 (Symptom Code 1) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0115 (Symptom Code 1) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the ECT sensor or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
C-57(B) E-41
93 1 2
ECT Sensor
2 1
2 1
Standard
resistance Go to Step 7 Go to Step 12
7 Using the DVM and check the ECT sensor signal
circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the ECT sensor connector.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
E-41
1
89 — Verify repair Go to Step 14
10 Using the DVM and check the ECT sensor ground
circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the ECT sensor connector.
3. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
E-41
2
Repair faulty
V harness and
Less than 1V Go to Step 11 verify repair
11 Using the DVM and check the ECT sensor ground
circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type A. (ECM
disconnected) Ref. Page 6E-103
3. Disconnect the ECT sensor connector.
4. Check the circuit for open circuit.
Was the problem found?
Breaker Box E-41
93
Repair faulty
2 harness and
93 — verify repair Go to Step 14
6E–164 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0115 (Symptom Code 2) (Flash Code 14)
Engine Coolant Temperature Sensor Circuit Low Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0115 (Symptom Code 2) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0115 (Symptom Code 2) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the ECT sensor or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
C-57(B) E-41
93 1 2
ECT Sensor
2 1
2 1
Standard
resistance Go to Step 7 Go to Step 8
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–167
Breaker Box
89 93
93
89
Repair faulty
harness and
— verify repair Go to Step 10
8 Substitute a known good ECT sensor assembly and
recheck.
Was the problem solved? — Go to Step 9 Go to Step 10
9 Replace the ECT sensor.
Is the action complete? — Verify repair —
10 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 11
11 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–168 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
15 P0180 B ON Fuel Temperature Sensor Cir- FT sensor output is high tem- The ECM use 75deg.C condi-
cuit Range/Performance perature (more than tions as substitute.
150deg.C) or low temperature
(below -40deg.C).
Diagnostic Trouble Code (DTC) P0180 (Symptom Code B) (Flash Code 15) Fuel
Temperature Sensor Circuit Range/Performance
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0180 (Symptom Code B) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0180 (Symptom Code B) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
5 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 6 Go to Step 7
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
7 Replace the injection pump assembly.
Is the action complete? — Verify repair —
6E–170 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0215 (Symptom Code A) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0215 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
6E–172 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0215 (Symptom Code B) (Flash Code 52) Fuel
Cutoff Solenoid Valve Circuit High Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0215 (Symptom Code B) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0215 (Symptom Code B) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the ECM or PSG
(pump control unit) connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
105
V
Less than 1V Go to Step 8 Go to Step 7
7 Repair the short to voltage circuit between the ECM
and PSG (pump control unit).
Was the problem solved?
C-57 E-6
5
105 — Verify repair Go to Step 8
8 Replace the injection pump assembly.
Is the action complete? — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–175
Diagnostic Trouble Code (DTC) P0215 (Symptom Code C) (Flash Code 52) Fuel
Cutoff Solenoid Valve Always Active
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0215 (Symptom Code C) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0215 (Symptom Code C) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the ECM or PSG
(pump control unit) connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
105
5
Repair faulty
harness and
— verify repair Go to Step 7
7 Replace the injection pump assembly.
Is the action complete? — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–177
Diagnostic Trouble Code (DTC) P0215 (Symptom Code D) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0215 (Symptom Code D) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0215 (Symptom Code D) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
5 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 6 Go to Step 7
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
7 Replace the injection pump assembly.
Is the action complete? — Verify repair —
6E–178 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
54 P0216 A ON Injection Timing Control 1. Engine speed is more Fuel injection quantity is
Circuit Malfunction than 700rpm. reduced.
2. Fuel injection quantity is
more than 4mg/stk.
3. Deviation of actual
injection timing and
desired injection timing is
more than +3 deg. CA or
-6 deg. CA for 8
seconds.
B ON Injection Timing Control 1. Engine speed is more
Circuit Malfunction than 2014rpm.
2. Fluctuation of actual
injection timing is more
than +-5.2 deg. CA.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–179
Circuit Description Air bleeding procedure:
The ECM is calculates an injection quantity and an 1.Operate the priming pump until strong resistance is
injection timing using the various sensors (crankshaft felt.
position sensor, camshaft position sensor, engine 2.Wait 1 minute, and operate the priming pump until
coolant temperature sensor, etc.). The timing control strong resistance is felt.
valve (TCV) operation performs an injection timing 3.Wait 1 minute, and operate the priming pump until
decision. strong resistance is felt.
The TCV performs as a variable throttle, using the rapid 4.Turn the ignition switch to the "ON" position. Wait
opening and closing cycle of the valve needle in the until the glow indicator lamp turns off.
TCV.
5.Turn the ignition switch to the "START" position and
The TCV is assembled in the injection pump. The signal
crank the engine until it starts.
of desired injection timing and actual injection timing are
exchanged via the CAN-bus between the PSG and 6.If the engine does not start, repeat Step 3 - 5.
ECM. 7.Allow the engine to idle for 3 minutes to bleed air
If the timer position is out of tolerance (deviation or completely form the fuel system and check for fuel
fluctuation), DTC P0216 will be stored. leakage.
• Poor connection at ECM and PSG-Inspect harness
connectors for backed out terminals, improper
Diagnostic Aids mating, broken locks, improperly formed or damaged
An intermittent may be caused by the following: terminals, and poor terminal to wire connection.
• Poor connections. • Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
• Misrouted harness.
the "Actual Injection Start" display on the Tech2 while
• Rubbed through wire insulation. moving connectors and wiring harness related to the
• Broken wire inside the insulation. sensor.
• Insufficient air bleeding of fuel line.
• Low fuel quantity in the fuel tank.
Check for the following conditions:
• Insufficient air bleeding of fuel line inside, clogged
fuel filter or pinched fuel pipe/hose may cause the
DTC store or improper engine performance.
6E–180 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0216 (Symptom Code A) (Flash Code 54)
Injection Timing Control Circuit Malfunction
Diagnostic Trouble Code (DTC) P0216 (Symptom Code B) (Flash Code 54)
Injection Timing Control Circuit Malfunction
Replace the
eye bolt with
gauze filter and
- verify repair Go to Step 8
8 Is the ECM programmed with the latest software
release? If
not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved? - Verify repair Go to Step 9
9 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
(if equipped) must be linked to the ECM. Refer to
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Go to Step 10 Go to Step 11
6E–182 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 3) (Flash Ccode 64)
Turbocharger Wastegate Solenoid "A" Range/Performance
Step Action Value(s) Yes No
1 Was the "On-Board Diagnostic (OBD) System Check" Go to On Board
performed? Diagnostic
(OBD) System
- Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor As Stored By ECU" in Refer to
"F0: Diagnostic Trouble Codes". Diagnostic Aids
Is the DTC P0243 (Symptom Code 3) stored as and Go to Step
"Present Failure"? - Go to Step 3 3
3 1. Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0: Refer to
Diagnostic Trouble Codes". Diagnostic Aids
Was the DTC P0243 (Symptom Code 3) stored in this and Go to Step
ignition cycle? - Go to Step 4 4
4 Remove the vacuum hose & vacuum regulating valve
and check for the following conditions.
• Objects blocking the vacuum hose.
• Objects blocking the vacuumregulating valve.
• Vacuum leaking at vacuum hose or vacuum
regulating valve.
• Objects blocking at the wastegate solenoidvalve.
If a problem is found, repair as necessary.
Was the problem found? - Verify repair Go to Step 5
5 Remove the vacuum pressure sensor and visually
check.
Was the problem found? - Go to Step 6 Go to Step 8
6 Substitute a known good vacuum pressure sensor
and recheck.
Was the problem solved? - Go to Step 7 Go to Step 8
7 Replace the vacuum pressure sensor.
Is the action complete? - Verify repair -
6E–186 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Approximately
14.7 - 16.1 W
at 20°C Go to Step 11 Go to Step 9
9 Substitute a known good wastegate control solenoid
and recheck.
Was the problem solved? - Go to Step 10 Go to Step 11
10 Replace the wastegate control solenoid.
Is the action complete? - Verify repair -
11 Using the pressure gauge and check the turbocharger
wastegate valve operation for broken diaphragm.
If a problem is found, repair as necessary.
Was a problem found? - Go to Step 12 Go to Step 13
12 Replace the turbocharger wastegate valve .
Is the action complete? - Verify repair -
13 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved? - Verify repair Go to Step 14
14 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
(if equipped) must be linked to the ECM. Refer to
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Verify repair -
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–187
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 4) (Flash Code 64)
Turbocharger Wastegate Solenoid "A" Low
Step Action Value(s) Yes No
1 Was the "On-Board Diagnostic (OBD) System Check" Go to On Board
performed? Diagnostic
(OBD) System
- Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor As Stored By ECU" in Refer to
"F0: Diagnostic Trouble Codes". Diagnostic Aids
Is the DTC P0243 (Symptom Code 4) stored as and Go to Step
"Present Failure"? - Go to Step 3 3
3 1. 1Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0: Refer to
Diagnostic Trouble Codes". Diagnostic Aids
Was the DTC P0243 (Symptom Code 4) stored in this and Go to Step
ignition cycle? - Go to Step 4 4
4 Check for poor/faulty connection at the wastegate
control solenoid or ECM connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
C-57 C-123
Approximately
14.7 - 16.1 W
at 20°C Go to Step 6 Go to Step 9
6E–188 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Repair faulty
harness and
- verify repair Go to Step 11
9 Substitute a known good wastegate control solenoid
and recheck.
Was the problem solved? - Go to Step 10 Go to Step 11
10 Replace the wastegate control solenoid.
Is the action complete? - Verify repair -
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–189
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 5) (Flash Code 64)
Turbocharger Wastegate Solenoid "A" Range/Performance
Step Action Value(s) Yes No
1 Was the "On-Board Diagnostic (OBD) System Check" Go to On Board
performed? Diagnostic
(OBD) System
- Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor As Stored By ECU" in Refer to
"F0: Diagnostic Trouble Codes". Diagnostic Aids
Is the DTC P0243 (Symptom Code 5) stored as and Go to Step
"Present Failure"? - Go to Step 3 3
3 1. Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0: Refer to
Diagnostic Trouble Codes". Diagnostic Aids
Was the DTC P0243 (Symptom Code 5) stored in this and Go to Step
ignition cycle? - Go to Step 4 4
4 Visually check the vacuum regulating valve.
If a problem is found, repair as necessary.
Was the problem found? - Verify repair Go to Step 5
5 Using the DVM and check the wastegate control
solenoid.
1. Ignition "Off", engine "Off".
2. Disconnect thewastegatesolenoid connector.
3. Measure the resistance of wastegate solenoid
coil.
Does the tester indicate standard resistance?
Wastegate Solenoid
Approximately
14.7 - 16.1 W
at 20°C Go to Step 8 Go to Step 6
6 Substitute a known good wastegate control solenoid
and recheck.
Was the problem solved? - Go to Step 7 Go to Step 8
7 Replace the wastegate control solenoid.
Is the action complete? - Verify repair -
8 Using the pressure gauge and check the turbocharger
wastegate valve operation for broken diaphragm.
If a problem is found, repair as necessary.
Was a problem found? - Go to Step 9 Go to Step 10
9 Replace the turbocharger wastegate valve .
Is the action complete? - Verify repair -
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–191
C-57 C-123
V Repair faulty
harness and
Less than 1V Go to Step 15 verify repair
13 Substitute a known good vacuum pressure sensor
assembly and recheck.
Was the problem solved? - Go to Step 14 Go to Step 15
14 Replace the vacuum pressure sensor assembly.
Is the action complete? - Verify repair -
15 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved? - Verify repair Go to Step 16
16 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
(if equipped) must be linked to the ECM. Refer to
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Verify repair -
6E–192 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 6) (Flash Code 64)
Turbocharger Wastegate Solenoid "A" Malfunction
Step Action Value(s) Yes No
1 Was the "On-Board Diagnostic (OBD) System Check" Go to On Board
performed? Diagnostic
(OBD) System
- Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor As Stored By ECU" in Refer to
"F0: Diagnostic Trouble Codes". Diagnostic Aids
Is the DTC P0243 (Symptom Code 6) stored as and Go to Step
"Present Failure"? - Go to Step 3 3
3 1. 1Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0: Refer to
Diagnostic Trouble Codes". Diagnostic Aids
Was the DTC P0243 (Symptom Code 6) stored in this and Go to Step
ignition cycle? - Go to Step 4 4
4 Visually check the turbocharger wastegate valve and
hose.
If the hose is clogged or disconnected, repair as
necessary.
Was the problem found? - Verify repair Go to Step 5
5 Using the pressure gauge and check the turbocharger
wastegate valve operation for broken diaphragm or
restrict shaft operation.
If a problem is found, repair as necessary.
Was a problem found? - Go to Step 6 Go to Step 7
6 Replace the turbocharger wastegate valve.
Is the action complete? - Verify repair -
7 Check for poor/faulty connection at the MAF sensor or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
C-57 C-116
- Verify repair Go to Step 8
8 Visually check the MAF sensor.
Was the problem found? - Go to Step 10 Go to Step 9
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–193
V Repair faulty
harness and
Less than 1V Go to Step 12 verify repair
10 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved? - Go to Step 11 Go to Step 12
11 Replace the MAF & IAT sensor assembly.
Is the action complete? - Verify repair -
12 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved? - Verify repair Go to Step 13
13 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
(if equipped) must be linked to the ECM. Refer to
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Verify repair -
6E–194 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 8) (Flash Code 64)
Turbocharger Wastegate Solenoid "A" High
Step Action Value(s) Yes No
1 Was the "On-Board Diagnostic (OBD) System Check" Go to On Board
performed? Diagnostic
(OBD) System
- Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor As Stored By ECU" in Refer to
"F0: Diagnostic Trouble Codes". Diagnostic Aids
Is the DTC P0243 (Symptom Code 8) stored as and Go to Step
"Present Failure"? - Go to Step 3 3
3 1. Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0:
Diagnostic Trouble Codes".
Was the DTC P0243 (Symptom Code 8) stored in this Refer to
ignition cycle? - Go to Step 4 Diagnostic Aids
4 Check for poor/faulty connection at the wastegate
control solenoid or ECM connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found? - Verify repair Go to Step 5
5 Using the DVM and check the wastegate control
solenoid.
1. Ignition "Off", engine "Off".
2. Disconnect thewastegatesolenoid connector.
3. Measure the resistance of wastegate solenoid
coil.
Does the tester indicate standard resistance?
Wastegate Solenoid
Approximately
14.7- 16.1 W at
20°C Go to Step 6 Go to Step 8
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–195
C-123
No continuity Go to Step 10 Go to Step 7
7 Repair the short to voltage circuit.
Is the action complete? - Verify repair -
8 Substitute a known good wastegate control solenoid
and recheck.
Was the problem solved? - Go to Step 9 Go to Step 10
9 Replace the wastegate control solenoid.
Is the action complete? - Verify repair -
10 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved? - Verify repair Go to Step 11
11 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
(if equipped) must be linked to the ECM. Refer to
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Verify repair -
6E–196 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0251 (Symptom Code 6) (Flash Code 53)
Injection Pump Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
6E–198 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0251 (Symptom Code 7) (Flash Code 53)
Injection Pump Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0251 (Symptom Code 7) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0251 (Symptom Code 7) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Was the DTC P0335 (Symptom Code B), P0335 Go to DTC
(Symptom Code D) or P1335 (Symptom Code A) Chart P0335
stored at the same time? (Symptom
Code B)
(Symptom
Code D) or
P1335
(Symptom
— Code A) Go to Step 5
5 Check for poor/faulty connection at the ECM or PSG
(pump control unit) connector. If a poor/faulty
connection is found, repair the faulty terminal.
Was the problem found?
C-57(B) 91 E-6
CH1
0V®
CH2
0V®
Not available:
Go to Step 7
Fixed at low:
Measurement Terminal: CH1: 90(+) / CH2: 91(+) GND(-)
Measurement Scale: CH1: 50V/div / CH2: 10V/div 1ms/div
Go to Step 7
Measurement Condition: Approximately 2000rpm Fixed at High:
— Go to Step 13 Go to Step 8
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–201
91 8
Repair faulty
harness and
— verify repair Go to Step 8
8 Using the DVM and check the CKP sensor output
circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the PSG (pump control unit)
connector.
3. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
E-6
8
Repair faulty
V
harness and
Less than 1V Go to Step 9 verify repair
6E–202 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0251 (Symptom Code 9) (Flash Code 53)
Injection Pump Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0251 (Symptom Code 9) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0251 (Symptom Code 9) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Replace the injection pump assembly.
Is the action complete? — Verify repair —
6E–204 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0251 (Symptom Code A) (Flash Code 53)
Injection Pump Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0251 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0251 (Symptom Code A) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Replace the injection pump assembly.
Is the action complete? — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–205
Diagnostic Trouble Code (DTC) P0251 (Symptom Code B) (Flash Code 53)
Injection Pump Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0251 (Symptom Code B) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0251 (Symptom Code B) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Replace the injection pump assembly.
Is the action complete? — Verify repair —
6E–206 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0251 (Symptom Code D) (Flash Code 53)
Injection Pump Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0251 (Symptom Code D) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0251 (Symptom Code D) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Replace the injection pump assembly.
Is the action complete? — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–207
Diagnostic Trouble Code (DTC) P0251 (Symptom Code E) (Flash Code 53)
Injection Pump Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0251 (Symptom Code E) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0251 (Symptom Code E) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Was the DTC P1650 (Symptom Code A) or P1651 Go to DTC
(Symptom Code B) stored at the same time? Chart P1650
(Symptom
— Code A) Go to Step 5
5 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 6
6 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 7 Go to Step 8
7 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
8 Replace the injection pump assembly.
Is the action complete? — Verify repair —
6E–208 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
E ON Engine Speed Input Circuit Engine speed is more than When intermittent malfunction:
Range/Performance 5700rpm. 1. MAB (fuel cutoff solenoid
valve) is operated.
2. Desired injection quantity
becomes 0mg/strk.
When preliminary malfunction:
ECM uses doubled pump cam-
shaft speed as substitute
engine speed.
Diagnostic Trouble Code (DTC) P0335 (Symptom Code B) (Flash Code 43)
Crankshaft Position Sensor Circuit Malfunction
Diagnostic Trouble Code (DTC) P0335 (Symptom Code D) (Flash Code 43)
Crankshaft Position Sensor Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
6E–210 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Breaker Box
90 98
Approximately
90 0.9k9 at 20°C Go to Step 10 Go to Step 7
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–211
1
2 Approximately
0.9k9 at 20°C Go to Step 8 Go to Step 14
8 Using the DVM and check the CKP sensor circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type A. (ECM
disconnected) Ref. Page 6E-103
3. Disconnect the CKP sensor connector.
4. Check the circuit for open, short to sensor wire or
short to ground circuit.
Was the problem found?
Breaker Box
90 98 101
Breaker Box
E-9
90 98
Repair faulty
harness and
— verify repair Go to Step 9
6E–212 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
1
2
V V
Less than 1V Verify repair —
10 Using the DVM and check the CKP sensor signal.
1. Ignition “On”, engine “On”.
2. Measure the CKP output voltage at the sensor
and ECM.
Does the tester indicate standard voltage?
0V®
Diagnostic Trouble Code (DTC) P0335 (Symptom Code E) (Flash Code 43)
Engine Speed Input Circuit Range/Performance
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0335 (Symptom Code E) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0335 (Symptom Code E) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Ask to the customer whether over-speed condition Explain the
such as miss-gear shifting etc. has been experienced reason of DTC
or not. — to the customer Go to Step 5
5 Check for poor/faulty connection at the CKP sensor or
ECM connector. If a poor/faulty connection is found,
repair the faulty terminal.
Was the problem found?
0V®
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
66 P0380 4 ON Glow Relay Circuit Voltage Glow relay circuit open or No fail-safe function.
Low short to ground circuit.
8 ON Glow Relay Circuit Voltage Glow relay circuit short to volt-
High age circuit.
Diagnostic Trouble Code (DTC) P0380 (Symptom Code 4) (Flash Code 66)
Glow Relay Circuit Voltage Low
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0380 (Symptom Code 4) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0380 (Symptom Code 4) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the glow relay or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
C-57 X-5 3
1
2
4
Grow Relay
Replace glow
Approximately relay and verify
1059 Go to Step 6 repair
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–219
X-5
V
10-14.5V Go to Step 8 Go to Step 7
7 Repair the open or short to ground circuit between the
ECM main relay and glow relay.
Is the action complete? — Verify repair —
8 Using the DVM and check the glow relay ground
circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type A. (ECM
disconnected) Ref. Page 6E-103
3. Remove the glow relay from the relay box.
4. Check the circuit for open or short to ground
circuit.
Was the problem found?
Breaker Box X-5
94
94
Repair faulty
harness and
— verify repair Go to Step 9
6E–220 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0380 (Symptom Code 8) (Flash Code 66)
Glow Relay Circuit Voltage High
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0380 (Symptom Code 8) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0380 (Symptom Code 8) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
5 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 6 —
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–222 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 4) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 8) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
67 P0381 4 ON Glow Plug Indicator Circuit Glow plug indicator circuit No fail-safe function.
Voltage Low open or short to ground cir-
cuit.
8 ON Glow Plug Indicator Circuit Glow plug indicator circuit
Voltage High short to voltage circuit.
Circuit Description the glow plugs remain active for a certain period
depending on engine coolant temperature.
The function of the glow time indicator lamp is to inform
the driver whether the glow system is activated.
Diagnostic Aids
When the lamp turned off, the engine can be started.
This does not imply that the glow plugs are no longer An intermittent may be caused by the following:
activated. • Poor connections.
In the after glow phase the lamp is not illuminated but
• Misrouted harness.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–223
• Rubbed through wire insulation. poor terminal to wire connection.
• Broken wire inside the insulation. • Damaged harness-Inspect the wiring harness for
Check for the following conditions: damage. If the harness appears to be OK, observe
• Poor connection at ECM-Inspect harness connectors the DTC P0381 display on the Tech2 while moving
for backed out terminals, improper mating, broken connectors and wiring harnesses. A change in the
locks, improperly formed or damaged terminals, and display will indicate the location of the fault.
Diagnostic Trouble Code (DTC) P0381 (Symptom Code 4) (Flash Code 67)
Glow Plug Indicator Circuit Voltage Low
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0381 (Symptom Code 4) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0381 (Symptom Code 4) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 1. Ignition “On”, engine “Off”.
2. Check the glow plug indicator lamp.
Does the lamp turn “On”? — Go to Step 5 Go to Step 6
5 1. Ignition “On”, engine “Off”.
2. Check the glow plug indicator lamp.
Does the lamp turn “Off”? — Go to Step 9 Go to Step 7
6 Check the glow plug indicator lamp bulb.
If the bulb is burnt out, repair as necessary.
Was the problem found? — Verify repair Go to Step 7
6E–224 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
6 B-24
Breaker Box B-24
43
43
6 B-24
Repair faulty
harness and
— verify repair Go to Step 9
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–225
Diagnostic Trouble Code (DTC) P0381 (Symptom Code 8) (Flash Code 67)
Glow Plug Indicator Circuit Voltage High
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0381 (Symptom Code 8) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0381 (Symptom Code 8) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
5 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 6 —
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–227
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 3) (Flash Code 32)
Exhaust Gas Recirculation Flow Excessive Detected
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0400 (Symptom Code 3) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0400 (Symptom Code 3) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Remove the MAF & IAT sensor assembly and check
for the following conditions.
• Objects blocking the air cleaner.
• Objects blocking the MAF sensor.
• Vacuum leaking at intake duct.
• Objects blocking the turbocharger.
If a problem is found, repair as necessary.
Was the problem found? — Verify repair Go to Step 5
5 Remove the MAF & IAT sensor assembly and visually
check.
Was the problem found? — Go to Step 6 Go to Step 8
6 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved? — Go to Step 7 Go to Step 8
7 Replace the MAF & IAT sensor assembly.
Is the action complete? — Verify repair —
8 Using the DVM and check the EGR EVRV.
1. Ignition “Off”, engine “Off”.
2. Disconnect the EGR EVRV connector.
3. Measure the resistance of EGR EVRV solenoid
coil.
Does the tester indicate standard resistance?
EGR EVRV
2 1
2 1
Approximately
149 at 20°C Go to Step 11 Go to Step 9
6E–230 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
• Solenoid 95%: EGR Valve Open
• Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
• Vacuum Apply: EGR Valve Open
• Vacuum Release: EGR Valve Close
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 4) (Flash Code 32)
Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0400 (Symptom Code 4) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0400 (Symptom Code 4) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the EGR EVRV or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
C-57 C-115
1 2
97 — Verify repair Go to Step 5
5 Using the DVM and check the EGR EVRV.
1. Ignition “Off”, engine “Off”.
2. Disconnect the EGR EVRV connector.
3. Measure the resistance of EGR EVRV solenoid
coil.
Does the tester indicate standard resistance?
EGR EVRV
2 1
2 1
Approximately
149 at 20°C Go to Step 6 Go to Step 9
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–233
V
10-14.5 V Go to Step 8 Go to Step 7
7 Repair the open circuit between the ECM main relay
and EGR EVRV.
Is the action complete? — Verify repair —
8 Using the DVM and check the EGR EVRV circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type A. (ECM
disconnected) Ref. Page 6E-103
3. Remove the EGR EVRV connector.
4. Check the circuit for open or short to ground
circuit.
Was the problem found?
Breaker Box C-115
97
97
Repair faulty
harness and
— verify repair Go to Step 11
9 Substitute a known good EGR EVRV and recheck.
Was the problem solved? — Go to Step 10 Go to Step 11
6E–234 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 5) (Flash Code 32)
Exhaust Gas Recirculation Flow Insufficient Detected
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0400 (Symptom Code 5) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0400 (Symptom Code 5) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Visually check the EGR control vacuum hose.
If the hose is clogged or disconnected, repair as
necessary.
Was the problem found? — Verify repair Go to Step 5
5 Using the DVM and check the EGR EVRV.
1. Ignition “Off”, engine “Off”.
2. Disconnect the EGR EVRV connector.
3. Measure the resistance of EGR EVRV solenoid
coil.
Does the tester indicate standard resistance?
EGR EVRV
2 1
2 1
Approximately
149 at 20°C Go to Step 8 Go to Step 6
6 Substitute a known good EGR EVRV and recheck.
Was the problem solved? — Go to Step 7 Go to Step 8
7 Replace the EGR EVRV.
Is the action complete? — Verify repair —
6E–236 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Tech 2:
3. Using the Tech 2, ignition "On" and engine "On".
4. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
5. Operate the Tech 2 in accordance with procedure.
• Solenoid 95%: EGR Valve Open
• Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
• Vacuum Apply: EGR Valve Open
• Vacuum Release: EGR Valve Close
C-116
5
Repair faulty
V
harness and
Less than 1V Go to Step 16 verify repair
14 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved? — Go to Step 15 Go to Step 16
15 Replace the MAF & IAT sensor assembly.
Is the action complete? — Verify repair —
16 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 17
17 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–238 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 8) (Flash Code 32)
Exhaust Gas Recirculation Circuit Short to Battery
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0400 (Symptom Code 8) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0400 (Symptom Code 8) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Check for poor/faulty connection at the EGR EVRV or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
C-57 C-115
1 2
97 — Verify repair Go to Step 5
5 Using the DVM and check the EGR EVRV.
1. Ignition “Off”, engine “Off”.
2. Disconnect the EGR EVRV connector.
3. Measure the resistance of EGR EVRV solenoid
coil.
Does the tester indicate standard resistance?
EGR EVRV
2 1
2 1
Approximately
149 at 20°C Go to Step 6 Go to Step 8
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–239
1 2
Diagnostic Trouble Code (DTC) P0500 (Symptom Code 1) (Flash Code 24)
Vehicle Speed Sensor Circuit High Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0500 (Symptom Code 1) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0500 (Symptom Code 1) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
6E–242 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
0V®
Refer to
Measurement Terminal: 68(+) GND(-) Diagnostic Aids
Measurement Scale: 5V/div 50ms/div and Go to Step
Measurement Condition: Approximately 20km/h
15 Refer the table
8 Replace the VSS.
Is the action complete? — Verify repair
9 Replace the TCM.
Is the action complete?
IMPORTANT: The replacement TCM must be
programmed. “SPS (Service Programming System)
is necessary.” — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–243
9
Repair faulty
V
harness and
Less than 1V Go to Step 11 verify repair
11 Using the DVM and check the VSS signal circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the VSS connector and meter
connector.
3. Check the circuit for open or short to ground
circuit.
If a open or short to ground circuit is found, repair the
faulty harness and verify repair.
Is the action complete?
B-24 E-44
— Verify repair —
12 Replace the speed meter.
Is the action complete? — Verify repair —
13 Using the DVM and check the VSS signal circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the meter connector and ECM
connector.
3. Ignition “On”.
4. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
B-24
10
Repair faulty
V
harness and
Less than 1V Go to Step 14 verify repair
6E–244 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
C-56
68
B-24 10
Repair faulty
harness and
— verify repair Go to Step 15
15 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 16
16 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–245
Diagnostic Trouble Code (DTC) P0500 (Symptom Code A) (Flash Code 24)
Vehicle Speed Sensor Input Signal Frequency Too High
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0500 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0500 (Symptom Code A) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Perform test drive and check the speed meter.
Does the speed meter indicate correct vehicle speed. — Go to Step 5 Go to Step 6
5 Perform test drive and use the Tech 2.
Monitor the “Vehicle Speed” in the data display.
Does the Tech 2 indicate correct vehicle speed as
same as the speed meter indication in the instrument
panel? — Go to Step 10 Go to Step 7
6 Remove the VSS from the housing case and visually
check.
Was the problem found? — Go to Step 8 Go to Step 7
6E–246 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
0V®
Refer to
Measurement Terminal: 68(+) GND(-) Diagnostic Aids
Measurement Scale: 5V/div 50ms/div and Go to Step
Measurement Condition: Approximately 20km/h
10 Refer the table
8 Replace the VSS.
Is the action complete? — Verify repair
9 Replace the TCM.
Is the action complete?
IMPORTANT: The replacement TCM must be
programmed. “SPS (Service Programming System)
is necessary.” — Verify repair —
10 Check any accessory parts which may cause electric Remove the
interference or magnetic interference. accessory parts
Was the problem found? — and verify repair Go to Step 12
11 Replace the speed meter.
Is the action complete? — Verify repair —
12 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 13
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–247
Diagnostic Trouble Code (DTC) P0500 (Symptom Code B) (Flash Code 24)
Vehicle Speed Sensor Incorrect Signal
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0500 (Symptom Code B) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0500 (Symptom Code B) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Perform test drive and check the speed meter.
Does the speed meter indicate correct vehicle speed. — Go to Step 5 Go to Step 6
5 Perform test drive and use the Tech 2.
Monitor the “Vehicle Speed” in the data display.
Does the Tech 2 indicate correct vehicle speed as
same as the speed meter indication in the instrument
panel? — Go to Step 17 Go to Step 7
6 Check for poor/faulty connection at the VSS, TCM (A/
T 2WD) and meter connectors. If a poor/faulty
connection is found, repair the faulty terminal.
Was the problem found?
E-44
1 3
2
B-24 9 10
C-94(10)
0V®
Refer to
Measurement Terminal: 68(+) GND(-) Diagnostic Aids
Measurement Scale: 5V/div 50ms/div and Go to Step
Measurement Condition: Approximately 20km/h
17 Refer the table
10 Replace the VSS.
Is the action complete? — Verify repair
6E–250 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
9
Repair faulty
V
harness and
Less than 1V Go to Step 13 verify repair
13 Using the DVM and check the VSS signal circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the VSS connector and meter
connector.
3. Check the circuit for open or short to ground
circuit.
If a open or short to ground circuit is found, repair the
faulty harness and verify repair.
Is the action complete?
B-24 E-44
— Verify repair —
14 Replace the speed meter.
Is the action complete? — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–251
10
Repair faulty
V
harness and
Less than 1V Go to Step 16 verify repair
16 Using the DVM and check the VSS signal circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type A. (ECM
disconnected) Ref. Page 6E-103
3. Disconnect the meter connector.
4. Check the circuit for open or shot to ground circuit.
Was the problem found?
Breaker Box B-24
68
68
B-24 10
Repair faulty
harness and
— verify repair Go to Step 17
6E–252 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
35 P0560 1 OFF System Voltage Too High System voltage is more than ECM uses 9V conditions as
20V. substitute.
2 OFF System Voltage Too Low System voltage is below 7V.
A OFF System Voltage Malfunction System voltage of PSG PSG uses default voltage as
(pump control unit) is below substitute.
4.5V or more than 27V.
Circuit Description voltage to the ECM excessively high or low, DTC P0560
(Symptom Code 1) or P0560 (Symptom Code 2) will be
The ECM and PSG monitors the system voltage on the stored. The system voltage to the PSG excessively high
ignition feed terminal to the ECM or PSG. The system
6E–254 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
or low, DTC P0560 (Symptom Code A) will be stored. • Poor connection at ECM and PSG-Inspect harness
connectors for backed out terminals, improper
Diagnostic Aids mating, broken locks, improperly formed or damaged
terminals, and poor terminal to wire connection.
An intermittent may be caused by the following:
• Damaged harness-Inspect the wiring harness for
• Poor connections. damage. If the harness appears to be OK, observe
• Misrouted harness. the “System Voltage” display on the Tech2 while
• Rubbed through wire insulation. moving connectors and wiring harness related to the
• Broken wire inside the insulation. sensor.
Check for the following conditions:
Diagnostic Trouble Code (DTC) P0560 (Symptom Code 1) (Flash Code 35)
System Voltage Too High
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0560 (Symptom Code 1) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0560 (Symptom Code 1) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Was the battery jump start cable incorrectly Verify
connecting? — procedure Go to Step 5
5 1. Using the Tech 2, ignition “On” and engine “On”.
2. Monitor the “System Voltage” in the data display.
3. Load the electrical system by turning on the Check the
headlights, etc.. charging
Does the Tech 2 indicate correct ignition voltage? 10 - 14.5V Go to Step 6 system
6 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 7
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–255
Diagnostic Trouble Code (DTC) P0560 (Symptom Code 2) (Flash Code 35)
System Voltage Too Low
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0560 (Symptom Code 2) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0560 (Symptom Code 2) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 1. Using the Tech 2, ignition “On” and engine “On”.
2. Monitor the “System Voltage” in the data display.
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate enough ignition voltage? 10 - 14.5V Go to Step 6 Go to Step 5
5 Using the DVM and check the battery voltage at the Check the
battery terminal. charging
Does the tester indicate enough battery voltage? system, charge
or replace the
10 - 14.5V Go to Step 6 battery
6 Check for poor/faulty connection at the ECM
connector. If a poor/faulty connection is found, repair
as necessary.
Was the problem found?
C-56
3
Replace ECM
main relay and
120-1509 Go to Step 8 verify repair
8 Check for poor/faulty connection of the ECM ground
at the body. If a poor/faulty connection is found, repair
as necessary.
Was the problem found?
C-109
Diagnostic Trouble Code (DTC) P0560 (Symptom Code A) (Flash Code 35)
System Voltage Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0560 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0560 (Symptom Code A) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the PSG (pump
control unit) connector. If a poor/faulty connection is
found, repair as necessary.
Was the problem found?
E-6
6
6 E-6
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
18 P0561 A OFF Ignition Switch Circuit Mal- The ECM recognized ignition ECM stops engine.
function switch turn off signal during
ECM is activated.
B OFF Ignition Switch Circuit Mal- Ignition switch circuit is mal-
function function.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–261
Circuit Description • Rubbed through wire insulation.
The ECM monitors the ignition switch signal on the feed • Broken wire inside the insulation.
terminal to the ECM. If the ignition switch signal with Check for the following conditions:
malfunction, DTC P0561 (Symptom Code A) or DTC • Poor connection at ECM-Inspect harness connectors
P0561 (Symptom Code B) will be stored. for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
Diagnostic Aids poor terminal to wire connection.
• Damaged harness-Inspect the wiring harness for
An intermittent may be caused by the following:
damage. If the harness appears to be OK, observe
• Poor connections. the “Ignition Status” display on the Tech2 while
• Misrouted harness. moving connectors and wiring harness related to the
sensor.
Diagnostic Trouble Code (DTC) P0561 (Symptom Code A) (Flash Code 18)
Ignition Switch Circuit Malfunction
Diagnostic Trouble Code (DTC) P0561 (Symptom Code B) (Flash Code 18)
Ignition Switch Circuit Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0561 (Symptom Code A) or P0561 and Go to Step
(Symptom Code B) stored as “Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0561 (Symptom Code A) or P0561 and Go to Step
(Symptom Code B)stored in this ignition cycle? — Go to Step 4 4
4 Check the “Engine fuse (10A)”.
If the fuse is burnt out, repair as necessary.
Was the problem found? — Verify repair Go to Step 5
6E–262 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
39
C-107
Repair faulty
harness and
9 — verify repair Go to Step 6
6 Check the ignition switch.
If a poor/faulty connection is found, repair as
necessary.
Was the problem found? — Verify repair Go to Step 7
7 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 8
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–263
Diagnostic Trouble Code (DTC) P0606 (Symptom Code A) (Flash Code 28) ECU
Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0606 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0606 (Symptom Code A) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
6E–266 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU
Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0606 (Symptom Code B) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0606 (Symptom Code B) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
5 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 6 Go to Step 7
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
7 Replace the injection pump assembly.
Is the action complete? — Verify repair —
6E–268 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
46 P0645 4 ON A/C Compressor Relay Circuit A/C compressor relay circuit No fail-safe function.
Voltage Low open or short to ground cir-
cuit.
8 ON A/C Compressor Relay Circuit A/C compressor relay circuit
Voltage High short to voltage circuit.
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0645 (Symptom Code 4) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0645 (Symptom Code 4) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the A/C
compressor relay or ECM connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
X-14
C-56
— Verify repair Go to Step 5
5 Using the DVM and check the A/C compressor relay.
1. Ignition “Off”, engine “Off”.
2. Remove the A/C compressor relay from the relay
box.
3. Check the relay coil.
Was the DVM indicated specified value?
Replace A/C
compressor
relay and verify
120-1509 Go to Step 6 repair
6E–270 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
X-14
V
10-14.5V Go to Step 8 Go to Step 7
7 Repair the open or short to ground circuit between the
ECM main relay and A/C compressor relay.
Is the action complete? — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–271
X-14
Breaker Box
41
Repair faulty
harness and
— verify repair Go to Step 9
9 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 10
10 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–272 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 8) (Flash Code 46) A/C
Compressor Relay Circuit Voltage High
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0645 (Symptom Code 8) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0645 (Symptom Code 8) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
5 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 6 —
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–273
The ECM monitors the brake switch signal on the feed • Broken wire inside the insulation.
terminal to the ECM. If brake switch 1 or 2 circuit with Check for the following conditions:
malfunction, DTC P0703 (Symptom Code A) or P0703 • Poor connection at ECM-Inspect harness connectors
(Symptom Code B) will be stored. for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
Diagnostic Aids poor terminal to wire connection.
• Damaged harness-Inspect the wiring harness for
An intermittent may be caused by the following:
damage. If the harness appears to be OK, observe
• Poor connections. the “Brake Switch 1” and “Brake Switch 2” display on
• Misrouted harness. the Tech2 while moving connectors and wiring
harness related to the sensor.
Diagnostic Trouble Code (DTC) P0703 (Symptom Code A) (Flash Code 25)
Brake Switch Circuit Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0703 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–275
C-56 C-44
1 2
Brake Switch
Pedal is not
stepped on:
Continuity
Pedal stepped Replace pedal
on: No switch and
continuity Go to Step 7 verify repair
7 Using the DVM and check the brake switch 1 power
supply circuit.
1. Ignition “Off”, engine “Off”.
2. Remove the brake switch connector from the
brake switch.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
C-44
V
10-14.5V Go to Step 9 Go to Step 8
6E–276 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
2 Fixed at 10-
Pedal is not 14.5V: Go to
stepped on: Step 10
Less than 1V Fixed at less
V
Pedal stepped than 1V: Go to
on: 10-14.5V Go to Step 12 Step 11
10 Repair the short to voltage circuit between the brake
switch 1 connector and ECM.
Is the action complete?
C-56 C-44
30 2
— Verify repair —
11 Repair the open circuit between the brake switch 1
connector and ECM.
Is the action complete?
C-56 C-44
30 2
— Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–277
Diagnostic Trouble Code (DTC) P0703 (Symptom Code B) (Flash Code 25)
Brake Switch Circuit Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0703 (Symptom Code B) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0703 (Symptom Code B) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the brake switch
or ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
C-56 C-44
3 4
65 — Verify repair Go to Step 5
5 Using the DVM and check the brake switch 2.
1. Ignition “Off”, engine “Off”.
2. Remove the brake switch connector at the brake
pedal.
3. Check the brake switch 2.
Was the DVM indicated specified value?
Brake Switch
Pedal is not
stepped on:
No continuity Replace pedal
Pedal stepped switch and
on: Continuity Go to Step 6 verify repair
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–279
C-44
V
10-14.5V Go to Step 8 Go to Step 7
7 Repair the open circuit between the “ECM fuse (10A)”
and brake switch 2.
Is the action complete? — Verify repair —
8 Using the DVM and check the brake switch 2 circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type B. (ECM
connected)
3. Ignition “On”, engine “Off”.
4. Check the circuit for open or short to voltage
circuit.
Was the DVM indicated specified value?
Breaker Box
65
65 4
— Verify repair —
10 Repair the open circuit between the brake switch 2
connector and ECM.
Is the action complete?
C-56 C-44
65 4
— Verify repair —
11 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 12
12 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–281
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
57 P0704 6 ON Clutch Switch Input Circuit Clutch signal does not change No fail-safe function.
Malfunction between vehicle speed
1.5km/h and 80km/h since
ignition switch was tuned on.
Diagnostic Trouble Code (DTC) P0704 (Symptom Code 6) (Flash Code 57)
Clutch Switch Input Circuit Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P0704 (Symptom Code 6) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P0704 (Symptom Code 6) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the clutch switch
or ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
31 C-56 C-77
1
2
V
10-14.5V Go to Step 8 Go to Step 7
7 Repair the open circuit between the “ECM fuse (10A)”
and clutch switch.
Is the action complete? — Verify repair —
8 Using the DVM and check the clutch switch circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type B. (ECM
connected) Ref. Page 6E-104
3. Ignition “On”, engine “Off”.
4. Check the circuit for open or short to voltage
circuit.
Was the DVM indicated specified value?
Breaker Box
31
C-56 C-77
2
31 — Verify repair —
10 Repair the open circuit between the clutch switch
connector and ECM.
Is the action complete?
C-56 C-77
2
31 — Verify repair —
11 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 12
12 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–285
Diagnostic Trouble Code (DTC) P1105 (Symptom Code 1) (Flash Code 86)
Barometric Pressure Sensor Circuit High Input
Diagnostic Trouble Code (DTC) P1105 (Symptom Code 2) (Flash Code 86)
Barometric Pressure Sensor Circuit Low Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1105 (Symptom Code 1) or P1105 and Go to Step
(Symptom Code 2) stored as “Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P1105 (Symptom Code 1) or P1105 Refer to
(Symptom Code 2) stored in this ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
6E–286 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1120 (Symptom Code 1) (Flash Code 21)
Pedal/Throttle Position Sensor Circuit High Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–289
49 C-56 39
57
E-22
1 2 3
TPS
3 2 1
3 2 1
Standard
resistance Go to Step 7 Go to Step 12
7 Using the DVM and check the TPS power supply
circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the TPS connector.
3. Check the circuit for short to voltage circuit.
Was the DVM indicated specified value?
E-22
3
V
Approximately
5.0V Go to Step 9 Go to Step 8
8 Repair the short to voltage circuit between the ECM
and TPS.
Was the problem solved?
C-56
57
E-22
2
Repair faulty
V
harness and
Less than 1V Go to Step 10 verify repair
10 Using the DVM and check the TPS ground circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the TPS connector .
3. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
E-22
1
Repair faulty
V
harness and
Less than 1V Go to Step 11 verify repair
6E–292 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
C-56
49
E-22
Repair faulty
harness and
1 — verify repair Go to Step 14
12 Substitute a known good TPS and recheck.
Was the problem solved? — Go to Step 13 Go to Step 14
13 Replace the TPS.
Is the action complete? — Verify repair —
14 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 15
15 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–293
Diagnostic Trouble Code (DTC) P1120 (Symptom Code 7) (Flash Code 21)
Pedal/Throttle Position Sensor Voltage Supply Circuit High Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1120 (Symptom Code 7) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1120 (Symptom Code 7) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the TPS or ECM
connector. If a poor/faulty connection is found, repair
as necessary.
Was the problem found?
49 C-56 39
57
E-22
1 2 3
E-22
3
V Approximately
5.0V Go to Step 12 Go to Step 7
7 Repair the short to battery voltage circuit between the
ECM and TPS.
Was the problem solved?
C-56
57
E-22
Diagnostic Trouble Code (DTC) P1120 (Symptom Code 9) (Flash Code 21)
Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1120 (Symptom Code 9) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1120 (Symptom Code 9) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the TPS or ECM
connector. If a poor/faulty connection is found, repair
as necessary.
Was the problem found?
49 C-56 39
57
E-22
1 2 3
3
V
Approximately
5.0V Go to Step 10 Go to Step 7
7 Using the DVM and check the TPS power supply
circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the TPS connector and ECM
connector.
3. Check the circuit for short to TPS ground circuit.
Was the DVM indicated specified value?
E-22
1 3
C-56
57
E-22
Diagnostic Trouble Code (DTC) P1120 (Symptom Code D) (Flash Code 21)
Pedal/Throttle Position Sensor Brake Switch Error
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1120 (Symptom Code D) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1120 (Symptom Code D) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Visually check the TPS.
Check for the following conditions.
• Accelerator pedal sticking.
If a problem is found, repair as necessary.
Was the problem found? — Verify repair Go to Step 5
5 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Throttle Position” in the data display.
Does the Tech 2 indicate correct “Throttle Position”
from 0% to 100% depending on accelerator pedal
operation? — Go to Step 7 Go to Step 6
6 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Throttle Position” in the data display.
3. Adjust the TPS within 0% to 100%.
Was the problem solved? — Verify repair Go to Step 11
7 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Brake Switch 1” and “Brake Switch 2”
in the data display.
Does the Tech 2 indicate “Inactive” when the brake
pedal was not stepped on? — Go to Step 13 Go to Step 8
8 Adjust the brake switch.
Was the problem solved? — Verify repair Go to Step 9
9 Substitute a known good brake switch and recheck.
Was the problem solved? — Go to Step 10 Go to Step 13
10 Replace the brake switch.
Is the action complete? — Verify repair —
11 Substitute a known good TPS and recheck.
Was the problem solved? — Go to Step 12 Go to Step 13
12 Replace the TPS.
Is the action complete? — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–299
Diagnostic Trouble Code (DTC) P1120 (Symptom Code E) (Flash Code 21)
Pedal/Throttle Position Sensor Idle Position Switch Error
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1120 (Symptom Code E) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1120 (Symptom Code E) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Visually check the TPS.
Was the problem found? — Go to Step 8 Go to Step 5
5 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Throttle Position” in the data display.
Does the Tech 2 indicate correct “Throttle Position”
from 0% to 100% depending on accelerator pedal Go to Step 6Go
operation? — Go to Step 7 to Step 6
6 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Throttle Position” in the data display.
3. Adjust the TPS within 0% to 100%.
Was the problem solved? — Verify repair Go to Step 8
7 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Idle Switch” in the data display.
Does the Tech 2 indicate “Inactive” when the
accelerator pedal was stepped on? — Go to Step 10 Go to Step 8
8 Substitute a known good TPS and recheck.
Was the problem solved? — Go to Step 9 Go to Step 10
9 Replace the TPS.
Is the action complete? — Verify repair —
10 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 11
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–301
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant Temperature
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1173 (Symptom Code 3) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–303
ECT Sensor
2 1
2 1
Standard
resistance Go to Step 9 Go to Step 7
7 Substitute a known good ECT sensor assembly and
recheck.
Was the problem solved? — Go to Step 8 Go to Step 9
8 Replace the ECT sensor.
Is the action complete? — Verify repair —
9 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 10
6E–304 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 7) (Flash Code 22) Fuel
Reduction Caused By High Fuel Temperature
Diagnostic Trouble Code (DTC) P1173 (Symptom Code A) (Flash Code 22) Fuel
Reduction Caused By Low Fuel Temperature
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1173 (Symptom Code 7) or P1173 and Go to Step
(Symptom Code A) stored as “Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P1173 (Symptom Code 7) or P1173 Refer to
(Symptom Code A) stored in this ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
5 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 6 Go to Step 7
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
7 Replace the injection pump assembly.
Is the action complete? — Verify repair —
6E–306 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
43 P1335 A ON Engine Speed Output Circuit The PSG (pump control unit) Fuel injection quantity is
Malfunction is recognized defective reduced.
engine speed signal form the
ECM.
Diagnostic Trouble Code (DTC) P1335 (Symptom Code A) (Flash Code 43)
Engine Speed Output Circuit Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1335 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1335 (Symptom Code A) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Was the DTC P0335 (Symptom Code B) or P0335 Go to DTC
(Symptom Code D) stored at the same time? Chart P0335
(Symptom
Code B)
(Symptom
— Code C) Go to Step 5
5 Check for poor/faulty connection at the ECM or PSG
(pump control unit) connector. If a poor/faulty
connection is found, repair the faulty terminal.
Was the problem found?
C-57(B) 91 E-6
CH1
0V
CH2
0V
Not available:
Go to Step 7
Fixed at low:
Measurement Terminal: CH1: 90(+) / CH2: 91(+) GND(-) Go to Step 7
Measurement Scale: CH1: 50V/div / CH2: 10V/div 1ms/div Fixed at High:
Measurement Condition: Approximately 2000rpm
— Go to Step 13 Go to Step 8
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–309
Breaker Box
91 E-6
91 8
Repair faulty
harness and
— verify repair Go to Step 8
8 Using the DVM and check the CKP sensor output
circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the PSG (pump control unit)
connector.
3. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
E-6
8
Repair faulty
V
harness and
Less than 1V Go to Step 9 verify repair
6E–310 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
45 P1345 A ON Camshaft Speed Malfunction The PSG (pump control unit) No fail-safe function.
is recognized incorrect cam-
shaft speed signal.
Diagnostic Trouble Code (DTC) P1345 (Symptom Code A) (Flash Code 45)
Camshaft Speed Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1345 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1345 (Symptom Code A) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pump Speed” in the data display.
Does the Tech 2 indicate correct “Pump Speed”
depending on engine speed? — Go to Step 6 Go to Step 5
5 Check any accessory parts which may cause electric Remove the
interference or magnetic interference. accessory parts
Was the problem found? — and verify repair Go to Step 9
6 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 7
7 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 8 Go to Step 9
8 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
9 Replace the injection pump assembly.
Is the action complete? — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–313
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
47 P1520 A ON Neutral Switch ON Error Neutral switch signal is input- No fail-safe function.
ted “On” three times consecu-
tively under driving
conditions.
B ON Neutral Switch OFF Error Neutral switch signal is input-
ted “Off” three times consecu-
tively under driving
conditions.
Diagnostic Trouble Code (DTC) P1520 (Symptom Code A) (Flash Code 47)
Neutral Switch ON Error
Diagnostic Trouble Code (DTC) P1520 (Symptom Code B) (Flash Code 47)
Neutral Switch OFF Error
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1520 (Symptom Code A) or P1520 and Go to Step
(Symptom Code B) stored as “Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1520 (Symptom Code A) or P1520 and Go to Step
(Symptom Code B) stored in this ignition cycle? — Go to Step 4 4
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–315
C-57
87
M/T
E-11 E-12
A/T
E-51
2 3
A/T
3 2
Neutral (P or
6 5 4 3 2 1 N): Continuity
Other than Replace neutral
10 9 8 7 neutral (P or switch (inhibitor
N): No switch) and
8 continuity Go to Step 6 verify repair
6E–316 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
V 3
V
10-14.5V Go to Step 8 Go to Step 7
7 Repair the open circuit between the “ECM fuse (10A)”
and neutral switch (between the “Back Up fuse (15A)”
and inhibitor switch).
Is the action complete? — Verify repair —
8 Using the DVM and check the neutral switch (inhibitor
switch) circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type B. (ECM
connected) Ref. Page 6E-104
3. Ignition “On”, engine “Off”.
4. Check the circuit for open or short to voltage
circuit.
Was the DVM indicated specified value?
Breaker Box
87 E-6
87
A/T
C-57 E-51
2
8
87 — Verify repair —
10 Repair the open circuit between the neutral switch
connector (inhibitor switch connector) and ECM.
Is the action complete?
M/T
C-57 E-11
87
A/T
C-57 E-51
2
8
87 — Verify repair —
11 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 12
12 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–318 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1605 (Symptom Code C) (Flash Code 55)
Seed and Key File Destroyed
Diagnostic Trouble Code (DTC) P1605 (Symptom Code D) (Flash Code 55)
EEPROM Defect
Diagnostic Trouble Code (DTC) P1605 (Symptom Code E) (Flash Code 55)
EEPROM Defect
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”. Refer to
Is the DTC P1605 (Symptom Code C), P1605 Diagnostic Aids
(Symptom Code D) or P1605 (Symptom Code E) and Go to Step
stored as “Present Failure”? — Go to Step 3 3
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–319
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
56 P1610 A - Security Key and Security Immobilizer functions are not 1. Engine does not start.
Code not Programmed programmed in the ECM. 2. Check engine lamp flash.
Diagnostic Trouble Code (DTC) P1610 (Symptom Code A) (Flash Code 56)
Security Key and Security Code Not Programmed
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1610 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1610 (Symptom Code A) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 1. Using the Tech 2, ignition “On” and engine “Off”.
Refer to
2. Select “Immobilizer” in the system selection menu “Immobilizer
“Body”. Workshop
3. Select “Read DTC Info Ordered By Priority” in the Manual” & Go
“Diagnostic Trouble Code”. to DTC Chart
Was the any DTC's B0002 or B0009 stored in this B0002 or
ignition cycle? — B0009 Go to Step 5
5 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 6
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–322 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
56 P1611 A - Wrong Security Code Entered Received security code is not 1. Engine does not start.
correct. 2. Check engine lamp flash.
Diagnostic Trouble Code (DTC) P1611 (Symptom Code A) (Flash Code 56)
Wrong Security Code Entered
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1611 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1611 (Symptom Code A) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 1. Using the Tech 2, ignition “On” and engine “Off”.
Refer to
2. Select “Immobilizer” in the system selection menu “Immobilizer
“Body”. Workshop
3. Select “Read DTC Info Ordered By Priority” in the Manual” & Go
“Diagnostic Trouble Code”. to DTC Chart
Was the any DTC's B**** stored in this ignition cycle? — B**** Go to Step 5
5 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 6
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–324 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
56 P1612 A - Immobilizer No or Wrong Sig- Received challenge signal is 1. Engine does not start.
nal not correct or not received. 2. Check engine lamp flash.
Diagnostic Trouble Code (DTC) P1612 (Symptom Code A) (Flash Code 56)
Immobilizer No or Wrong Signal
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1612 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1612 (Symptom Code A) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 1. Using the Tech 2, ignition “On” and engine “Off”.
Refer to
2. Select “Immobilizer” in the system selection menu “Immobilizer
“Body”. Workshop
3. Select “Read DTC Info Ordered By Priority” in the Manual” & Go
“Diagnositic Trouble Code”. to DTC Chart
Was the DTC B0007 stored in this ignition cycle? — B0007 Go to Step 5
5 Check for poor/faulty connection at the immobilizer
control unit connector or ECM connector. If a poor/
faulty connection is found, repair as necessary.
Was the problem found?
C-56 42
35
B-68
8
7 — Verify repair Go to Step 6
6E–326 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
7
Repair faulty
V
harness and
Less than 1V Go to Step 7 verify repair
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–327
42
B-68
Repair faulty
harness and
7 — verify repair Go to Step 8
6E–328 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
8
V Repair faulty
harness and
Less than 1V Go to Step 9 verify repair
9 Using the DVM and check the ECM and immobilizer
control unit communication circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type A. (ECM
disconnected) Ref. Page 6E-103
3. Disconnect the immobilizer control unit connector.
4. Check the circuit for open or short to ground
circuit.
Was the problem found?
Breaker Box
35 B-68
B-68 35
Repair faulty
harness and
8 — verify repair Go to Step 10
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–329
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
56 P1613 A - Immobilizer No or Wrong Sig- Received response signal is 1. Engine does not start.
nal not correct or not received. 2. Check engine lamp flash.
Diagnostic Trouble Code (DTC) P1613 (Symptom Code A) (Flash Code 56)
Immobilizer No or Wrong Signal
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1613 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1613 (Symptom Code A) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 1. Using the Tech 2, ignition “On” and engine “Off”.
Refer to
2. Select “Immobilizer” in the system selection menu “Immobilizer
“Body”. Workshop
3. Select “Read DTC Info Ordered By Priority” in the Manual” & Go
“Diagnositic Trouble Code”. to DTC Chart
Was the any DTC's B**** stored in this ignition cycle? — B**** Go to Step 5
5 Check for poor/faulty connection at the immobilizer
control unit connector or ECM connector. If a poor/
faulty connection is found, repair as necessary.
Was the problem found?
C-56 42
35
B-68
8
7 — Verify repair Go to Step 6
6E–332 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
7
V Repair faulty
harness and
Less than 1V Go to Step 7 verify repair
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–333
42
B-68
Repair faulty
harness and
7 — verify repair Go to Step 8
8 Using the DVM and check the ECM and immobilizer
control unit communication circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the immobilizer control unit connector.
3. Ignition “On”.
4. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
B-68
8
Repair faulty
V
harness and
Less than 1V Go to Step 9 verify repair
6E–334 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
B-68 35
Repair faulty
harness and
8 — verify repair Go to Step 10
10 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 11
11 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–335
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
56 P1614 A - Wrong Transponder Key Received response signal is 1. Engine does not start.
not correct from the transpon- 2. Check engine lamp flash.
der key.
Diagnostic Trouble Code (DTC) P1614 (Symptom Code A) (Flash Code 56)
Wrong Transponder Key
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1614 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1614 (Symptom Code A) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 1. Using the Tech 2, ignition “On” and engine “Off”.
Refer to
2. Select “Immobilizer” in the system selection menu “Immobilizer
“Body”. Workshop
3. Select “Read DTC Info Ordered By Priority” in the Manual” & Go
“Diagnostic Trouble Code”. to DTC Chart
Was the any DTC's B**** stored in this ignition cycle? — B**** Go to Step 5
5 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 6
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must e
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–337
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
76 P1625 A OFF ECM Main Relay Switched When ignition switch was No fail-safe function.
Off Too Early turned off, timing of the ECM
main relay turning off is too
early.
B OFF ECM Main Relay Switched When ignition switch was
Off Too Late turned off, timing of the ECM
main relay turning off is too
late or does not off.
Diagnostic Trouble Code (DTC) P1625 (Symptom Code A) (Flash Code 76)
ECM Main Relay Switched Off Too Early
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1625 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P1625 (Symptom Code A) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
5 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–339
Diagnostic Trouble Code (DTC) P1625 (Symptom Code B) (Flash Code 76)
ECM Main Relay Switched Off Too Late
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1625 (Symptom Code B) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P1625 (Symptom Code B) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Using the DVM and check the ECM main relay.
1. Ignition “Off”, engine “Off”.
2. Remove the ECM main relay from the relay box.
3. Check the relay switch.
Was the DVM indicated specified value?
Replace ECM
main relay and
No continuitly Go to Step 5 verify repair
5 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 6
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–340 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
51 P1630 A ON Fuel Injection Quantity Circuit The PSG (pump control unit) Fuel injection quantity is
Malfunction detects high pressure sole- reduced.
noid valve control circuit mal-
function due to high current.
B ON Fuel Injection Quantity Circuit The PSG (pump control unit) 1. MAB (fuel cutoff solenoid
Malfunction detects high pressure sole- valve) is operated.
noid valve control circuit mal- 2. Desired injection quantity
function due to continuous becomes 0mg/strk.
current.
Diagnostic Trouble Code (DTC) P1630 (Symptom Code A) (Flash Code 51) Fuel
Injection Quantity Circuit Malfunction
Diagnostic Trouble Code (DTC) P1630 (Symptom Code B) (Flash Code 51) Fuel
Injection Quantity Circuit Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1630 (Symptom Code A) or P1630 and Go to Step
(symptom Code B) stored as “Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P1630 (Symptom Code A) or P1630 Refer to
(symptom Code B) stored in this ignition cycle? — Go to Step 4 Diagnostic Aids
4 Replace the injection pump assembly.
Is the action complete? — Verify repair —
6E–342 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
44 P1650 A ON CAN Device Offline CAN controller detects Bus- MAB (fuel cutoff solenoid
off or canceling. valve) is operated.
B ON CAN Device Hang-up CAN controller does not react
under engine running.
Diagnostic Trouble Code (DTC) P1650 (Symptom Code A) (Flash Code 44)
CAN Device Offline
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1650 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1650 (Symptom Code A) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Check for poor/faulty connection at the ECM or PSG
(pump control unit) connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
C-57 E-6 2
1
100 99 — Verify repair Go to Step 5
5 Visually check the PSG (pump control unit).
Was the problem found? — Go to Step 18 Go to Step 6
6 Using the DVM and check the CAN high circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the ECM connector and PSG (pump
control unit) connector.
3. Check the circuit for short to CAN low circuit.
Was the DVM indicated specified value?
E-6
2
Repair faulty
harness and
1 No continuity Go to Step 7 verify repair
6E–344 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
100 2
Repair faulty
harness and
— verify repair Go to Step 8
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–345
C-57 E-6
99 1
Repair faulty
harness and
— verify repair Go to Step 9
9 Using the DVM and check the CAN high circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the PSG (pump control unit)
connector.
3. Check the circuit for short to power supply circuit.
Was the DVM indicated battery voltage or
approximately 5V?
E-6
2
V
— Go to Step 10 Go to Step 11
6E–346 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
100 2
— Verify repair —
11 Using the DVM and check the CAN low circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the PSG (pump control unit)
connector.
3. Check the circuit for short to power supply circuit.
Was the DVM indicated battery voltage or
approximately 5V?
E-6
1
V
— Go to Step 12 Go to Step 13
12 Repair the short to voltage circuit between the ECM
and PSG (pump control unit).
Is the action complete?
C-57 E-6
99 1 — Verify repair —
13 Using the DVM and check the PSG (pump control
unit) ground circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the PSG (pump control unit)
connector.
3. Check the circuit for open circuit.
Was the problem found?
E-6
6
Repair faulty
harness and
— verify repair Go to Step 14
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–347
Diagnostic Trouble Code (DTC) P1650 (Symptom Code B) (Flash Code 44)
CAN Device Hang-up
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1650 (Symptom Code B) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P1650 (Symptom Code B) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
5 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 6 Go to Step 7
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
7 Replace the injection pump assembly.
Is the action complete? — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–349
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
45 P1651 A ON CAN Malfunction The PSG (pump control unit) 1. MAB (fuel cutoff solenoid
does not recognize CAN sig- valve) is operated.
nal from the CAN controller. 2. Desired injection quantity
becomes 0mg/strk.
B ON CAN Malfunction The ECM does not read CAN
signal from the PSG (pump
control unit).
Diagnostic Trouble Code (DTC) P1651 (Symptom Code A) (Flash Code 45)
CAN Malfunction
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1651 (Symptom Code A) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P1651 (Symptom Code A) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
5 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 6 Go to Step 7
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
7 Replace the injection pump assembly.
Is the action complete? — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–351
Diagnostic Trouble Code (DTC) P1651 (Symptom Code B) (Flash Code 45)
CAN Receives Error
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1651 (Symptom Code B) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1651 (Symptom Code B) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 Was the DTC P1650 (Symptom Code A) stored at the Go to DTC
same time? Chart P1650
(Symptom
— Code A) Go to Step 5
5 Check for poor/faulty connection at the ECM or PSG
(pump control unit) connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
C-57 E-6 2
1
100 99 — Verify repair Go to Step 6
6 Visually check the PSG (pump control unit).
Was the problem found? — Go to Step 19 Go to Step 7
7 Using the DVM and check the CAN high circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the ECM connector and PSG (pump
control unit) connector.
3. Check the circuit for short to CAN low circuit.
Was the DVM indicated specified value?
E-6
2
Repair faulty
harness and
1 No continuity Go to Step 8 verify repair
6E–352 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Breaker Box
100 E-6
C-57 E-6
100 2
Repair faulty
harness and
— verify repair Go to Step 9
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–353
C-57 E-6
99 1
Repair faulty
harness and
— verify repair Go to Step 10
10 Using the DVM and check the CAN high circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the PSG (pump control unit)
connector.
3. Check the circuit for short to power supply circuit.
Was the DVM indicated battery voltage or
approximately 5V?
E-6
2
V
— Go to Step 11 Go to Step 12
6E–354 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
100 2
— Verify repair —
12 Using the DVM and check the CAN low circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the PSG (pump control unit)
connector.
3. Check the circuit for short to power supply circuit.
Was the DVM indicated battery voltage or
approximately 5V?
E-6
1
V
— Go to Step 13 Go to Step 14
13 Repair the short to voltage circuit between the ECM
and PSG (pump control unit).
Is the action complete?
C-57 E-6
99 1 — Verify repair —
14 Using the DVM and check the PSG (pump control
unit) ground circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the PSG (pump control unit)
connector.
3. Check the circuit for open circuit.
Was the problem found?
E-6
6
Repair faulty
harness and
— verify repair Go to Step 15
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–355
Condition for setting the DTC and action taken when the DTC sets
Flash Code Symptom MIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
Code Code
77 P1690 4 OFF Check Engine Lamp (MIL) Check engine lamp circuit No fail-safe function.
Circuit Voltage Low open or short to ground cir-
cuit.
8 OFF Check Engine Lamp (MIL) Check engine lamp circuit
Circuit Voltage High short to ground circuit.
Diagnostic Trouble Code (DTC) P1690 (Symptom Code 4) (Flash Code 77)
Check Engine Lamp (MIL) Circuit Voltage Low
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1690 (Symptom Code 4) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0: Refer to
Diagnostic Trouble Codes”. Diagnostic Aids
Was the DTC P1690 (Symptom Code 4) stored in this and Go to Step
ignition cycle? — Go to Step 4 4
4 1. Ignition “On”, engine “Off”.
2. Check the “Check Engine” lamp.
Does the lamp turn “On”? — Go to Step 5 Go to Step 6
5 1. Ignition “On”, engine “Off”.
2. Check the “Check Engine” lamp.
Does the lamp turn “Off”? — Go to Step 9 Go to Step 7
6 Check the “Check Engine” lamp bulb.
If the bulb is burnt out, repair as necessary.
Was the problem found? — Verify repair Go to Step 7
7 Check for poor/faulty connection at the meter
connector and ECM connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
C-56 42
17 B-24
C-56
42
B-24
Repair faulty
harness and
17 — verify repair Go to Step 9
9 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 10
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–359
Diagnostic Trouble Code (DTC) P1690 (Symptom Code 8) (Flash Code 77)
Check Engine Lamp (MIL) Circuit Voltage High
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” Go to On Board
performed? Diagnostic
(OBD) System
— Go to Step 2 Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in Refer to
“F0: Diagnostic Trouble Codes”. Diagnostic Aids
Is the DTC P1690 (Symptom Code 8) stored as and Go to Step
“Present Failure”? — Go to Step 3 3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P1690 (Symptom Code 8) stored in this Refer to
ignition cycle? — Go to Step 4 Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 5
5 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 6 —
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–361
SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS Road test the vehicle with a Digital Multimeter
connected to a suspected circuit. An abnormal voltage
Before using this section, perform the “On-Board when the malfunction occurs is a good indication that
Diagnostic (OBD) System Check” and verify all of the there is a fault in the circuit being monitored.
following items: Using Tech 2 to help detect intermittent conditions. The
• The engine control module (ECM) and check engine Tech 2 have several features that can be used to
lamp (MIL=malfunction indicator lamp are operating located an intermittent condition. Use the following
correctly. features to find intermittent faults:
• There are no Diagnostic Trouble Code(s) stored.
• Tech 2 data is within normal operating range. Refer to To check for loss of diagnostic code memory,
Typical Scan Data Values. disconnect the MAF sensor and idle the engine until the
check engine lamp (MIL=malfunction indicator lamp)
• Verify the customer complaint and locate the correct
comes on. Diagnostic Trouble Code P0100 should be
symptom in the table of contents. Perform the
stored and kept in memory when the ignition is turned
procedure included in the symptom chart.
OFF.
If not, the ECM is faulty. When this test is completed,
VISUAL/PHYSICAL CHECK make sure that you clear the Diagnostic Trouble Code
Several of the symptom procedures call for a careful P0100 from memory.
visual/physical check. This can lead to correcting a
problem without further checks and can save valuable An intermittent check engine lamp (MIL=malfunction
time. This check should include the following items: indicator lamp) with no stored Diagnostic Trouble Code
• ECM grounds for cleanliness, tightness and proper may be caused by the following:
location. • Check engine lamp (MIL=malfunction indicator lamp)
wire to ECM short to ground.
• Vacuum hoses for splits, kinks, and proper
connection. Check thoroughly for any type of leak or • Poor ECM grounds. Refer to the ECM wiring
restriction. diagrams.
• Air intake ducts for collapsed or damaged areas.
Check for improper installation of electrical options such
• Air leaks at throttle body mounting area, mass air flow as light, cellular phones, etc. Check all wires from ECM
(MAF) sensor and intake manifold sealing surfaces. to the ignition control module for poor connections.
• Wiring for proper connections, pinches and cuts. Check for an open diode across the A/C compressor
clutch and check for other open diodes (refer to wiring
INTERMITTENT diagrams in Electrical Diagnosis).
Important: An intermittent problem may or may not turn
If problem has not been found, refer to ECM connector
on the check engine lamp (MIL=malfunction indicator
symptom tables.
lamp) or store a Diagnostic Trouble Code. Do NOT use
the Diagnostic Trouble Code (DTC) charts for • Check the “Broadcast Code” of the ECM, and
intermittent problems. compare it with the latest Isuzu service bulletins and/
The fault must be present to locate the problem. or Isuzu EEPROM reprogramming equipment to
Most intermittent problems are cased by faulty electrical determine if an update to the ECM's reprogrammable
connections or wiring. Perform a careful visual/physical memory has been released.
check for the following conditions.
This identifies the contents of the reprogrammable
• Poor mating of the connector halves or a terminal not
software and calibration contained in the ECM.
fully seated in the connector (backed out).
If the “Broadcast Code” is not the most current
• Improperly formed or damaged terminal. available, it is advisable to reprogram the ECM's
• All connector terminals in the problem circuit should EEPROM memory, which may either help identify a
be carefully checked for proper contact tension. hard-to find problem or may fix the problem.
• Poor terminal-to-wire connection. This requires The Service Programming System (SPS) will not allow
removing the terminal form the connector body to incorrect software programming or incorrect calibration
check. changes.
• Check engine lamp (MIL=malfunction indicator lamp)
wire to ECM shorted to ground.
• Poor ECM grounds. Refer to the ECM wiring
diagrams.
6E–362 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Replace the
eye bolt with
gauze filter and
— verify repair Go to Step 18
18 Check the engine compression pressure for each
cylinders.
If a problem is found, repair as necessary.
Was the problem found?
Repair as
— Go to Step 20 necessary
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–365
Repair voltage
supply circuit
— Go to Step 11 and verify repair
11 Check the glow plugs for continuity.
If a problem is found, repair as necessary.
Was a problem found?
Replace the
eye bolt with
gauze filter and
— verify repair Go to Step 16
16 Remove the injection nozzles from the engine and
check for the following conditions.
• Improper splay condition.
• Operating pressure is incorrect.
If a problem is found, repair as necessary.
Was the problem found?
4JH1-TC
Approximatly Approximatly Replace the
19.5 Mpa 33.8 Mpa
injection nozzle
— and verify repair Go to Step 17
17 Check the engine compression pressure for each
cylinders.
If a problem is found, repair as necessary.
Was the problem found?
X
Rough Idle
Stall
time
Actual
Low
Time
— Go to Step 29 Go to Step 26
6E–374 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
• Solenoid 95%: EGR Valve Open
• Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
• Vacuum Apply: EGR Valve Open
• Vacuum Release: EGR Valve Close
Replace the
eye bolt with
gauze filter and
— verify repair Go to Step 32
31 Remove the injection nozzles from the engine and
check for the following conditions.
• Improper splay condition.
• Operating pressure is incorrect.
If a problem is found, repair as necessary.
Was the problem found?
Surge
time
Actual
Actual
Low Low
Time Time
— Go to Step 25 Go to Step 24
6E–380 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
• Solenoid 95%: EGR Valve Open
• Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
• Vacuum Apply: EGR Valve Open
• Vacuum Release: EGR Valve Close
Replace the
eye bolt with
gauze filter and
— verify repair Go to Step 28
28 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
• Visual/physical inspection
• Tech 2 data
• All electrical connections within a suspected circuit
and/or system
Was a problem found? — Verify repair Go to Step 29
29 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 30
30 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 31 Go to Step 32
31 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–382 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Hesitation
time
Actual
Actual
Low Low
Time Time
— Go to Step 27 Go to Step 24
6E–386 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
• Solenoid 95%: EGR Valve Open
• Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
• Vacuum Apply: EGR Valve Open
• Vacuum Release: EGR Valve Close
Replace the
eye bolt with
gauze filter and
— verify repair Go to Step 29
29 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
• Visual/physical inspection
• Tech 2 data
• All electrical connections within a suspected circuit
and/or system
Was a problem found? — Verify repair Go to Step 30
30 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 31
31 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 32 Go to Step 33
32 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
6E–388 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
time
Unstable Data
Low
Time
— Go to Step 11 Go to Step 8
8 Check the VSS harness for the following conditions.
• Check for poor connector connection.
• Check for misrouted harness.
• Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 9
9 Substitute a known good VSS and recheck.
Was the problem solved? — Go to Step 10 Go to Step 31
10 Replace the VSS assembly.
Is the action complete? — Verify repair —
11 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “Mass Air Flow” in the data display.
Does the Tech 2 indicate correct “Mass Air Flow”
depending on accelerator pedal operation? — Go to Step 16 Go to Step 12
12 Remove the MAF & IAT sensor assembly and check
for the following conditions.
• Objects blocking at the MAF sensor element.
If a problem is found, repair as necessary.
Was the problem found? — Verify repair Go to Step 13
13 Check the MAF sensor harness for the following
conditions.
• Check for poor connector connection.
• Check for misrouted harness.
• Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 14
14 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved? — Go to Step 15 Go to Step 31
15 Replace the MAF & IAT sensor assembly.
Is the action complete? — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–391
Actual
Low
Time
— Go to Step 29 Go to Step 26
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–393
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
• Solenoid 95%: EGR Valve Open
• Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
• Vacuum Apply: EGR Valve Open
• Vacuum Release: EGR Valve Close
Replace the
eye bolt with
gauze filter and
— verify repair Go to Step 30
30 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
• Visual/physical inspection
• Tech 2 data
• All electrical connections within a suspected circuit
and/or system
Was a problem found? — Verify repair Go to Step 31
31 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 32
32 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Go to Step 33 Go to Step 34
33 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–395
Actual
Actual
Low Low
Time Time
— Go to Step 22 Go to Step 20
20 Using the Tech 2 or the vacuum pump and check the
EGR valve operation for the following condition
through the small window.
ÅERestrict shaft movement. Check for objects sticking
the shaft, broken diaphragm or excessive carbon
deposit.
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
• Solenoid 95%: EGR Valve Open
• Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
• Vacuum Apply: EGR Valve Open
• Vacuum Release: EGR Valve Close
Replace the
eye bolt with
gauze filter and
— verify repair Go to Step 25
6E–400 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Repair voltage
supply circuit
— Go to Step 16 and verify repair
16 Check the glow plugs for continuity.
If a problem is found, repair as necessary.
Was a problem found?
Actual
Actu al
Low Low
Time Time
— Go to Step 23 Go to Step 22
22 Check the exhaust system for a possible restriction.
• Damaged or collapsed pipes or catalytic converter.
• Internal muffler failure.
If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 23
23 Visually/physically inspect for the following conditions.
• Restrict fuel supply system. Check for a pinched
fuel hose/pipe.
• Check for a condition that causes fuel waxing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mixed with the
fuel.
If a problem is found, repair as necessary.
Was a problem found? — Verify repair Go to Step 24
24 Replace the fuel filter.
Was the problem solved? — Verify repair Go to Step 25
6E–410 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Replace the
eye bolt with
gauze filter and
— verify repair Go to Step 26
26 Remove the injection nozzles from the engine and
check for the following conditions.
• Improper splay condition.
• Operating pressure is incorrect.
If a problem is found, repair as necessary.
Was the problem found?
Replace the
injection nozzle
— and verify repair Go to Step 27
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–411
More than 20
Mpa Verify repair Go to Step 28
28 Check the inlet/exhaust valve clearance for each
valves.
Are the valve clearances within the specified value?
Actual
Actual
Low Low
Time Time
— Go to Step 20 Go to Step 15
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–415
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
• Solenoid 95%: EGR Valve Open
• Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
• Vacuum Apply: EGR Valve Open
• Vacuum Release: EGR Valve Close
More than 20
Mpa Verify repair Go to Step 19
19 Check the inlet/exhaust valve clearance for each
valves.
Are the valve clearances within the specified value?
Installation Procedure
1. Connect the two connectors to the ECM.
2. Put on the ECM to the floor panel.
3. Tighten the ECM cover by four bolts with specified
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–419
Installation Procedure
1. Install the CKP sensor to the clutch housing.
2. Tighten CKP sensor by a bolt with specified
tightening torque.
Tightening Torque
Installation Procedure
• Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)
1. Apply sealer to threads of screw at the ECT sensor.
3. Connect a CKP sensor connector to the CKP
sensor. 2. Tighten the ECT sensor with specified tightening
torque.
4. Connect the negative battery cable.
Tightening Torque
NOTE: Verify any DTCs (diagnosis Trouble Code) are • Bolt: 13N·m (1.3kgf·m)
not stored after replacement. 3. Connect a ECT sensor connector to the ECT
sensor.
4. Fill the engine coolant.
5. Connect the negative battery cable.
Installation Procedure
Installation Procedure 1. Temporary tighten the TPS by two screws.
1. Install the MAF & IAT sensor assembly into intake 2. Connect a TPS connectors to the TPS.
air duct.
3. Connect the Tech2 to the vehicle.
2. Tighten the clips.
4. Connect the negative battery cable.
3. Connect a MAF & IAT sensor connector to the MAF
5. Select “Data Display” with the Tech2.
& IAT sensor assembly.
6. Check the throttle position data and adjust the TPS
4. Connect the negative battery cable.
position.
NOTE: Verify any DTCs (diagnosis Trouble Code) are 7. Tighten two screws.
not stored after replacement.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–421
Removal Procedure
1. Disconenct the negative battery cable.
2. Disconnect a EVRV connector from the EVRV.
3. Disconnect two hoses from the EVRV.
4. Loosen two bolts and remove the EVRV from the
bracket.
Installation Procedure
1. Tighten the purge solenoid by tow bolts.
2. Connect a connector to the EVRV.
3. Connect two hoses to the EVRV.
4. Connect the negative battery cable.
5-8840-0285-0
(J 39200)
High Impedance
Multimeter
(Digital Voltmeter -DVM)
5-8840-0385-0
(J 35616-A/BT-8637)
Connector Test Adapter Kit
Breaker Box
5-8840-0279-0
(J 23738-A)
Vacuum Pump with Gauge
EXHAUST SYSTEM 6F – 1
SECTION 6F
EXHAUST SYSTEM
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 6F - 2
General Description........................................................................................................... 6F - 3
Removal and Installation................................................................................................... 6F - 4
Inspection and Repair ....................................................................................................... 6F - 6
General Description........................................................................................................... 6F -7
EGR System Diagram ........................................................................................................ 6F 9
Inspection........................................................................................................................... 6F-11
EGR Cooler (4JA1TC/4JH1TC Euro-III model)................................................................. 6F-12
Turbocharger ..................................................................................................................... 6F -15
Main Data and Specifications....................................................................................... 6F -15
General Description........................................................................................................... 6F -16
Inspection and Repair ....................................................................................................... 6F -17
Special Tools...................................................................................................................... 6F -19
IHI Service Network ........................................................................................................... 6F -20
6F – 2 EXHAUST SYSTEM
! "
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+ , - )
%,
.# $ /
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EXHAUST SYSTEM 6F – 3
GENERAL DESCRIPTION
RTW46FLF000201
RTW46FLF000101
Removal Steps
1. Rear hanger rubber 6. Front hanger rubber
2. Silencer front nut 7. Front pipe nut
3. Exhaust silencer 8. Exhaust pipe gasket
4. Silencer hanger rubber
5. Middle pipe nut
EXHAUST SYSTEM 6F – 5
´4 only)
2. Middle pipe Nut (4´
Connect the middle pipe to the front pipe.
Torque N×m (kg×m/lb×ft)
43 (4.4/32)
GENERAL DESCRIPTION
This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber
through the intake manifold.
4JA1T(L):
The two EGR valves are controlled by two Vacuum Switching Valve (VSV) controlled by EGR controller according to
signals from various sensors.
The amount of EGR depends on the number of engine rotations and the opening of the accelerator.
RTW46ELF001201
6F – 8 EXHAUST SYSTEM
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to “Engine driveability and emissions” section for detail.
RTW46ELF001101
EXHAUST SYSTEM 6F – 9
RTW46AMF000301
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to “Engine driveability and
emissions” section for detail.
RTW46EMF000701
EXHAUST SYSTEM 6F – 11
INSPECTION
4JA1T(L)
Vacuum switch valve (VSV)
Use a circuit tester to measure the V.S.V. resistance.
V.S.V Resistance W at 20°C
37 ~ 44
EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.
Negative Pressure
4JA1TC/4JH1TC
EVRV
Use a circuit tester to measure the EVRV resistance.
EVRV Resistance W at 20°C
14
RTW46ESH000301
EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.
RTW46EMF000201
Removal Steps
1. Bolt 7. EGR Pipe Assembly
2. Gasket 8. Gasket
3. Bolt 9. Bolt
4. Gasket 10. EGR Cooler Assembly
5. Bolt 11. Gasket
6. Bolt 12. EGR Cooler Adapter
Removal
1. Bolt
2. Gasket
3. Bolt
4. Gasket
5. Bolt
6. Bolt
7. EGR Pipe Assembly
8. Gasket
9. Bolt
10. EGR Cooler Assembly
11.Gasket
12.EGR Cooler Adapter
EXHAUST SYSTEM 6F – 13
RTW46EMF000901
Installation steps
1. EGR Cooler Adapter 8. Bolt
2. Gasket 9. Gasket
3. EGR Cooler Assembly 10. EGR Valve Assembly
4. Gasket 11. Bolt
5. Bolt 12. EXH Manifold
6. EGR Pipe Assembly 13. Gasket
7. Bolt 14. Bolt
6F – 14 EXHAUST SYSTEM
Installation
1. EGR Cooler Adapter
2. Gasket
3. EGR Cooler Assembly
4. Bolt
Tighten the bolts to the specified torque.
EGR adapter bolt torque N×m(kg×m/lb ft)
27(2.8/20)
5. Gasket
6. EGR Pipe Assembly
7. Bolt
Tighten bolts temporarily.
8. Bolt
Tighten bolts temporarily.
9. Gasket
10. Bolt
Tighten bolts temporarily.
11.Gasket
12.Bolt
Tighten bolts temporarily.
Finally tighten all bolts to the specified torque.
Confirm that there is no misalignment on the sealing
surface.
Bolt torque (Cooler-pipe) N×m(kg×m/lb ft)
27(2.8/20)
Bolt torque (Cooler-bracket) N×m (kg×m/lb ft)
24(2.4/17)
Bolt torque (Adapter-EGR valve) N×m (kg×m/lb ft)
27(2.8/20)
Bolt torque (Pipe-manifold) N×m (kg×m/lb ft)
27(2.8/20)
EXHAUST SYSTEM 6F – 15
TURBOCHARGER
MAIN DATA AND SPECIFICATIONS
GENERAL DESCRIPTION
036LV002
The turbocharger internal mechanism consists of the turbine wheel, the compressor wheel, and the radial bearings.
These parts are supported by the bearing housing.
The turbocharger external mechanism consists of the compressor housing air intake port and the turbine housing
air exhaust port.
The turbocharger increases air intake efficiency. This results in increased engine power, reduced fuel consumption,
and minimal engine noise.
The turbocharger operates at very high speeds and temperatures. Part materials have been carefully selected and
machined to extremely high precision.
Turbocharger servicing requires great care and expertise.
If reduced performance is noted, check the engine for damage or wear. If there is no apparent engine damage or
wear, trouble with the turbocharger is indicated.
EXHAUST SYSTEM 6F – 17
150RY00032
150RY00034
150RY00036
EXHAUST SYSTEM 6F – 19
SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER TOOL NAME
901RX00143
6F – 20 EXHAUST SYSTEM
HEADQUARTERS
ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD.(IHI)
General Machinery Division
Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku
Tokyo 100-0005 JAPAN
TEL: 81-(3)-3286-2405 to 2407 (3 lines)
FAX: 81-(3)-3286-2430
CHINA
IHI BEIJING OFFICE
Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue
Beijing, People’s Republic of CHINA
TEL: 86-(1)-505-4997, 0408
FAX: 86-(1)-505-4350
TLX: 210343 IHIPK CN
TAIWAN
IHI TAIPEI OFFICE
Room 1202, Chia Hsin Building, No. 96 Chung Shan
North Road, Section 2, Taipei, TAIWAN
TEL: 886-(2)-542-5520, 5521, 5523
FAX: 886-(2)-542-4362
TLX: 11320 IHICO
THAILAND
IHI BANGKOK OFFICE
8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND
TEL: 66-(2)-236-3490, 7356, 9099
FAX: 66-(2)-236-7340
TLX: 82375 IHICO TH
MALAYSIA
IHI KUALA LUMPUR OFFICE
Letter Box No. 52, 22nd Floor, UBN Tower,
10 Jin. P. Ramlee 50250 Kuala Lumpur, MALAYSIA
TEL: 60-(3)-232-1255, 1271
FAX: 60-(3)-232-1418
TLX: IHI KLMA 20257
INDONESIA
IHI JAKARTA OFFICE
9th Floor, Skyline Building JI. M. H. Thamrin, No. 9, Jakarta, INDONESIA
TEL: 62-(21)-32-2147, 390-2211
FAX: 62-(21)-32-3273
TLX: 44175 IHIJKT
ACCELERATOR CONTROL 6H – 1
SECTION 6H
ACCELERATOR CONTROL
TABLE OF CONTENTS
PAGE
Removal and Installation............................................................................................... 6H - 2
Removal...................................................................................................................... 6H - 6
Inspection................................................................................................................... 6H - 6
Installation.................................................................................................................. 6H - 6
6H – 2 ACCELERATOR CONTROL
RTW46HLF000301
ACCELERATOR CONTROL 6H – 3
4JA1T(L)/LHD
RTW46HLF000601
6H – 4 ACCELERATOR CONTROL
4JA1TC, 4JH1TC/RHD
RTW46HLF000201
ACCELERATOR CONTROL 6H – 5
4JA1TC, 4JH1TC/LHD
PTW46BMF000101
6H – 6 ACCELERATOR CONTROL
Removal
1. Disconnect the accelerator control cable from the
accelerator pedal and dash panel.
2. Remove the cable clips.
3. Remove the accelerator control cable from accelerator
control cable bracket.
1) Slide the lock in direction A
2) Rotate the ratchet ring in undirection an arrow 90°.
4. Remove the accelerator control cable from the throttle.
Inspection
Check the following items and replace the control cable if
any abnormality is found.
· The control cable should move smoothly.
· The control cable should not be bent or kinked.
· The control cable should not be damage or
corrosion.
RTW46HMH000201
Installation
1. Install the accelerator control cable to accelerator
control pedal dash panel.
2. Install the accelerator control cable to throttle.
Attach T-END and inner cable to throttle cam of
engine.
3. Install accelerator control cable to accelerator bracket.
1) Rotate the ratchet ring in direction an arrow 90°
until both white marking are aligned.
2) Confirm marking of outer cap must be upper side.
3) Slider the lock in direction B.
4) Confirm ratchet ring is locked.
4. Install the cable clips to accelerator control cable.
NOTE:
Confirm that the throttle (engine side) is at full stroke
when the accelerator pedal is at full stroke.
No. TF4JE-WE-0431